millennium falcon

Parts are ordered.... Should be here by the weekend. R&P gears and mini install kit. Hopefully be putting it back together next weekend.

millennium falcon

Parts are here!

millennium falcon

So ZUK, I have my gears and I have begun re-assembly. I went with "motive gear" 4.88's to match the rear..... What would you recommend as a starting point for pinion shims? I am re-using all the stock bearings. Stock shim was .096

ZUK

iTrader: (1)

In the front...re-using bearings.... .101"


Gag...stick finger down throat.....Motive

millennium falcon

Yeah I know I know..... Motive sucks but keep in mind they are going in a truck I paid $300 for so if we are going by the ratio of "cost of vehicle / cost of gears" technically I am putting yukon gears in my truck. LOL. If I had the money I would love to put really good parts in my truck but that is not the case...... sadly So Motive it is. I did put them in the rear too. I don't know how many miles I have on it.....but so far I haven't had any trouble with the rear gears. Have you had failures with motive gears? My toy budget was blown on my VW TDI project, but that worked out well because now I have an awesome Daily driver and the yota has been promoted to firewood truck/weekend off-road warrior! So anywho... this is where I got to tonight....

Mail call...



Smells so fresh!



New and old comparison.


Ring gear....


Filing all surfaces...


New bolts....red locktite, 71 ft.lbs.




dunzo.


Pinion shot!

millennium falcon

Thanks for the info ZUK! I will go with .101 and post results.... and advice on carrier bearing shims? It was at roughly .115 on both sides with the stock gears.

Here is a throwback shot of "el guapo"
I can't wait to have 4wd again and hit the trails with the old girl!

ZUK

iTrader: (1)

On the washer plates it's best to put the stock ones back in and see if the backlash is .006" or maybe .008".
If the backlash is in spec then if you noticed that the plates went in too easy and that means you need to add an equal amount of to each side.

millennium falcon

OK Great! I will let you know how it goes! Thanks!

ZUK

iTrader: (1)

And with carrier bearings being used, you'll probably want to add about .004" to each side by using .120" washer plates. Trying to pound/tap in a washer plate with a thin .oo4" shim up against it brings crinkly results.

millennium falcon

Yes I can imagine paper thin shims would not slide in very well.

millennium falcon

Ok, I will try to source some .120 Plates Have you ever made your own. I have a lathe and a heat treatment oven..... And mad skilz haha! Do you know what material/hardness the plates need to be to hold up?

ZUK

iTrader: (1)

Never made my own like that. Once you post some pics of the 1st paint of the new gears and measure Backlash then we can guesstimate what adjustment to do.

millennium falcon

Here is my first reading... The only shim combo I could come up with given the shims in my kit was.105. Not sure whats going on but if I torque the carrier caps down tight i cant even turn the ring gear. so, they are just snug when I took this reading. Pretty much zero backlash.

ZUK

iTrader: (1)

The pattern look s shallow by about .005" but I wouldn't say for sure until you have some backlash in there. You'll need a thinner shim on the ring side and a larger shim on the other side. If you have .115 on both sides right now..........Maybe .108 and .122 respectively will work for at least a valid paint check..

millennium falcon

OK, what about not being able to rotate the gear once I tighten the caps? Is that do to the lack of backlash?

ZUK

iTrader: (1)

I think so too

millennium falcon

K... this will be on hold until I figure out something for carrier shims...

millennium falcon

I monkeyed around with some shims I had laying around. Here is where i'm at now. I have .008 BL I am able to torque the bearing caps down and this is my pattern now. Carrier shims are very hard to drive in.... So Im assuming there is enough Pre load on them. I have to use a big hunk of brass and drive them in little by little on both sides.

ZUK

iTrader: (1)

Great on the BL....but that pinion depth shim will need about .020" more.

If you have .105 already for the pinion depth then you need about .125" now which is unusual for it to be that high. Are you sure you really had .105 in there?

Note that going .020 deeper means the backlash will be affected.....instead of .008 you will now have .003 to .004.

millennium falcon

I will double check my pinion shims when I remove the bearing. I have a feeling if I add .020 more on the pinion I will be back in trouble with the BL like you said. and I dont have any more shims or plates to move the carrier over. What would you say is the minimum I could add to the pinion as to not throw off my BL much more? Also, how hard should the carrier plated drive in? Thank you!