LOKKA install real time advice needed (1 Viewer)

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I'm going at this thing now. It's been going OK until it came time to measure clearances.

The spider gear spacing is supposed to be between 0.006 " and 0.020". With the stock thrust washers I was right at .020" on both sides.

Next you put the thing together, and measure the maximum gap between the gears. Pry them apart and see what you can fit in there. Spec is 0.140 to 0.165"

I measured and my clearance is 0.09" or 2.28 mm. So I would need to reduce each side by 0.78mm to bring it to the middle of that tolerance range. (Range is 3.5mm to 4.19mm or 0.140" to 0.165") reducing the thickness by 0.78mm on each side would increase cam gap to 3.84 mm or around 0.150".

I measured all my stock thrust washers and they all appear to be 2mm thick. So I would in. Theory need 2 thrust washers that are 1.22mm thick to make this work (2mm - 0.78mm)

Toyota doesn't sell washers that thin, so I'm kinda boned here unless I can get them machined I guess?

Toyota does list a 1.525mm washer but that would bring me just outside the range still only increasing the theoretical gap to 3.23 mm. I'm wondering if that is close enough.

Any ideas?
 
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I had an epiphany after taking a shower and drinking a PBR.....I measured the wrong gap. The instructions were a little hard to follow, but my gap is correctly in spec at 0.145 " between the cam gears.

The instructions say to lever the cam gears apart as far as they will go and measure the maximum clearance. I incorrectly measured the clearance between where the gear meshes together, they want the space between the flat side of the cam gears where the spider rides.
20201024_151141.jpg
 
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Joined
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Ok well Lokka says since this doesn't replace the carrier you don't have to check backlash, but after putting this back together going by the FSM. It says backlash is adjusted using an SST on the adjuster nut. Dammit, guess I gotta go buy a dial gauge setup and build a tool to get this done.

My backlash definitely seems to be sloppy right now and cant be the 0.13mm to 0.18 it's supposed to be.

Screenshot_20201024-212923_Drive.jpg
 
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Well, I got it done, checked it 10 times. FSM is actually pretty easy to follow here.

You real differential specialists would cringe at some of this haha, but it's all set now. Scraping old gasket off so I can set it in there now....
20201025_110552.jpg
 
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first test ride tonight since I couldn't wait. Definitely can hear the clicks with the window down. It was pretty loud when I first pulled out of the driveway, but quieted down after a couple miles , I guess because the fluid circulated.

I can feel the ticks in the floorboard a little bit, and you can sort of feel it unlock as you turn from a stop.

I drove some curves about 30mph and even when on the gas I didn't notice it at all. Only can hear it on really slow turns as others have said. From a stop and turning right at a stop sign I can just barely feel it unlock.
 

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