Randy double boxed the front 8" 3rd also...did a nice job.

The second box was full of rolled up cardboard strips. There was so much packing tape holding it together that there was no chance of the boxes self destructing.

The 3rd was pretty gooey.

The plan is to install 571 PRECISION gears and an Aussie Locker. A solid collar will be used. If the bearings are ok then they will be re-used which is considered ok by me in this front application.

There was no carrier bearing pre-load at all as determined by the ring gear rattling back and forth thru the backlash region. I marked everything before I tore it apart.

Putting the Aussie in is the first task. Remove the ring gear and use a long punch to knock out the roll pin.

Slide the power pin out and throw away the sidegears and spiders.

Both of the sidegear thrust washers measured .067" with the micrometers so it was not important to keep track of what side they went on.

A partial assembly is done to measure the gap between the power pin and the 2 spacers showhn in my hand. This is one of two measurements that should be done during an Aussie install...but I suspect few folks actually measure anything.

The first measurement...

The last 3 Aussies that I installed required mild filing to get the last coupler to slip into the case. This one squeaked its way thru.

By rotating one coupler at a time, I was able to get the pins in properly...I think I figured the easiest way to get the springs in also...

I employed 2 screwdrivers to spread the couplers from each other...that gave me maximum room to get the springs in. I start by pushing the spring in at the bottom side first...

...Then I push the top side in with a small screwdriver...

...then I tap it in evenly with a small screwdriver and hammer.

Aussie then recommends a second measurement be made. The gap between the 2 couplers measured .150" all the way around so this one is well within spec and should be trouble free for years to come.

The power pin now goes in and the roll pin gets tapped back in.

A couple of raps with a dull chisel will partially cave in the hole so the roll pin won't wiggle its way out.

DRIVE. The new 571 Precision ring gear goes on now. The surfaces were filed first and red loctite with 75 ft/lbs of torque will keep things tight. Shown here is the drive side. The pattern are classic picture perfect. All PG gears get this pattern check from the factory. That's a gear company that cares! :)

EDIT 1-8-2011....Too bad Tom (President) retired from that company because the gear source changed and things are no longer the same.

COAST. The coast side is perfectly placed also. If the Toyota carrier is within spec, I should be able to duplicate these painted patterns.

The ring gear went on very tight...no sloppy fit here for sure. I bet they hold that tolerance to "two tenths of a thou". ;)

The front 3rd does not see the 100% duty use that the rear does....actual usage is probably closer to 1% for most wheelers so as long as the bearings are in decent shape, I will often re-use them in a front end application to help keep costs down. Close inspection reveals these are ok....not pitted and no score marks.

My first choice is .071" for the pinion shim. Harbor freight has some great deals on these micrometers...usually right at $20.

Backlash is set near the .008" recommended spec while the carrier bearing pre-load is set to medium high levels... turning the pinion while rapping the bearing cap will allow both carrier bearings to equalize with each other.

The gear marking compound that comes in the Yukon master install kits is my favorite. The bright yellow is of the right consistency and easy to read.

This has got to be the best and easiest way to run a pattern on the Toyota 3rd...mild drag applied to the pinion while turning the ring back and forth with a 17mm wrench. This takes 3 seconds to do.

DRIVE. Too shallow (high and to the heel)

COAST. shallow agrees.

No ZUK....check your math again. We want to try 5 thou deeper for a value of .076".

DRIVE. Probably would work just fine with this but it's still a touch shallow...

COAST. Just a little shallow.

Add .002" for a final pinion value of .078".

DRIVE. Nice.

COAST. Nice again. :)

Sometimes I get "gabby" so I add my two cents ;)

If the 3rd is sent to me clean on the outside, I will do a 2 step paint process that seems to be unbelievably durable...I spray a special "adhesion promoter" followed almost immediately by a shot of Krylon glossy black.

I served time back in '76 at R.I.T. and documentation was drilled in my head...so I include a tag with the important data. Done. :)