Since this carrier is the wrong pinion offset
all I have to do now is switch the pinion and
races over to the new one..... 



The 10 ton press is a cheap investment.....
worth it's weight in gold. 



I pressed the races into the new 3rd and used
a soft chisel to make sure the races were in
all the way. When the races are bottomed out,
the chisel wants to jump out of your hand 
when smacked.


edit---Best to stay away from all punches...use an old race to
evenly "pat" the new race down.
1-7-2011 ZUK
 

 
Ended up using .030" for the pinion 
pre-load shim......14 in/lbs.
 


Just put the case in and carefully aligned
the bearing caps making sure to get the right 
mesh on the adjuster threads. 



While maintaining about 8 thou backlash,
the carrier bearing pre-load needed to be 
high. This will prevent ring gear deflections
....at least due to 'relaxed' bearings. 



Using .076" on the pinion results in this
good drive side pattern. But it was still
a tad deep.....taking 2 thou off will 
make it a winner. 



Coast side 



Out everything comes again....case...pinion....
and now safely remove the bearing with a
bearing separator.
 


Man, I couldn't believe how snug of a fit 
that bearing was on that pinion! With some 
negotiating, everything worked out. 



I maintained the 8 thou BL and really 
snugged the bearings down. 



I like to take a large screwdriver and
wedge it in there to create good drag
for excellent paints. 



Shim is now .074"...Nice.....this kind of 
pattern keeps both the ring gear teeth and 
pinion teeth in their strong region......
neither tooth is too deep nor too shallow.....
the contact patch is in the ideal center
of BOTH sets of teeth(pitch line). Follow this
link HERE for some interesting
'contact' info/good pics. 



Coast side
 


Dry start-up on this seal?....I doubt it. 



I used blue Loctite on the pinion nut and 
a cheater bar. I staked the nut......hehehe. 
OK Josh....give it the usual new gear
break-in......don't drive it on the 
highway for a couple weeks....but it's
ok to drive around town all you want. 
Stay under 60. Lotsa stops and starts 
are a good thing. Change the oil after a 
month or so. 

.....And as far as being offroad and 
in the boulders......be as hard as you
want....the 529 gears won't be the weak link.