Ok, Iím by no means a newb but it seems that for the life of me I canít get my kanai diffs to co-operate with me. Itís the front diff that has really been causing me problems. A worn out original diff the (TCLD or whatever) prompted me to install a standard diff. I ordered all the correct parts but keep chewing up parts. Here is the low down:
Installed everything identical to the initial set-up and wore the teeth off of the pinion after one day. I thought perhaps I shimmed it too much. Also thought perhaps diff case was getting worn out.
Put everything back together with new diff case as per the manual drawings. Seemed to have a good mesh but the whining and screeching told me otherwise. Tore everything apart, checked for drag brake, replaced the internal gears and fluid on all three diffs, checked wheel bearings. Replaced the drive pinions on front and rear.
In a very late night haste to get ready for a race I accidentally installed the thick washer between the inner bearing and the pinion gear...which caused friction, heat and a case meltdown. AAAAARRRRRRRRGGGGGHHHHHHHHH. I bought completely new bearings for the diffs, a new case, and Iím ready to re-install everything.
So.... the questions are.... 1st. Where does the thick washer go? It seems that it should go behind the inner diff bearing and the case. If I leave the washer out the pinion is too far back in the case to mesh well with the ring gear. The manual shows the washer but doesnít show where to put it in!!! 2nd. When shimming the diff left and right..how tight should it be? Is a little play acceptable? 3rd. Iím using the diff case with the grooves on the outside, should I be using the smooth diff case with the non TCLD gears?. they seemed to fit well.
Any help would be greatly appreciated. In 3years of MTís, stadium trucks and buggies I have never had problems like this before.