The areas of the tooth you are marking is just machining kerf.
Every OE gearset has this, it's normal both on the pinion and ring.
You should inspect the areas of the tooth centered between the heel - toe, and root-face.
Where the contact pattern is located.
Yup any change, a bearing, a...
Polished to a mirror gear faces aren't unusual, I see them all the time.
Usually the ones that are not abused / well taken care of.
But in your case, not sure.
Hard to diagnose these things over a forum.
Did you do full rotations of the diff while out of the vehicle before teardown.
Or get it direct from a connector supplier.
Mfr: OEM Yazaki
Series: 090II Sealed Series
OEM P/N: 7283-1015-10
I can kind of hear the noise.
What speed were you going?
Next step would be seeing if it's tied to wheel rotations.
Can't tell much from my end but the knocking sounds too slow to be tied with wheel rotations. (Hitting the same spot again and again on the ring gear)
I have some annoying poly...
A photo I took :)
I liked the small Japanese Subaru Kei Van that showed up that day.
Send the word if you are doing another meet there, I like small meetups.
Gives me a good excuse to get out of the house :)
Richmond might be ok.
But I agree with Andrew, stay away from SVL / Dana gearsets.
They key is getting another with 27 spline pinion.
Otherwise go with a new Nitro gearset, you will have to convert the seal/flange/nut to the larger 29 spline.
Otherwise find another good used OEM gearset
It's is the same fitment yes. G series Toyota diff. Yes.
You checked the coast side gear mesh, should have felt an inconsistency there.
A bit strange, but there might be a mark on the pinion or ring somewhere.
Don't think the diff is causing the noise you are referring to.
A worn diff transitioning from accel to decel will clunk once, as well as the other way.
Only thing that may cause a noise like this would be a physical damage to the ring/pinion.
One of your photos showed a chipped ring tooth on...
For those you would need large circlip pliers. They are very stiff.
99% of the diffs never need them replaced.
I think I've only ever encountered one or 2 with problems, otherwise fine to just re-use them.
A slightly deeper pinion seal is no problem, better this way to ride the lip seal on a...
Did you disassemble and do anything with the center carrier LSD unit?
Assembled you can't check spider gear backlash, only can do that when it's apart.
I would say no, that won't be any cause of the clunk noise.
You are correct the sloppy pinion / loss of crush sleeve preload probably was the...
I would keep it where it is on used bearings.
You could edge it up a little with a breaker bar on the pinion nut if you like at the very last assembly.
Or leave it as is.
Edit: meant extension pipe on breaker bar.
Just scratching the surface man.
The fun is when 1 change or adjustment affects 3 others.
Have to really understand the relationship between everything to hit your targets correctly.
Landing a perfect gear mesh is my peak elation on a diff build.
Once that lands into place the rest becomes...
Just be sure to maintain the solid spacer parallel trueness.
The bearings need to run straight in their bore, solid spacer maintains this.
It's not just there, hardly any shops here know how to set up a diff properly.
Most only know how to swap out bad parts and that's it.
Time is money and...