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Looks like my gears are coming this week only, probably friday 28th October. And I need to leave for Mantova, Italy on the 30th, and stay for 2 weeks for my job. My rebuild has to wait till I get back 2 weeks after. Sigh. In the meantime, I got the hand crank that I designed, made by lasercut...

I insert the carrier with bearing shell into housing and slot the ring gear shim in, then slot the opposite side shim in, tapping the last shim in place with mallet and socket driver. Btw, your carrier shims total is very thick, I went the tightest at 0.23" which is 5.8mm. On that build, there...

Piratetip, since I do have some time to kill, I need some info from you. 1. For the last few mk3 diffs you rebuilt, could you let me know the carrier shim thickness you used on ring gear and opposite side ? With this info, I can guess if my carrier preload is in the ballpark. 2. This guy Zuk...

Which town in Italy ?

@Piratetip I need your help since you would have at least 1 mk3 diff with you out of the car. I plan to make a spinning wheel jig and I need this center to center measurement in mm. I plan to make it with a double use, able to attach to the companion flange as well as this side flange, with...

Thanks for your help MoparMarq. The hats i designed based on your measurements are spot on.

Thanks Piratetip. I have not checked the open diff carrier center, but I did check the China ring gear runout and it was only 0.03mm maximum, well under the 0.1mm allowed. I still believe it is the ring and pinion based on 4 reasons. 1. The previous rebuild with the old gears had no noise on...

It's supposed to be a good day today, but its not. Its utterly a horrible end to all this work. The diff made a lot of noise, this time far worse than before. It made noise on both accel and decel. Much louder on decel. This time its not a knocking type sound but a grind hum-whine. I am stumped...

Thanks, andrew, but is the pattern acceptable ? This is the pinion pattern : I am contemplating going a little deeper, perhaps 0.03mm to 0.05mm, because looking at the actual tooth pattern today after the paint has dried, it still feels a little shallow. But If I go deeper, I need to order a...

Update: I bought some shims from a local seller, but he only has a few thicknesses. 1.7mm, 1.73mm , 2.3mm and 2.36mm. I decide to try 2.3mm(0.09") first. It is 0.33mm(0.013") over the original shim of 1.97mm(0.078") with the pinion so deep, i had to use a thinnest carrier shim i have to get...

Sorry @Piratetip I di not understand what you mean about the kerf. The pattern is too shallow from what I see. I should add a thicker shim ?

Update . Saturday 1st October 2022. I decide to try a local brand of gears ASLI 4x4, for the Toyota Landcruiser, ratio 9x41 8". There seems to be very little difference measurement wise vs the originals. I installed the inner bearing and original 2mm shim with the fire and ice method. I...

Yes I did test them both ways and no sound showed up. But I tested it by rotating the pinion. Its very difficult to force the ring gear to rotate with the diff cover on, while diff is off the car. When you said this : Maybe the previous guy that "built" the diff allowed it to run too long in a...

I drained the oil today. Again the oil looked dark, and the drain plug is full of gunk. But how can this be when the oil and gears only has 4 hours runtime ? The only conclusion I can come up with is the gears are grinding each other. Wasted my money on Amsoil 75W-110 thrice.. So i decide to...

The speed is never more 50kmh at maximum and i tried my best to get it between 20 to 13kmh up to near stop to replicate that sound only and isolate the noise from exhaust, turbo, engine and tyre noise. It is tied to wheel rotations, as most of the road has no major bumps, plus this is a 4.56...

@Piratetip here is a video. from the website onallcylinders , this is what I would describe as the closest symptom I dont know why but the camera could not capture the sound properly. I was only able to spot the sound right after 13:10 and 13:45 mark, pay attention when I decelerate. sounds...

My prop shaft was rebuilt and rebalanced. It seems smooth at the joints and no vibrations felt under me. As for the pinion preload, i was getting about 8 in lb constant turning. The breakaway was over the scale of the wrench, but then again the upper limit of that wrench is about 25 in lb only...

I did some investigation today. I know for sure that the noise is happening when the rear wheels are on the ground and moving forward, even though the speed is very low (15 to 10kmh) and transmission is D (engine braking) as well as N (no engine braking) . So naturally I suspect the ring and...

Thanks for the heads up. There is one more in Rock Auto. Is this ok ? or maybe I need to buy from somewhere else. Edit, if I find that it is R & P, i might as well just buy OEM. I dont want waste my time again. Planning to find a way to put a drill to turn the side flange to mimic the...

On this coming weekend, I will detach the prop shaft and lift one wheel up, and spin that lifted wheel as fast as i can. this would forcefully turn the ring and pinion, like decelerating, lets see if that same sound is there, i will get it recorded. Also gonna try with the prop shaft attached...