ARGH! To those of you with solid shim spacers- help!

[supraguy@aol]

Hey guys-
I'm trying to reassemble my spare diff, using a solid shim spacer.
My problem is that while I'm trying to properly shim for preload on the pinion, it seems like the pinion flange(where the driveshaft bolts to) is bottoming out on the differential case! I don't understand how this would or could happen. I installed new front and rear pinion bearings on the pinion, and i did reinstall the original pinion shim as well. I just don't get why there would be additional thread section of the pinion available out the front, as I assume this is the root problem. If anyone has any insight, please le me know.
thanks.

 

[supraguy@aol]

Nevermind, guys- I found the problem:

Old front pinion bearing, "new" front bearing...

The new one is obviously the incorrect part(thanks, Rockauto), as it is at least 5mm too shallow.

 

[supraguy@aol]

Just to show what I've been doing:
Installed a Weir Performance "maxgrip" kit, stage 1.
Basically all it is, is a set of various spacer shims, and an additional "assist" spring,
which mounts inside the original spring, to increase tension. The new breakaway torque should be around 100ft-lbs.

Here's one half of the LSD, with already shimmed, and the spider gear lash checked.
You can see the new spring:

Solid pinion spacer:

My home made torque bar:

I checked the gearlash on the assembled unit, and I was a bit on the loose side, but I was simply able to swap spacers from one side to the other, and it put me exactly in the middle of tolerance. All I have to do now is get a new flange nut for it, because the original's threads are kinda ratty. Then I'll fill it with oil and install it.
:icon_bigg

 

[planemos]

That's neat. I just did an lsd install on my 2wd toyota pickup. I used a detroit tru trac in the 7.5 rearend. So do you use that marking stuff? I mean the grease stuff? You just apply it on the gears and spin it and you can tell how they mesh together by the pattern of the grease.

 

[supraguy@aol]

Yes, or they make a special paint in red , yellow and prussian blue.

 

[planemos]

I've never seen inside a Supra diff lol. So is there a ring gear? Is the lsd/carrier held down with bearing caps? Or how does it get bolted into the diff casing? I used the prussian blue. If you will be using that stuff you should take a picture of the pattern.

 

[supraguy@aol]

Yes, there is a ring gear- it's bolted to the other half of the unit, not shown in the pics. and yes-the LSD is held in by two bearing caps.

 

[supraguy@aol]

Well, I finally got it sealed up:

Plus, I set a personal best record of replacing the differential, Jack-up to Jack-release in 1hour, 25 minutes. Yay me!
Man! What a difference!!! I've had a mystery "clunking" in my rear end for over two years now. I really wasn't sure if it was rear suspension bushings, of in the diff,
but now I know. That clunk, going from on throttle to off-throttle, used to be horrible. Backing out of a parking space, and then going into forward gear- pedestrians would turn their heads
to see what was making that sound. But now it's gone! Nice, tight diff, no clunk. I think now I'll rebuild the old diff the same exact way, and either put in on a shelf for later, or I'll sell it as an
upgraded rebuilt. I have yet to test out the increased LSD function properly, but honestly, I'm just glad it's quiet again.