Destroyed front pinion on Zachary's 94 FZJ80
(53 BIG pics loading)
NOV 17 2016

Zachary's front 8" diff in his 94 FZJ80 finally gave up the ghost as he put it. He said it was loudly knocking/pinging and sometimes making BANG sounds.
This double box arrived to me. That's a good 410 take-out that will be installed for Zach.
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Pretty good job of cushioning the 3rd.
Elocker high pinion 3rd is a little dirty and will fix that shortly.
Ring teeth are hammered. Will also clean the gasket surface like new.
Pinion teeth have been nuked.
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Flange is removed and pinion pressed out.
Seal was removed and all the rubber materials were "brittlized".
Cleaned up the soft rubber has been transformed into a hard brittle plastic. There must have been extreme heat to do this.
The pinion probably was approaching red hot and that made the teeth soft.
A smaller sized set of front tires was run for a period of time and he figures that was probably the cause due to the transfer case viscous coupler does not take kindly to the difference in driveshaft speeds.
Some good scars/gouges just above the race.
The extreme heat did not get to the elocker case...sidegears and spiders turned smoothly.
The 8 case bolts were verified to be 45 ft/lb and they all were.
Some cleaner/high speed wire brush/satin paint made this happen.
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The good 410 reverse cut ring will be mounted....
...and torqued to 70 ft/lb with blue loctite.
A Nitro bearing kit from JustDifferentials and a Marlin eco seal.
Cleaned up to the max.....there was somewhat of a groove as can be seen so I may go ahead and replace it with a tnew triple drilled flange.
I actually think these Marlin seals are the best seal to help guarantee no gear oil leakage. I know there has been some talk out there about leaks but there were likely other serious issues going on.
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Excuse the bottle mistake. In reality, Loctite #638 retaining compound was used on the pinion races to firmly lock them in place.....the wrong bottle was posed in the pic.
Same here.....the green retaining compound was used here, too.
For the first pinion shim depth we will use .0795"
Press the new bearing on with the 12 ton. The white Yota flatbed is a 92 22re 5 speed. It was a fun build. The white Sami was bought off the showroom floor in 1990. Moab Rim trail....the Devil's Crack. My sister painted that kitty. That's Bullseye.
Zach also sent the e-motor with the 3rd. It was not working most of the time and all I could do was run a 1.5 volt test and it failed....no movement noted with the battery applied to pins 2 and 3.
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Pinion was loaded into the empty 3rd. For this paint test, the pinion preload does not have to be precise.....just as long as it turns "firmly".
Drive side....hmmmm...a touch deeper than my taste.
Coast....a little deep.
Drive on the pinion tooth.
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Taking .003" off with this new .077" shim.
Drive. Looks good.
Coast deepish but good.
Drive.
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I would recommend a solid collar for hardcore useage. 37" tires.....double cases.....manual transmission is the formula for a solid collar. Zach does not need one with his intended useage and an auto tranny. Crush it is.
Crush is already in and the Marlin seal was tapped in place.
Was going to use the factory flange with a small groove but changed my mind.
Elected to use a new triple drilled one.
A nice 12 in/lb of smooth, repeatable pinion start torque noted.
Ding and this will not loosen on its own.
Loading up the elocker guts now.
70 ft/lb on the 4 bearing cap bolts.
Carrier bearing preload and backlash are "synchronized". BL checked on every other tooth.
The correct bottle is posing in the pic. 10 ft/lb and some blue loctite.
Date coded.
Final assembly notes.