My gear install
 

First of all, thanks to ZUK and gearinstalls.com for all of the awesome documentation and work he does. I did quite a bit of studying on his site over the last 4 months while i sourced all parts from East Coast Gear Supply and Low Range Off Road.

I have a 2004 Toyota Hilux Turbo Diesel (1-KZ engine), which comes with about 3.7 ratio diffs. Since putting on 33" tyres i am tired of the sluggish feel and loss in fuel economy. Decided this year to go with ARB front and rear along with 4.1 gears. The pics are from a new v6 housing with v6 Nitro 4.3 gears, and ARB RD132, purchased master install kit as well FWIW.

Here are some pics from my pattern check last night. BL is at .006 (I think i need to open it up to centre the coast pattern toe to heel more) and the pinion shim is .078... There is some preload on the pinion and carrier bearings. Please all do tell me what you think!

Drive:
http://i162.photobucket.com/albums/t...90A926421E.jpg

Coast:
http://i162.photobucket.com/albums/t...90B04A6EF8.jpg


Pinion shots 1 and 2:
http://i162.photobucket.com/albums/t...90BAADFF8D.jpg

http://i162.photobucket.com/albums/t...90C47259FD.jpg




Hopefully i get this all done and ready to swap out this weekend, and concentrate on the front (pull, drop in the ARB RD90, and reinstall) this Sunday. I really hope the front in a day wont be too tall of an order for me!

Thanks all!

BL is not going to center the coast heel to toe. The pinion shims will + or - change that. I would add a little more shim to the pinion and see what that does.

Did you use a solid collar or a crush sleeve? What's the pinion preload?

Bigbluepile,
The preload was about 10in/lbs for that reading... I think I will be using a crush sleeve, as I wont be doing anything as extreme as rock crawling or the like. I'll try adding a thou or 2 and share pics.

Thanks for the advice!

Have you crushed the sleeve yet? Make sure you put gear oil on the bearing while you are setting your preload. Use lots of antiseize :D

No, I haven't used the sleeve yet, and yes lots of oil being used as well as antisieze on the spanner wheels.

Did you get a chance to redo the shims yet?

Nope... Tonight is the night though ;)

Yay! :D

And here we are. This time around I felt much more comfortable with the assembly. PPL was about 14in/lbs. pinion shim set at .081 by my measurements. I like this pattern more!

Drive
http://i162.photobucket.com/albums/t...0E91AC6D51.jpg

Coast
http://i162.photobucket.com/albums/t...0E9B372BE3.jpg

Pinion
http://i162.photobucket.com/albums/t...0EAA7C9D91.jpg


What ya think?

That is A LOT better! Time to set your crush sleeve and completely install everything.

Thanks for the help there BigBluePile!

I'm going to go ahead tonight with a solid collar, assemble and ready for swap tomorrow; and then the front in one go on Sunday. Fingers crossed! Thanks again!

The solid collar is the way to go. Again, take your time with it and get a good preload

Add some pinion shim thickness. And, if necessary, add some BL.

What you're shooting for is the contact patch on the drive side to be in the center of the tooth vertically(between the face and flank), and towards the toe horizontally. See below..

http://i173.photobucket.com/albums/w...shpatterns.jpg

Thank goodness! Pictures!

.......

Installed today! Drive stream with the 4.3 ratio... Breaking-in driving for the next 800KM

And onto the front tomorrow in one go!

Thanks for the diagram there mudhippy.

Do a couple of 10 mile runs around ~50 mph, let diff completely cool down. No hard starts or racing. Change the diff oil. Then run 500 miles, easy miles, and change fluid again.