Blew up 8.75 BD22AN rear locker

I recently jacked up the rear axle because my locker wasn’t engaging. Relay was receiving power so I knew it was something in the gears. When I engaged the locker I could hear a clicking noise coming from inside the third member. I pulled the third member and saw some metal tooth chips floating around, one of the spider gear teeth have chipped if not multiple that I can’t see. The ring and pinion are totally fine, no abrasions to them.

does anyone know if I can just weld all 6 spider gears together to lock up the rear for good? Otherwise my only 3 options are either buy an arb air locker. Buy a new locker third member from a totalled Tacoma. Or buy an open (no locker) third member from a Tacoma to weld the spider gears. I am a desert racer so going through the whoops you need constant power to both rear wheels so you can keep the rear med straight hopping over the big whoops at 60+ mph, This truck is not a daily driver so I need the rear locked indefinitely if it’s going to ensure reliability.

 

As a means of avoiding vibrations with welds, a spool from ECGS could be a cheap option.
Either way sounds like a blast and hope the fix goes smoothly.

 

This TW member is selling theirs

https://www.tacomaworld.com/threads/oem-e-locker.848580/

 

nobody makes a spool for the 8.75” axle.

 

right on I’ll hit him up.

 

If, as you say this is off-road only and you have had the rear locked doing the 60MPH and jumps then I would go with the welded locker. I don't believe a replacement e-locker will last, your original didn't!

 

Right here ^^^

If you need both axles locked, another E-locker is not the answer. Lock your side gear to the lock collar. And then rock the side gear when locked. There is a fair amount of play in the assembly. This play at high speed will be amplified and the force on the couple of teeth keeping the axles locked will huge. Over extend use these teeth will fail, as you have found out.

Since there is no spool option, save yourself the trouble, find an open diff from a manual non Offroad or Pro Truck and lincoln locker it!

 

Are they the same size? Will it fit into his existing third member case? I do not know the answer to this question. That is why I suggested welding his existing setup spider gears.

Another question to consider is if any mod will produce a code or dash light from the 4WD ECU. Since the vehicle is used off road only a code or light might not bother the OP?

Just some additional thoughts I have no interest in looking into again. I've made my decision to move to ARBs when I get the time.

 

Haha sounds good. Yea an ideal option would be to get a bd22a open diff assembly. Yes it would fit as they share the same housing. As y'all said, cheapest would be to just weld the existing spider gears together right. Thiers a housing protecting the spider gears, I can see about 6 gears within I think.. typically it’s only 4 but I think these have 6. Have any of you dissected one of these 3rd member before? Would you know which spider gears out of the 6 to specifically weld together?

 

could you further explain? Which spider gear would I weld to the collar? Could you maybe show me in a photo? Or I could FaceTime you idk.

 

I have pulled one apart. A core, and I have a like new take off unit. Stupidly I never took any pictures when I tore open the core.

There are 4 spider gears and 2 side gears. One side gear has a cog on the back of it that matched to the locking cog on the carrier. Ideally you would weld the side gears and spider gears to the carrier and each other. The issue with the locker, is there is no way to get a welder into the carrier to get a sufficient weld.


As you can see there are only these small windows to access the gears. ( The blue arrow is pointing to the plate that triggers the lock switch for dash light indicator)


On an open differential, you have more space to weld the spiders and side gears. More weld, more stronger. ( I googled 'open 8.75 Toyota diff' and found this on the Marlin Crawler website, so I hope it is representative of an open diff ) another thing to add strength is to make a plate to fit into the opening and weld that to the teeth on both sides. This will add more strength.


Not my photo. I found it on the web.

 

Here you go:
Stock 8.75" BD22AN Locker dissection | Tacoma World

Pic by:
@Jowett

Added:
Perhaps the welding could be done before putting on the case cover that the 12 bolt heads are against?

 

I was able to get a decent bit of weld down as hot as I could. Seems to be holding up and working as it should. It’s locked up from my testing today drifting the truck. gonna pull the plug and see if any chips came out from romping on it today.

 

If my uniballs have a bit of play is it safe to keep romping on them through whoops? Will they pop out eventually if I keep beating on them without replacing soon?

 

No personal experience with uniballs, but typically undesired play in suspension components leads to failure. I would recommend replacing ( or rebuilding if possible ) as soon as possible.

 

Wired up these harbor freight lights to the bumper I recently built. Super bright!

 

I don’t see a bumper?

That last picture answers a lot of questions my wondering mind had that are all answered by your truck being a trailer queen.

 

These sorts of threads make me jealous that when I was 16 I didn’t have enough money to buy a $10k pickup and treat it like a $500 dirt bike (1980’s dollars)

 

I started 4-wheeling with a bunch of late teens and early 20-somethings while being 20 years older than any of them. They did some really stupid (and to me incredible) things to their vehicles and would break down often. They however did show a lot of ingenuity in getting going again. One of them is now an Ag Mechanics instructor at a regional High School.

 

Helps that I don’t have a wife & Kids haha. I started working as a project manager for a roofing company about 4 years ago at 19. Now 23 and stacked up a good amount of money! Kids these days just don’t want to put in the effort. I was working 12hrs a day 4/5 days a week back when I was doing roofing. Now 23yrs old. Before my Dad died recently he raced Ferrari Challenge all over the world. Racings in my blood, the only thing I dream about. Plan is to turn this taco into a 1450 class truck. Still have my Dads helmet/Hans Device! We had the same name too so don’t need to change any name tags.