specifications for LSD rebuild

[Plex]

yeah, and your diff will blow up.

I've heard on how to set the backlash.. what you do is put a pieve of paper (just printer paper) between the gears and run it through them, if the paper tears, back it off a little, to just before the tearings point (tearing would mean too much friction... = diff dies)

[H7ERO]

Progress so far:

axle shafts removed, after messing around with a hammer on the brake disc with no avail so i fabricated a slide hammer (which actually only takes about 30-40 mins if you have welder) and it came off with a few hits! (picture to follow)

wheel bearing replaced - after using 100kn of force the outer race just split!
so i used angle grinder to remove inner races unfortunatly i slightly damaged axel shaft two or three 1.5 mm deep cuts in to axle (unfortunatly in my lecture (on structural mechanics (mechanical engineering degree) on friday i learnt how in a drive shaft maximum shear stress is a the outermost point in its diameter under tosional load!!)
so i am pissed off lets just hope toyota put in a suitible safety margin!!!
(my car is striped out so it is under reduced load anyway-i pray)

the spacer on top of the bearing requred the most force to remove and replace so consider cutting this off first and replacing with a new one as it should make bearing removal easier - in hind sight

differential assembly removed -easy undo driveshaft bolts undo diff housing bolts knock with rubber mallet, diff assm falls out (its v heavy) provide soft landing!

removing diff from assembly- ok either side of the bearing caps are the preload adjuster caps winding these in and out is how you adjust first the backlash (the tolerance between the pinion and ring gear) and then the preload on the conical bearings either side of the diff.

"I've heard on how to set the backlash.. what you do is put a pieve of paper (just printer paper) between the gears and run it through them, if the paper tears, back it off a little, to just before the tearings point (tearing would mean too much friction... = diff dies)"

plex this sounds about right, because there is an axle specialist near me im going to try and persuade him to let me take photos of him doing the job and see what tools/technique etc he uses (he is reasonably priced so i might as well (finding any of these parts in uk is hard so im not going to risk it- shame as this is the first work apart from changing tyres i will have had someone else do!)


diff dissasembly straight forward see thread!
http://www.toymods.org.au/Repository/ind.../rear_susp
http://forums.club4ag.com/topic.asp?TOPIC_ID=64357

whats inside? i was really hoping to find some mashed and broken clutch plates or scored and warped spline plates but no these parts looked as good as the new ones i have from toyota!!! (i knew regular diff oil changes payed off!) remember i ordered the thickest ones from toyota
after checking with micrometer these new ones are only 0.15mm thicker!!!!
you can imagine now i am thinking why i have i wasted my time!!! so guys think if your LSD feels good and you change oil regularly and there is nothing in the oil ask yourself is all of the above necessary?

currently i am researching into the toleraces the diff works to and so how to modify it safley and efectivley via shimming etc so any info/ links etc would be greatly appreciated,
check this:
http://forums.club4ag.com/topic.asp?TOPIC_ID=91049
so from what i can tell T3 kit is not uprated as such (only O.E parts suplied) and toyota europe seem to have all these parts in stock (or at least my main dealer can get them)

final verdict:

LSD rebuilt with new springs, spline plates, clutch plates, and the thickest adjusting washers #6 and brass bushings


unfortunatly my grandfather has fallen ill so i am going to visit him in india so will not be able to continue updating this thread till i return (when i will complete the job and add photos)
(there is only electricity every two weeks where i am going so unlikly to be any internet!)

[Mux213]

H7ERO,

Whow, took me weeks to get my axle out, I guess I really need a slide hammer for the future

Sorry to hear about your grandpa, hope he'll be alright.

[H7ERO]

the slide hammer made of some 50mm mild steel and some other off cuts of mild steel. takes about 30-40 mins to make cost is very cheap
if you ask anyone who has removed axle shafts this is very little time to take to make this job easy for you (even to buy a scrap wheel and the metal and have some one quickly fabricate it should be less than 40 euros

just use a brake disc as a template on some sheet steel (mine was 3mm thick) to cut holes fo wheel nuts

weld the 50mm pipe to it (about 500mm long)

put it through any wheel this one happened to be an alloy as long as it slides very freely along th 50mm pipe at least (5mm clearance)

weld on a bar at the other end for the wheel to hit

bolt to axel shaft with wheel nuts

and throw wheel back against the bar using max as much speed as possible
(use as much speed on the wheel as possible and let the wieght of the wheel do the work, a heavier wheel (maybe with a tyre on) will require less acceleration from you)

mine took less than 5 hits befor axle came out!

[H7ERO]

just found this link! jpgs 25-32

http://www.toymods.org.au/Repository/ind.../rear_susp

my questions answered

http://forums.club4ag.com/topic.asp?TOPIC_ID=91049

so from what i can tell T3 kit is not uprated as such and toyota europe seem to have all these parts in stock (or at least my main dealer can get them)

final verdict:

LSD rebuilt with new springs, spline plates, clutch plates, and the thickest adjusting washers #6 and brass bushings

[Ivan141]

Hmm...interesting topic on club4ag. I'd like to hear Gabe Tyler on the subject of the clutchplates he supplies. If they are really only OEM parts, then he's still cheaper than the toyota dealer, which is perfectly okay with me. My T3 rebuild kit is currently on it's way over from america so I could do some measuring myself. Somehow the fact that he has a waitinglist for the diff kit doesnt seem to be very logical if he simply sources his parts from toyota.

The following questions still pop up in my head:
-How do you check the clearance of the clutch assebly inside the diff? Since there are 6 sizes of washers (#6 being the thickest) can you simply throw this in without measuring?
-I read about resurfacing the inner friction surfaces, just like you do with flywheels once in a while. Is this really recommendable or just nice for perfectionists?
-I need an exact write-up of setting preload and backlash. I still have very little info on that.

[Kas]

How much money for rebuild kit with shipping to Europe?

[Ivan141]

159 dollars...

[Kas]

Put on some pictures of changing proces.
Some tips and tricks also.
When will you change LSD, this year or ........

[Ivan141]

It's going to be done sometime next year. Probably together with the bushings since the axle is going to have to be removed anyway.