For additional support, clamp the diff locker into a bench vise. Next, new bearings need to be pressed onto the diff locker housing. This is done with a shop press and the correct diameter pipe or some bearing press dies. Make sure you do not apply pressure to the bearing cage when pressing, otherwise you will damage the bearing and you'll need to purchase a new one.
Before your new diff locker carrier and crown wheel can be installed into the housing, you must setup your shims. The best way to start is to use the original shims that came in your diff housing. This gives a good baseline to install the locker carrier. A good tip is to use a small amount of grease to stick the shims to the inside of the housing.
Insert the carrier carefully back into the housing making sure not to displace or damage the shims on either side of the housing. Once it is pushed in by hand as far as it will go, tap the carrier fully into place with a rubber mallet. Reinstall the diff bearing caps and do not attempt to "pull" the diff carrier into place by the caps. Torque the bolts to spec and you will be ready to test the diff pattern. This is the most important part of diff gear setup. Supplied with your install kit is a small sachet of gear marking compound and a brush.
The compound is brushed onto teeth of the crown gear and then the crown gear is rotated against the pinion gear to mark a pattern into the compound. It is important to "load up" the diff while marking a pattern. A trick I used was to wrap a shop rag around the pinion yoke and hold tightly. Turn the crown gear using a spanner to force load against the pinion. Once you have marked your first pattern, rotate the crown gear to a position where you can see the pattern clearly and inspect.
You'll notice areas on the grown gear where the marking compound has been displaced by the pinion gear. This is the contact point. Should the contact pattern be incorrect, you will then need to remove the diff locker carrier housing and the pinion and adjust the shim heights in order to achieve a better pattern.
This is done in increments of 3 thou of an inch each time. Once you have an ideal contact pattern showing on your diff gears, it's time to do a final installation. For the last time, remove the carrier and pinion from the housing.
Install your brand new bearings if you were using dummy bearings to do set-up , then re-install the pinion. Make sure you include all components such as the oil slinger and crush sleeve. Before installing your pinion yoke, be sure to install the new pinion oil seal.
Now that the pinion components are all installed, it's time to tighten the new pinion nut. This operation will crush the crush sleeve to create the proper preload on the pinion. If you over-tighten the crush sleeve and create too much pinion preload, it is unable to be reused and you must replace it before continuing.
Now the pinion has been installed, re-install the carrier with new bearings and correct shims. Make sure to use the carrier bearing caps in the correct locations and torque to spec.
After we verified the pattern once more it was time to install the diff cover. We replaced the diff cover with an aftermarket one that is thicker and stronger than the original. Carefully run a bead of sealant around the diff cover and install the bolts in a star pattern making sure to alternate tightening.
Our diff cover came with torque specs, make sure to follow the instructions with yours and don't overtighten. Your new diff gears and locker are now ready to use. Take note of the run-in procedure with your new gears. Ours mentioned driving carefully with minimal load on the diff for the first km. An early oil change is recommended to clear the diff housing of any minor metal shavings or debris. Universal Oil Cooler Kit - Large. Universal Oil Cooler Kit - Medium.
Why regear a differential? Why do you need diff lockers? Diff Locker Types Sometimes we think half the fun of owning an off-road vehicle is modifying it and adding accessories. Axle dis Assembly Prior to starting, it is very important to research how your diffs are assembled. Required Tools Your differential may require additional specialist tools other than what is listed here. Check the sizes of sockets you require. The JK requires an 18mm, 21mm, 30mm and 35mm socket which you may not own.
Larger breaker bars Digital Calipers able to read 0. The calipers are required to measure shim thicknesses. What is Preload? What is Backlash? Installation This installation begins from a bare axle housing with the axle seals, pinion seal and bearing races removed. This is what the diff should look like once you've got it empty and clean. Diff Gear Setup Patterns This is the most important part of diff gear setup.
The following picture shows the desirable pattern and how to achieve it. Final Installation Once you have an ideal contact pattern showing on your diff gears, it's time to do a final installation. Rear 2wd Axle: Toyota 7. All Tacomas with a factory rear electric locker came with the Toyota 8" TV6 rear axle, while open differential Tacoma trucks were built with the Toyota 8.
All Tacomas with a factory rear electric locker came with the new Toyota 8. Tacomas 34 Spl. Give us a call! Join Our Mailing List. Built with Volusion.
Gear Ratio Recommendations Tire Size. Bolts Standard Rotation Gears 3. T Thick gears for 3. The front axle is equipped with a factory e-locker that switches between an open differential and a locked differential while the rear axle features a locker that switches from a limited slip differential to a locked differential. These axles are very strong and can handle moderate to aggressive off-roading with up to 40" tires.
The OEM lockers are also lower carriers that require the use of "thick" gears. Gears 3. The Dana 30 front axle is the weak link in this combination and good for mild to moderate off-roading with up to 35" tires when properly built, whereas the rear axle can manage up to 40" tires under more aggressive use.
When changing gears or differentials in these axles you will need to pay attention to the ring gear bolt sizes.
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