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I didnt mean to post anything till I get my gear pattern, but something came up..as always. I received my gears today, and to my horror, there are two chipped areas on the pinion tooth. However I think this wont affect the pinions function or cause noise, notice the red lines i drew, they are...

Frankly, I can't tell thats anything wrong with it, just like the second rebuild. But there are bits of metal on the ring gear surface as well as the pinion. On pinion there are some gasket material I sanded off the diff case and some metal bits

Thanks dave, but I am pretty sure preload is not too high. I was very careful not to exceed the preload I set in the 3rd rebuild. In the 4th rebuild, the breakaway wasn't that much higher than rotating. I will be equally careful on this 5th rebuild.

Update, after roughly 700 km with no improvement and a lot of metal in the oil, I pulled the diff apart and decide to rebuild with new gears. My new gears are coming tomorrow. I pulled the diff off the car on Saturday the 8th of July. I removed the ring gear and did a runout check on the...

So I was looking at the mk4 subframe and how the diff is secured, and found that it is very similar to BMW way of doing things. On the Mk4, there are two horizontal bushings that go on the diff that attach to the subframe. This allows the diff to move up and down a little . The Prop shaft also...

Update, it's a week later, drove 35km to work and 35 km back Diff casing temp was 152 F. , and some short distances on the next day 5km to 15km . The noise has gone down in some conditions and went up in some. The whine/groan at 59kmh onwards is still there, but the high level of groan goes down...

Yes I hope so. I went for another drive which is a bit longer. 10km + 10km to the city center. parked and returned. It was a large highway so had to go at least 80kmh for 1km. The noise was loud at 59 kmh and kept getting louder and louder till 77 kmh, then after that to 80kmh, almost no sound...

I got my used prop shaft and installed it with the diff. Just went for a test drive. A 7km trip to breakfast and 7km back home. There is a small amount of noticable noise. It is mostly on light acceleration over 35kmh. Its like a hum /whine. on decel at 60 to 20kmh its hardly makes any noise I...

I did not disasmble the bearing, carrier or the pinion, i just removed companion flange, installed seal, oiled seal, and reinstall companion flange with new nut. The increase I measured is including the carrier, not pinion preload only. So I think the seal stiction is causing the increase in...

Ok looks like I now have one additional problem. Since preloads are good, I then removed companion flange to install the front seal. Oiled the lip, installed companion flange with new toyota Nut. Went 147ft lb, then used a breaker bar and got another 1/10th of a turn. Now I am measuring a total...

Yes max runout on ring gear was 0.07mm or 0.0027". Toyota says runout should not be more than 0.1mm or 0.0039", So i guess this is ok. I am going to take the risk and button up as is, as on previous rebuild, I had no clunk, then eventually the clunk came back after some time, I correlate with...

The reason i think i can get away with it is.. As you can see many individual measurements are over the lowest limit of 0.13, So I dont think the gears will get stuck , and since this carrier preload is the same before, I think the backlash will open up again down the line, by not more than...

Final Backlash averages (out of all 41 tooth) out at 0.0048" (0.12mm), just a tiny bit under 0.005". Currently has 2.94mm on L, 2.88mm on R. I need 2.91mm shims on both sides to get the backlash to be at 0.0055" but I only have one 2.91mm shim. I think its ok as the rotation test is not noisy...

5th June Pinion preload without seal Breakaway - 13inlb Rolling 7 in lb Total carrier shim 2.94+2.88 = 5.82mm Breakaway 19inlb , rolling 11inlb With Carrier shim 2.91+2.94 = 5.85 Breakaway 22inlb So I went with 19inlb shim set. Next will be checking backlash, final gear pattern, and listen...

I wet sanded it with 1000 grit sandpaper, with no pressure. Blemish is gone But there are some lines moving in other direction I guess due to the wet sanding. Still feels smooth.

Oh dear, i was instaliling the bearing races, and once i was done with the front race, i had a look and noticed a smudge on the inner race. I should have checked earlier. My repeated attempts to spray with brake clean and wipe has not removed it. I ran my fingers and finger nail over the area...

Piratetip, i have not checked breakaway torque for pinion or carrier as I have not changed any of the bearings yet. My logic since the bearings only have 1000 miles on them their wear is minimal and I can avoid risk of damaging the new bearings by pressing off the pinion bearings so many times...

Now on this post only 0.076" shim, taken early yesterday morning

Here are pinion pics to the best of my ability. I added more prussian blue and ran another pattern with loaded pinion. All these pics are for 1.9mm or 0.075" shim only

Next , little more shim, Coast looks nice and not running off the toe with wide contact patch Drive, partial rugby ball shape above but straight bottom, bigger contact patch than 0.073", still within toe edge Last shim, stock shim Not ideal shape, but coast has large contact patch and still...