Builds 94 FZJ80 - Let the Adventure Ensue (1 Viewer)

[FMC80]

More updates from Zuk last night:

Factory outer race tapped in very firmly

And the large inner race also tapped in firmly ( no loose fits )

Going to reuse the original .053" shim and see how the pattern looks with that

And now to mount the pinion inside the differential carrier.......

 

[FMC80]

Tighten the pinion up .....with well oiled bearings .....and a nice smooth 10 inch pounds of pinion preload

Backlash is close enough and no need to change the carrier bearing washer plates yet so let's see what the pattern looks like with a little bit of yellow paint on three teeth

Drive side.... reverse painted tooth.... the depth looks perfect ...it is centered from left to right but also from the root to the top of the tooth is very well balanced so this pinion shim of 053 was perfect.

The coast side says I should try a little deeper maybe so I will give it a shot.. a little deeper which is a little thicker pinion shim

Before changing out the pinion shim, I am looking at the pattern on the pinion tooth and it looks very well balanced on this drive side

 

[Bullgump]

I probably missed it but which kit are you using for it?

 

[FMC80]

I probably missed it but which kit are you using for it?

Are you asking which gears I bought? I bought the Revolution gears.

As for everything else, it is all OEM Toyota peripherals.

 

[cruisermatt]

You were going to take this to Windrock with that paint job?

 

[Broski]

You were going to take this to Windrock with that paint job?

One could always hang out in camp and meet cool Cruiser heads !!

 

[FMC80]

You were going to take this to Windrock with that paint job?

Windrock has malls nearby.

 

[FMC80]

Zuk continues his artistry:
Okay this is much better on the coast side.. I went 003 deeper and I also tightened up the backlash a little bit and the combination brought the coast pattern near perfect

Drive side looks good

Here's the same drive side but on the reverse painted teeth and it makes it look even better

Here's the coast side on the reverse painted teeth and looks really good also.

As a confirmation I also look at the pinion teeth and very well centered and very well load matched from top of tooth to the root of the tooth

.056 is a winner and now to disassemble the pinion end ....put in the crush sleeve and the new factory seal

 

[FMC80]

The new metal factory seal has to have some sealant on the metal to metal contact .....this will make sure there's no dripping..... You would think it wouldn't be needed on a tight metal to metal surface but I found out otherwise in the past

Seal is recessed exactly 2 mm

A smooth 11 inch pounds
That was basically the time consuming end of things which is getting the pinion depth set just right.

Ding! and this end is done.

 

[FMC80]

Doing a final pattern check and this is the drive side

And this is the coast
Now to record the backlash on 20 teeth

Made a backlash adjustment and recorded on 20 teeth......

Rear differential complete and now on to the front

 

[FMC80]

I painted the teeth on the old 410 in the front and the drive side which is used 99% of the time has some unusual wear on it probably from loose bearings

Looking at the coast side which is only used 1% of the time it looks really good a nice oval football pattern with in good position
I suppose the drive side being worn like it is could have been the result of a lot of towing

This old 410 is heading for the garbage for sure.

The old carrier bearings came off with mild resistance so there probably was some rattling or looseness going on there for many miles and it beat the bearings loose on the journals so these new factory bearings did go on tighter but I wanted to make sure that they never rattle loose with this green sleeve locking compound

 

[TLC94LS]

I saw he know longer takes mail in assemblies. But we may need to circumvent that but a MUD member logisitcal train for drop offs. Those rebuilds would take my cruiser to the end with as few miles I'll end up putting on it just on the weekends. FMC80 you live nearby? I even thought about just flying in and doing a drop off. HMM.

 

[FMC80]

I saw he know longer takes mail in assemblies. But we may need to circumvent that but a MUD member logisitcal train for drop offs. Those rebuilds would take my cruiser to the end with as few miles I'll end up putting on it just on the weekends. FMC80 you live nearby? I even thought about just flying in and doing a drop off. HMM.

I’m heading that direction 30 June. Pull your thirds and I can deliver them.

 

[TLC94LS]

Oh man. I’ve got to drive it first so I can see what gears I’d need. Man.

 

[FMC80]

Oh man. I’ve got to drive it first so I can see what gears I’d need. Man.

Some say it’s worth doing, some say it’s not. I rebuilt my engine with a new short block and rebuilt top end and basically skipped past the breakin and sent it to get painted. Since I happened to be in the same state as the painter and the diff rebuilder I decided to capitalize on the opportunity although it cost a lot more to do it the way I did, but the level of service I’m getting from the guru is worth it for me. His communication, professionalism, experience, expertise, and just plain technical prowess is worth every penny. I’d have paid more.

 

[FMC80]

The sleeve lock has had a chance to set up for about 24 hours and the ring gear is firmly bolted on with those 5 lock brackets that prevent any possibility of ring gear bolts loosening up

Now on to the pinion end of things

Same thing with this pinion nut ... You can tell that it's never been removed before because it has the factory ding mark undisturbed, when I turn the flange it almost feels a touch loose but I cannot visually see it in any case these bearings are worn but we knew that

I just cleaned all the grit off the inside of the steel dust cover and sanded the seal area using 2000 extra fine grit

Flange looks perfectly good for reuse

The oil was blacker and smells real raunchy so this oil led a harder life

Got to get this worn out race out of here without damaging the oil retainer...... I have a truck

Two half washers and a rubber cork......

 

[FMC80]

Bingo

New race tapped in nice and firm

The new factory race punched in nice and firm also

I looked up the stamped markings on this ring and pinion

and I did a similar install with similar install with the same markings stamped on the ring and pinion and I used a 072 that time so that would be a good starter shim this time

072

 

[OffRoadScott]

View attachment 3354819
The sleeve lock has had a chance to set up for about 24 hours and the ring gear is firmly bolted on with those 5 lock brackets that prevent any possibility of ring gear bolts loosening up
View attachment 3354820
Now on to the pinion end of things
View attachment 3354821
Same thing with this pinion nut ... You can tell that it's never been removed before because it has the factory ding mark undisturbed, when I turn the flange it almost feels a touch loose but I cannot visually see it in any case these bearings are worn but we knew that

I just cleaned all the grit off the inside of the steel dust cover and sanded the seal area using 2000 extra fine grit

Flange looks perfectly good for reuse
View attachment 3354823
View attachment 3354824
View attachment 3354825
The oil was blacker and smells real raunchy so this oil led a harder life

Got to get this worn out race out of here without damaging the oil retainer...... I have a truck
View attachment 3354826
View attachment 3354827
Two half washers and a rubber cork......
View attachment 3354828
View attachment 3354829

Love seeing the progress, makes me want to get my 3rds done. But I want to find some 3rds and use those as my builds to limit the down time of my 80 since I DD the big bastard.

 

[FMC80]

This is getting a little picky maybe but it's just the slightest bit too deep you can see that in this drive pattern

Dang, the number I read out of the book was 71.7 thou and I decided to use 72.8

You can see that in my write-up from February of 2022

So I'm going to pull it one last time and tweak it with 71.7 which is barely over .001 inch difference

Here's the drive side with 0728
You can see in the root of the tooth that the length of the line is longer than the length of the line on the outside of the tooth so it's too deep because there's a longer line inside the root..... Not by very much
It's actually not bad at all but I'm splitting hairs here and getting this thing right on because it will only take 001 change which is an extremely small amount to tweak it much closer to better

Coastside

 

[FMC80]

Everything is the opposite when you're talking about the pinion tooth so instead of being too deep on the pinion you will see that now we are too far to the outside of the tooth

Basically you're looking for the loading from top of tooth to the root of the tooth and putting everything in the center