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Harrop e-locker for Gilbert's 1994 FZJ80 Rear-end
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(63 BIG pics loading)
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MAY 26 2016
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Rear '94 3rd....Harrop....pinion bearing kit.....solid collar.
Koyo carrier bearings are already included in the box.
Contact Ward Harris (National importer/authorized dealer for Harrop) at 1-800-224-7801
or email info@cruiserbrothers.com
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The pinion pre-load was all but gone. These bearings have some miles on them. Not so loose that
it wobbles around but it was definitely ready for new ones.
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Same with carrier bearings.
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A quick paint test.....
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...reveals that the drive pattern is ok. Looks shallow right here but that will change
with a fresh inner pinion bearing.
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Coast side sees far less use and, as expected, the pattern looks excellent.
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Drive side of pinion tooth.....good.
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The Nitro pinion bearing kit
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,,,,,,,,,,,,,,,,,,,,,,
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Koyo carrier bearings.....32010 part number. As mentioned earlier, these can be tossed in the Harrop
box for about 50ish per pair(at the time of this writing).
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Well machined.
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A quick test of the electro-mechanism......without 12v, the grey piece spins easily.
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With 12 volts, there is a very soft thud noise and it feels like a strong magnet coupling to the ring below it.
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Backlash was checked and it was around .008"
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All I need to remove is the ring gear from the open carrier.
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A glance over to the pinion paint shows it's looking good, too.
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Ring gear is removed and almost ready to mount to the Harrop.
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Surfaces felt good using a file.
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The lead filled plastic hammer was able to seat the ring gear.
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81 ft/lb and red loctite.
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Carrier bearings are pressed on.
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,,,,,,,,,,,,,,,,,,
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This end is now complete.
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This pinion nut does not appear to have ever been off before....looks like the oem square dent in the nut.
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That means this is probably the original seal. Now to press the pinion out....
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patented seal removal tool
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Old race tapped out and now putting in the new one.
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Looks good.
Not shown but do the same for the small outer race....tap the old one out and replace with a new one.
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New bearing and solid collar to be installed next.
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OTC-1130 bearing separator allows easy removal of the original inner pinion bearing.
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Re-using the oem .051" pinion depth shim with the new KOYO bearing.
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Pressing the bearing on.
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Solid collar will also be installed at the same time.
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It took 6 times to finally get the perfect shimpack with the collar....
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....but now it's ready for the seal.
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Flange surface is in excellent shape.
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All together on this end and with the pinion nut extra tight I was measuring 11 in/lb for pinion preload.
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I save the drilling of the hole til the last possible moment.... X marks the spot.
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.453" drill bit right here feels right.
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...................
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Hole is drilled and now the Harrop is mounted in place. 70 ft/lb for the 4 bearing cap bolts.
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Adjuster wheels are tightened until the minimum backlash checks in at .006" or more.
Also, there needs to be a good amount of carrier bearing pre-load at the same time.
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The bearings have to be "settled in"....equalized in tension uniformly on both sides.
A sharp rap on the 4 corners will let that happen.
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Also, making sure that the "anti-rotation tabs" have about 2mm of up/down play.
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The Harrop instructions say to bend the welded on tabs slightly to make the 2 mm free play happen.
I like the idea of tapping on the bolted on bracket instead ;)
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Now is a good time to test the e-locker. It's non-polarized so hook it up either way to 12 volts.
A slight clunk can be heard in a quiet room. By NOT allowing the sidegears to turn and then
turning the pinion, the 3 pins will be seen to start their journey up the ramp ring.
And the locker is in lock mode.
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I measured the backlash on every other tooth and recorded the values. The oem spec is .0055"~.007"
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The total preload was measured at 20 in/lb start torque. That means if the pinion bearing preload is 11
then the carrier bearings must be responsible for the remaining 9.
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10 solid ft/lbs (120 in/lb) on the 2 remaining lock tabs.
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Goop on your favorite rtv...
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...and the grommet will go in with about 1/2 the effort.
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Looks good.
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Final drive side check.....good.
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Coast...even better.
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''''''''''''''''''
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''''''''''''''''''''''''
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Notes taken during this install.
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Harrop is now packed up.....
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....and ready to take to the Fedex Office and Print Center down the road from me.
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