Lokka issue

[GotFlex]

Hey im after some help
i just bought a lokka already in a carrier but the ring gear was broken, so i got me mate to change my 4.8 ring gear on to it, at this point he noticed my bearings were not looking to nice so he got a bearing kit for it,
finished building the diff and then he noticed the carrier is touching the end of the pinion, it wont even turn over its touching that much, what do i do?? i assume i have the wrong carrier to suit the diff i had and assume the lokka wont fit my carrier, can i machine my carrier down?

Any advice im desperate fix so i can go for a play

[Fakey]

Got any pics? Toyota?

[GotFlex]

oh yea sorry Hilux early one coz the bearing kit was the smaller of the 2, i cant do pics atm
on the carrier you can see inside 2 sides and the 2 covered side connect with the end of the pinion end and binds up, can you over tighten the pinnion to the point it do that??

[kbushnz]

Hi Yah

When you changed the ring gear did you swap in the pinion gear with it (matched set).

If the pinion is not the correct ratio for your ring gear it wont run / fit correctly.

Have a look at this website, its full of install info for various toyota diffs and Zuk is great for info.
http://gearinstalls.com/index.htm
He helped me with regards an issue when I put 4.88 gears in my factory electric locker. (cant use gears from the 2.4 Prado as they wont fit in an elocker)

Calvin

[GotFlex]

yip they are matched, its like the carrier is too big but it all bolted together fine, are there bigger carrier options?

[kbushnz]

There is a differance between 4cyl diffs (small bearings and 4cyl V6 units (large bearings).
But this is in the bearing size. The carriers can be swapped....
I take it the spool is hitting the pinion.
It sounds like the pinion is set too deep....
Unless your man does regular diff swaps / setups it is best left to the guru's or diff shops. (not wanting to offend)
Without a photo to see exactly the problem we are all shooting in the dark.

Have you measured your old diff to see if there are any big differances???

Here is a link to a toyota diff overhaul, and ARB install.
But the proceedures are the same.

http://www.4x4wire.com/toyota/tech/gear_setup/

Calvin

[GotFlex]

so you can set it up too deep? is that done my cranking the pinion nut up way to tight? be the flange is qutie stiff to turn from what i am used to.

Thanks heaps for your help mate

[kbushnz]

Only to happy to help and share what I have learnt / observed.
You need to have a good read in the links posted.
The pinion has a spacer under the bearing. Then when it is assembled the assy is preloaded.. usually a crush tube and torqued up..
This sets the pinion gear in position.
Then when you assy the spool into the carrier and adjust it to get the backlash you need to check the mating footprint on the gears from the pinion.
If you use the wrong spacer the gear will be too deep or not deep enought on the ring gear. You may get the backlash right but it will not mesh correctly. This can cause noise and premerature failure.
So you have to pull it down again and change the spacer on the pinion gear. And start again.
Real fiddly job.
No two diffs are the same.

Cheers
Calvin

[GotFlex]

Ok well he set it up as per normal but had this issue, can you machine the carrier to help it clear?? i would think you cant machine the pinion as its hardend steel.

[Pedro]

Ok well he set it up as per normal but had this issue, can you machine the carrier to help it clear?? i would think you cant machine the pinion as its hardend steel.

did he remove the pinion bearing and change them , if so perhaps the either the cup is not seated into the pinion bearing area, there is no way the pinion should touch the carrier, put some bearing blue onto the crown wheel and check the pattern, it will show up the pinion being to deep.

pedro