OEM ring gear and pinion 41201-69166 -> 41201-80527 ?

[Reinhardtius]

They are part of the final gear kit.

Thanks, I am going to create a parts list. What may be helpful (if I can ask you) is to have a complete list of parts that you used to install this final gear kit. These parts are what were required for your 60 series, but I assume (and will test in due course) that they would be the same for a 70 series owner who must replace the R and P with this factory superseeded final gear kit.

Could you list out the parts you purchased? I'll then make a table of the factory parts, the replacement part, and some notes. This is a great thread, by the way. Thank you!

 

[Eurasiaoverland]

Thanks, I am going to create a parts list. What may be helpful (if I can ask you) is to have a complete list of parts that you used to install this final gear kit. These parts are what were required for your 60 series, but I assume (and will test in due course) that they would be the same for a 70 series owner who must replace the R and P with this factory superseeded final gear kit.

Could you list out the parts you purchased? I'll then make a table of the factory parts, the replacement part, and some notes. This is a great thread, by the way. Thank you!

I could read through this thread again and make a list of the parts, but you can just as easily do that. Detailed here is the final drive kit, pinion bearings and the flange and seal you need to use to run them on the original housing. You'll also need to look up the part numbers for your diff carrier bearings (if you want to replace them). If you have a pre-1990 70 series, your differentials will be identical to post 1984 60 series differentials.

 

[Vitek]

For anybody that after some search for the ring gear set part number ended up here:
Our hzj75 needs to have the the rear ring gear set replaced as its broken (original pn.: 41201-69355)
I also ended up ordering the 41201-80527 and luckily for me it came with the seal and crush tube included.
However, the bearing issue was the same and also the flange has to be replaced. I ordered the ones Eurasiaoverland posted earlier, hope those will also work in the hzj75 1997 carrier. Will update, but just wanted to clarify for anybody going throught this with a 75 series, that situation and hopefully the resolution will be the same.

 

[Eurasiaoverland]

For anybody that after some search for the ring gear set part number ended up here:
Our hzj75 needs to have the the rear ring gear set replaced as its broken (original pn.: 41201-69355)
I also ended up ordering the 41201-80527 and luckily for me it came with the seal and crush tube included.
However, the bearing issue was the same and also the flange has to be replaced. I ordered the ones Eurasiaoverland posted earlier, hope those will also work in the hzj75 1997 carrier. Will update, but just wanted to clarify for anybody going throught this with a 75 series, that situation and hopefully the resolution will be the same.

No luck involved, those accessories are part of the kit you bought. However, unless you find a 100 series flange, you'll need to buy another oil seal to suit.

 

[sodafeld1]

That is really interesting, so toyota has gone to the 33mm pinion.
I have been swearing and cursing at an aftermarket ring and pinion for my hj75. It too had the pinion shaft size made to 33mm, with different bearings and flange. My biggest bummer was I wanted a solid spacer so aftermarket from one company would not fit the wider pinion.
I was told the later vdj had a 33mm pinion, so went for a vdj solid spacer but it is a sloppy fit. A local diff specialist said a little play in spacer is ok, but I am a little wary.

Look forward to seeing your ring gear patterns please.
Good to know that someone else is encountering a 33mm pinion. You are not interested in a solid spacer?

Personally I got some extra bearings and made some slip bearings. The bigger bearings changes pinion depth a fair bit, so I have been fiddling and pulling apart and trying different pinion shims and looking like it is either the thickest shim toyota supplies or may have to get some extra .05mm , .1mm, .2mm shims made up..to compensate for the thicker, deeper bearings.

As soon as you replace something on a diff it gets expensive for sure! Have been told terrain tamer make their kits complete and true to oem size. Drivetech do not supply a solid spacer.

 

[Eurasiaoverland]

That is really interesting, so toyota has gone to the 33mm pinion.
I have been swearing and cursing at an aftermarket ring and pinion for my hj75. It too had the pinion shaft size made to 33mm, with different bearings and flange. My biggest bummer was I wanted a solid spacer so aftermarket from one company would not fit the wider pinion.
I was told the later vdj had a 33mm pinion, so went for a vdj solid spacer but it is a sloppy fit. A local diff specialist said a little play in spacer is ok, but I am a little wary.

Look forward to seeing your ring gear patterns please.
Good to know that someone else is encountering a 33mm pinion. You are not interested in a solid spacer?

Personally I got some extra bearings and made some slip bearings. The bigger bearings changes pinion depth a fair bit, so I have been fiddling and pulling apart and trying different pinion shims and looking like it is either the thickest shim toyota supplies or may have to get some extra .05mm , .1mm, .2mm shims made up..to compensate for the thicker, deeper bearings.

As soon as you replace something on a diff it gets expensive for sure! Have been told terrain tamer make their kits complete and true to oem size. Drivetech do not supply a solid spacer.

I'm of the 'OEM is right' school (hence chasing Genuine parts and keeping the original final drive ratio) so didn't want to go down the aftermarket solid spacer rule, even though it seems a superior setup.

No progress on my rear diff build as the LSD carrier is still in Russia...

I think the TT kit is a Joint Fuji item. On the 60 Series Aus FB group someone who knows their stuff reported the TT (I think) 37:9 aftermarket diff was not great quality (he could not get a good pattern) and soft metal. I even spoke to a gentleman at Joint Fuji in Japan who told me, in a roundabout way, that their 37:9 R&P were not 'original quality'. You can spot the JF pinion as the splined section has a strange waisted profile (no idea why) which must make it weaker.

Hence I persevered with the 33 mm / 32 spline newer OEM pinion with all the additional paraphernalia.

 

[Eurasiaoverland]

Quick update on this, as the diff is all put together. To recap:

Original 60 Series housing
Late 80 Series LSD carrier (these have 4 friction discs instead of 6 in the 60 Series and early 80 Series LSDs)
60/80 Series LSD internals
OEM 4.11 ring and pinion 41201-80527 - 33 mm pinion shaft diameter
80/100/200/Late 70 Series 50 mm OEM carrier bearings
100/200/Late 70 Series pinion shaft bearings
200/Late 70 Series companion flange and oil seal (100 Series would fit but is NLA).
100/200/Late 70 Series oil slinger and pinion shaft nut.
Terrain Tamer 100 Series solid spacer (overpriced and with useless shim selection).

So, yes, you can build an all-new, all OEM 60 Series diff with the ring and pinion kit 41201-80527, but you need a lot of extra hardware to go with it. But as I see it, this is the only quality 37:9 (not 41:10) ring and pinion set out there.

To set the pinion depth, I used a 1.30 mm shim which seems to be the standard size on these diffs.
To set the pinion pre-load I ended up with 3x 0.02 mm hand cut shims, so 0.06 mm in total. Torquing the pinion nut up to around 200 Nm I got around 2.0 Nm of starting pre-load on the bearings with the oil seal installed but without the carrier in place.
I set the backlash at between 0.13 and 0.16 mm around the ring gear.
Added about 0.5 Nm of pre-load on the carrier bearings to end up with about 2.5 Nm of preload at the flange, which is towards the top end of the range for new bearings (1.8 - 2.6 Nm as far as I can tell from various FSM versions, all of which are either vague or plainly contradict themselves in places.)

And this is the pattern:

EO

 

[sodafeld1]

yeah the tt shims are pathetic.

 

[Eurasiaoverland]

yeah the tt shims are pathetic.

I wrote to them asking what their solution is for this 'kit' of theirs - no response of course. I think they are on a par with Cruiserparts in the US for unprofessionalism.

 

[sodafeld1]

I ended up getting a variety of 'shims australia', as you know a range is required.

I think the future has become less individual orientated and more orientated to cover the wool over the eyes for the masses. bahhhaha (sheep)