12:17 am
Well, here's a picture of an 1999 4Runner E-locker that I'm going to put into my 83 pickup. Came with a bad pinion bearing which apparently is a common failure and they sell a repair kit with just the parts needed. Dis-assembly took much longer than typical. The outer pinion bearing would not budge under the press and had to be drilled. Ordered the parts from East Coast Gear Supply and got free shipping using the Pirate 4x4 discount code PBB. I'll use the ring/pinion from the old differential which is possible but requires some custom pinion spacers.
4:20 am
I'll be doing it for the first time. Might take some time and I'll miss some runs. Right now the whole front axle is in pieces. The e-locker goes in the rear and the rear has a LSD that will move to the front.
3:11 pm
Parts arrived yesterday. Should have ordered a solid pinion spacer. Apparently, a rock hit on the pinion flange can deform the crush sleeve and lead to pinion bearing failure. I found a nice writeup of the installation of my existing gears into the e-locker. http://www.gearinstalls.com/abe.htm
6:48 pm
"RockinCrawler" wrote: Parts arrived yesterday. Should have ordered a solid pinion spacer. Apparently, a rock hit on the pinion flange can deform the crush sleeve and lead to pinion bearing failure.
I'm convinced this is what caused my rear end to fall apart. I destroyed my driveline at the Hammers. Wait for the spacer. The money you save will be worth it.
3:23 pm
Thanks Bender, I ordered the spacer. After 3 tries, I've got the pinion bearing shim nailed down in a 0.020" range. I'll wait on the solid spacer before continuing. It will be interesting to see how many times it takes to get it right. You have to dis-assemble everything to change that shim.
12:32 am
Project is almost done. 3rd member and electronics are all done and most of the rear axle modifications. Just have to weld some and drill/tap some holes to bolt in the new e-locker. Lesson learned was that I should have marked/recorded the wear pattern on the old 3rd member gears before dis-assembly. Not an issue with new gears, but the used gears produced some strange looking wear patterns during the setup that were hard to interpret. Having a picture of the original patterns would have been real helpful. Control box has 2 relays, 4 diodes, 3 LED's and a switch. LEDs are for indication of Unlocking, Locking and Locked. Should have it all finished for the next trip.
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