My Big Can of Worms Build

Working on getting the alignment dialed in prior to going forward with the shock hoops.




Got some teasing pics from LSK



Been getting invaded by strange creatures at night! Never seen this kind of snail before and saw 2 that night.



Found 2 of these guys in my apartment - they are as loud as mice haha



Sold my old coilovers and got some more welding practice tools




Thanks to @Tacomoto23 got the double shears installed on one side





Checking for bumpsteer



We out here poppin' dat um seltzer



A week after Thanksgiving, but it's not too late for some stuffing



Time to turn in for the night (er morning)

 

Thanks! Nothing like living someone's life vicariously through their build page! There's some on here and Dezertrangers.com I've read more than once haha!

Thanks Justin! How's your girlfriend's truck coming along? Did you ever replace that stolen light bar?

 

Packed up the rear diff for @ZUK to install my BF deal locker in it



Followed his packing instructions here:

http://www.gearinstalls.com/box.htm

Shipping was only $55! Spent $5.00 or so on packing materials.

This was in the parking lot. Do you even overland bro?



Digging the tri-tone look on this side - may keep it for awhile.



Getting more ideas for a front bumper - love @Spoonman's diy he made

 

Some fun things showed up at ZUK's

 

Hey Dalandser-
Just got this ........... The plan looks like a new OEM factory pinion seal and install the awesome Harrop elocker and
re-use the carrier bearings if they are acceptable
More pics to come.
ZUK
ps-----the box held up great. Good use of that "insta-foam paks"

 

Shown is the A13457 Harrop elocker for the well deserved 8.4".......
Anthony ordered it from ECGS and had it sent directly to me........
Just a couple years ago there was no 8.4" Harrop option......
Distributors Ward and Georg over at https://www.cruiserbrothers.com/harrop-elockers/ get 95 % of the credit for pursuing this market void....
I get 5% for bringing it to Wards attention

I love the workmanship of these babies.





So, we are keeping the 4.56 factory gears and adding a Harrop and solid collar and new Genuine 44007 seal.
Here, I am checking the pattern and noting the backlash in 7 different places which was a nice snug .004" ~ .005" right from the factory.

Now to tear it down.....

 

Removed the brace and the carrier bearing washer plates came right out with just 2 fingers. There was no preload at all. But, when I get down with it,
it will be like "factory".....and probably a bit more than the factory at that.





I'm going to recommend to Anthony that we should replace both carrier bearings
based on the race condition.



The original race was fairly worn. New one shown on the right for comparison.
Both races thoroughly cleaned with tissue paper.

 

Cool let's get new bearings

 

Will do


Factory uses a good threadlock with the 12mm flange bolts.....but no problem for the electric impact.








92 ft/lb with red Loctite.




Pinion feels smooth and no noise.






Big pinion bearing in good shape.





The pinion flange is perfectly reusable. Using 1500 wet/dry to smooth it out.
The digital photo is deceiving....the seal surface looks much better than what is depicted here.
Funny how that works out.......






The all important outer pinion bearing/race is ok too.






A solid collar will replace the factory crush sleeve. Note that the factory always shims the 8.4" diff crush sleeves with 2 shims.
And the "internet" says to never do that

 

29/64 hole drilled. Gasket surface hit with a high speed 10,000 rpm wire brush.
Nothing like a new wire wheel to get a perfect surface

 

Solid collar going in. Re-using the two .032" factory shims plus another .027" that I calculated......got lucky....hit it right on the money.




Genuine Toyota




The prepped pinion flange surface looks great. #1500 sandpaper with a little water really is good insurance against a leak....if the surface is actually good with no pitting.

 

I made about 4 adjustments to get the bearing pre-load and backlash correct.
It's nice to have a full selection




Minor tweaking of the stop tabs to get the desired 2mm of freeplay.





Your favorite RTV to help the rubber grommet push thru the hole.






success

 

One more final pattern check.....drive side.....nice






Coast .....beautiful.

 

Harrop 12 volt test......





12 volts has been applied....the 3 pins just need to recess inwards







....turn the pinion a very small amount and the pins ramp up into the case and it is locked.

 

The weather is nice right now here in Chandler AZ so a nice coat of satin black paint is drying right now(not shown here)
Ready to box it up and get this 72 pound box to Anthony (Dalandser).

 

The black satin 3rd and the Harrop harness





Final assembly notes.

 

@Tacomoto23 all this and he didn't even charge me for shop rags ^^^^^^^

 

Stopped by LSK to pick up the rear kit:



Anthony250 helped me make the driver's side shock hoop.





I added some gussets after he left.




Super excited about the work we got done today! Never thought I'd see the shocks mounted since being busy with work has kept my free time to a minimum

Also my rear disk kit came in:

 

Another long work day - stoked with what we were able to accomplish.

Anthony welded on the double shears on the passenger side.



We popped the circuit breaker with all the tools going so we had to cut power to a few things while Anthony welded.



One complete:



Tried mig welding for the first time - had a couple hiccups without gas being on, power loss, and a large gap on one side of this, but I was happy since they were my first beads



The shock hoops are pretty similar I'd say



Made some bump gusset templates once Anthony left - had to quit after that though.

 

On it's own weight - gotta drive it tomorrow and turn it around