1987 4runner, 5-speed, mostly stock.
I will be installing a new Aussie locker in my front 7.5 diff.
What spare/replacement parts should I have on-hand before pulling the diff from the truck? i.e. are there any clips, gaskets, seals, or bearings that I should buy and have ready?

Mark

 

Get a solid pinion spacer. The crush sleeve on the pinion, shouldn't be re-used, if you need to remove the pinion. A locker will over-crush the stock sleave, during heavy usage. You can keep tightening the pinion nut when this happens, but only so many times. The bearings should be fine, seals are cheap if you'd rather do it now instead of when they go, gasket maker(RTV) is good enough for third member case seal, get a OEM gasket if convenient, or make one out of bulk material. Dang, the pinion nut, forgot, try to get a new one. I re-use them , holding them with BLUE, NO RED, threadlocker. I use the blue, and I still need the torch to get them nuts off. The torque on that nut is specific, but a free-hand method can be used. If it's too tight, it will "howl", try to get it just not howling. Too loose will wear things out, quick. One more, I can't believe the price, but the fully synthetic gear oils are a "cheap" safe-guard, as well as minor performance enhancer.

 

The carrier does not get dropped out of the vehicle for an Aussie install....only the case gets pried out.Nothing else needed.

only the cross brace comes off to access the case...
http://www.gearinstalls.com/ifs.htm

 

(I know it has been a few months, but I have been putting off this project)

I'm not sure I quite understand. Are you saying the entire third member does not need to be dropped from the truck, only remove the cross brace and remove the cover?
I would have to get the stubby axle shafts out to remove the ring gear/carrier assembly. And to get the axle shafts out, I would have to remove the cv's, so one might as well drop the whole third member from the truck. Or am I missing something.
Thanks for your help Zuk, your the Man! (BTW, I haven't seen any IFS lunchbox locker installs on your page)
Also, what about shims to raise CBPL? I see you usually throw in .003 or .006 of shims on each side. Shims from a dana axle? I really don't know anything about dana's,...do you have any part#'s for those .003 shims? and what type of dealer would have those? Jeep?

Mark

 

I've dropped mine out a couple of times in the last 18 months. Definitely worth it to get OEM seals while you're at it. I found it relatively easy to drop it out and work on it with the tube lightly clamped in the vise. The only thing that you'll need, other than RTV, will be the tab locks to bolt on the ring gear. Alternatively, you can use Locktite on the threads of the ring gear bolts.

Most likely you will have to take the ring gear off the case to get the pin out that holds the pinion shaft. Speaking of that pin, you can hit it from both sides, but it will only come out one way. HTH.

 

Don't have part numbers for the 003 shims. I've been buying the OEM shims from the Toyota dealership lately.....about 5 bucks each. I have all the part numbers on my webpage .....about the 3rd link down under bearings.
I believe the whole 3rd does not need to be dropped. remove the aluminum cover and slide the CV axle stubs out 2 inches.

 

You're probably right. There's probably enough give in the CV linkage to allow a couple of inches of movement.