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@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...

The clunk is not constant, its only on lower speed decel. Nothing on accel at all. I did not really test the diff much in opposite direction. I am stumped as to why it only happens on decel. I mean afaik if its u joint , cv axle or wheel bearings its supposed to make noise all the time it...

After struggling the whole day installing the diff, i took it for a test drive. Looks like all my work is for nothing. The knocking sound (kluk kluk kluk) on decel is still there. The sound is loudest at lower speeds at 45 to 15kmh, worse when engine braking is in effect. I was thinking of...

Thanks piratetip. I brought the diff home already and preparing to install tomorrow, its like 5 weeks already. I have not changed the side gear flange clips. I tried using a normal circlip plier but it seems its not opening large enough to open up the clip. Is there another tool to remove this...

Received my shims. I proceed to put the thickest shim of 2.79mm on the left, and 3mm on the right, which gives me a reasonable preload, that is tighter by 0.09mm than the original shim stack. I measured backlash on 18 tooth randomly. The tightest is 0.124mm and loosest is 0.175mm The average is...