RE: Gear Install Advice for DFW Mark
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... Any advice on how to do this, if I do it myself what tools do I need?
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I've been down this road. Do a search for other threads relating this experience.
I bought a used traction lock differential and a used stock center section. I then bought a new 4.10 gearset, deluxe install kit and a traction lock rebuild kit.
Then I studied the manual, asked a lot of questions and enlisted the help of a friend/co-worker to do the install. My previous experience with gears were years ago - and all straight axle. However, I felt confident and with the moral support of my friend, we succeeded.
The traction lock rebuild kit will come with instructions, and is easy enough to follow if you elect that is what you want to do.
Your first obstacle is the case spreader, which is a tool used to spread the case to allow easy removal of the differential and ring gear. We found it wasn't necessary, but it would make it easier to remove and install the differential. Removal of the pinion wasn't an issue.
The setting depth of the new pinion is critical. The manual calls for a special tool, but you can come up with the shim selection without it. A digital caliper is what I used. The installation of the pinion is not too difficult, but requires some brute force to crush the crush sleeve to set the preload - and you only get one shot.
The ring gear bolts on the differential and the you install the differential with shims and bearings. Now you need to measure the backlash and then adjust the shims left and right to establish the preferred backlash. It took me three tries at this to get it just right.
Once the center section has been set up, the actual R&R is not too bad. There has been a couple of good threads recently about this process. It took us one afternoon to do the gears and another short 4 hour afternoon to do the swap. This was the first IRS either of us had worked on.
So, IMHO, number one - get a manual. Number two - call Max at fivestar and he'll get you what you need for the install. Number three - enlist the help of a friend. Number four - we're here to try and help. I'm not sure I would've done it myself without people on this site and others who answered many questions long before the install.