Clam Regear for Matt's 2004 Tacoma with G2 488
(60 BIG pics loading)
FEB 18 2016

Matt's 2004 Double cab Tacoma.
The plan is to re-gear the front clam to 488 to match the rear. Typically, the bearings in the clams are very much re-usable so if they look good then there will be a cost savings.
Matt is local to me and dropped the heavy clam assembly off to me.
The electric impact wrench took those three 17mm bolts off effortlessly.
Two more 17mm bolts gets this other carrier mount off. They get re-torqued to 80 ft/lb fyi
And, finally, take these four 17mm bolts off....2 are long and 2 are short (E14 socket 58 ft/lb).
Tap tap and the rtv seal gives way and the arm falls off. Use 2 large slotted screwdrivers to easily pry/wedge the stub axle out of the clam.
Matt supplied me with the G2 488 reverse cut gears. 41231-22010 is the correct Toyota part number for the crush sleeve.
Remove the 10 bolts and the lid will tap off. The 2 steel locating dowels are a tight fit so it will take a bit of tapping to free the lid.
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The 488 ring will be installed first.
Both surfaces are checked with a file to see if any burrs or irregularities are present. All was good.
70 ft/lb on all 10.
Now to remove the pinion nut.
Axle stub seal just came in so it gets put off to the side for now.
Whoever installed the ARB did some damage to this air bearing assembly. Also, note the scuff ring on the washer plate from the cage of the carrier bearing rubbing on it.
Appears they tapped it in with a hammer making direct contact with these soft delicate edges.
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The washer plate with the drilled holes and the air bearing assembly will be pressed out at the same time.
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This assembly will be replaced.
Pinion pressed out very smoothly.
I noted the washer plates on both the lid cover and the deep dish bowl. The bowl side only had a single thick .092" washer plate. Where's the 20 to 30 thou of additional shim that is required for a proper ARB install? Not using that shim means the cage of the bearing grinds against the factory washer plate.
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Race is pressed out of the damaged air bearing assembly.
Skipped a photo or 2....new assembly is pressed on the race.....then that unit is pressed into the lid as shown above with a washer plate AND .024" worth of thin shouldered shims...shims that will prevent the cage of the ARB supplied bearing from scraping the plate in the future.
Backlash check with the new washer plates.....a normal dial indicator will not work for the clams..... a test indicator must be used.
Drive side....using the oem .0795" shim shows to be too shallow.
Coast is shallow.
Changing washer plates to get the BL and CBPL closer to target. Not shown but the pinion shim depth was replaced with a thicker .084" shim
Test indicator is in place and now to check BL by rocking the ring gear back and forth using the crosspin.
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Drive side....Very good....exact depth but I still want it a few thou deeper for maximum strength.
Coast
One more teardown for pinion depth....
This is it....3 thou deeper than the last pattern check for a final shim of .087"
OEM crush is going in now. 41231-22010
So is the oem pinion seal. 90311-47012
Recessed down per spec .177"...... plus or minus .012"
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Tighten in small increments in order to not overshoot the spec.
Used pinion bearings so I now have a final PPL of 6 in/lb.
A double check to verify there are no high spots or burrs and all is good.
Final pattern check with the thicker .087 shim and this is the slight deep condition that I like.
Coast is very nice.
Comet tail says it all....the tail is not tucked hard into the root.
Nice.
A final backlash check....the minimum BL measured in 4 places on the ring was .005"
New o-rings
Comparison of the old style o-rings on the left with the newer style Viton o-rings (quad ring design).
Lubed and in place.
Per the FSM, a single bead of Toyota FIPG sealant.
These 10 lid bolts get 51 ft/lb.
ARB test....85 psi at 10 minutes or so....never lost a pound.
New axle stub seal 90311-47012
Notes during the install....sorry about the missing info on the exact washer plates used on lid versus the deep bowl. Will be more thoughtful on future clams.