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Ok I am back and drove the car for roughly 2 days for some short trips. Noticed a few things. Overall everything is stiil good. Noise isnt getting worse. I do notice some hum on slow decel (30kmh and less), and some hum on hard accel. Since I am still in the break in period and only put about...

I havent got the chance to put more miles on it, so far I have only gone about 80km on that Sunday itself. I am still in Italy and will only be back on the 25th. I plan to fill up a tank full and drive till i finish that tank before swapping out to AMSOIL synthetic fluid.

Here is a video showing the sound of the diff with the china made ring and pinion.

Ok update. I pmed Piratetip yesterday that that knock is back on reverse, but its very faint. So this morning I finally tested the car. I am glad to report that the diff is as close to perfect as possible, its like 97% there. Hardly any whine in accel and decel, and very faint "knock" at very...

I think I found the pinion spot that is causing the sound. It was two tooth upper from where I thought it was supposed to be, I cant feel any dent/lift with my fingers but I can see it with a magnifying glass. I proceed to dremel polish that spot the best I could. I then pulled 0.004" of the...

I replaced the carrier bearings today. I also received my new range of shims, 2.82, 2.85, 2.88, 2.91 and 2.94mm. So I reassembled everything, and from a 2.79mm Left shim I increased it to 2.85mm to get a good backlash. And indeed I got very good backlash. However, I still have that cyclical...

Problem is yellow compund is im possible to get, i used water colour before but it doesnt seem to give an accurate pattern . With the water colour it seems to wipe off the edges giving impression its too shallow. I decide to change the carrier bearings too just to make sure. The carrier bearing...

So it seems my trip is postponed to 6th, which is the following week, I took the chance to quickly rebuild the diff since i have everything, or at least i thought i did. When I took apart the China made gears, I saw the reason why it was so noisy. The scuff marks show that the pinion is too...

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...