Jay from Edmonton, AB, Canada gets 488's, spool, new aftermarket diff housing.
(68 BIG pics loading)
NOV 17 2016

Jay supplied all the product including the new aftermarket diff housing. Jay had actually sent 2 diffs....1 in the grey plastic container and the other in another plastic container. As shown, the other diff arrived in a heavy duty cardboard box which seemed strange. Numerous phonecalls revealed they damaged the plastic container and had to rebox. write up for diff #2 (the 488 elocker)
Double boxing the diffs that are sent to me is still the way to go.
Items are laid out.
Start with the ring gear....verify there were no burrs or high spots.
Blue loctite and torque to 70 ft/lb.
Then the new carrier bearings are pressed on.
This end is done.
Both pinion races can now be tapped in place.
Selecting the starter shim. 075" will probably be a good bet.
Pressing the shim and bearing in place.
Mounting the pinion.
Mount the ring gear/spool assembly and dial in about .006" backlash.
Wow....not only is it deep it's VERY deep.
Coast confirms that.
Drive on the pinion tooth is riding on the tips.....shallow on the pinion means deep on the ring.
Remove the pinion from the diff housing.
Press the bearing off...
Selecting a thinner pinion shim.....this time it will be 065.
065 is slightly better but way too deep still.
Same on the coast.
Tear down again....this is with 043".....still too deep but getting much closer.
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Tear down again.....038" still deep but better.
Coast is better.
Drive side....
Pedrhaps jut a tad too deep still.
035".....I like this look. After 1 full row of Oreos it now kinda looks like the outline of a Ferrari.
I like the coast side...it's even in the center which doesn't happen all the time.
Drive.............
Looks like the comet tail is tucking in some........ 035 is the desired pinion shim. This is highly unusual to have this small of a shim....a typical shim would be 080 and 035 is a long way from it. Just the way this aftermarket bore hole was drilled.
Tucking in but not harshly to the root.
The Marlin seal on the right is extra insurance against leaks.
The aftermarket seal is "ok".
The Marlin eco seal has 3 sealing surfaces and the main bottom seal lip is riding in a location that none of the other seals can reach.
Solid collar to be installed now.
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Getting the just right pinion preload involves re-shimming the solid collar numerous times .....assemble then disassemble....assemble then disassemble. Note the shop flange is used for this operation.
This time it took 6 tries.
Now the Marlin seal can be tapped down evenly with the special tool.
Final PPL checked in at 11 inch/pounds.
A low profile DING! takes care of this end.
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These wheel adjusters are well machined and very beefy.
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70 ft
Backlash and carrier bearing preloads are dialed in.
Masking off the wheel adjuster, the sides can be clearanced with a flapper wheel.
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The clearancing will allow the 3rd to fit into the axle housing hole. 10 ft/lbs on the 2 lock tabs.
Last final check and the drive side looks nice.
Coast.
Engraving the specs on the ring gear.
Notes taken.
Nice looking hi-pinion 3rd.
Sometimes, I use an old blanket to wrap the 3rd for the double box.
Some extra cushioning.
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3rd dropped in.....
More cushioning on the topside...
Now to final wrap the box 6 or 7 times with a heavy duty tape and ready to go to Fedex.