Outer Limits 4x4 Board

Hey guys just wondering if anyone can give me some more ideas on my current problem:

Current Problem:

-i buggered my pinion (breaking 3 teeth straight off) i managed to pick up a second hand crownwheel and pinion. I had to machine down the new pinion to fit with the Airlocker housing due to it being larger then the standard carrier. The new pinion was machined to the same size as the old. The new and old crownwheels and pinions are the same ratio however the teeth and diameter of the new pinion are larger then the old. Even after machining the new pinion and removing the shims between the pinion bearing and the pinion it is still hitting the airlocker housing.

my questions are:

-Does the new pinion need machining further?
-Is the airlocker housing bent causing these problems?
-Or is it something else?

thanks guys

sounds like needs more machining.

What model airlocker are u using? And wat year model is the C&P set from?

Later model trucks from about 89 on use the larger 8" C&P, earlier trucks use smaller profile gear. This is commonly refered to as either 4cyl or V6 diffs but it in fact goes by year more then engine. Could this be your issue? Have a read of the blog below.

http://www.locktup4x4.com.au/blog/?cat=6" onclick="window.open(this.href);return false;

Sounds like you might have a v6 cw&p I know the pinion bearings on them Are quite a bit larger and 90% sure the crownwheel is thicker also so you will need the 3rd member to match it, also think you will need different carrier bearings to match it up with the airlocker or you could machine a spacer up for it.

Sounds like you might have a v6 cw&p I know the pinion bearings on them Are quite a bit larger and 90% sure the crownwheel is thicker also so you will need the 3rd member to match it, also think you will need different carrier bearings to match it up with the airlocker or you could machine a spacer up for it.

I recently fitted a new V6 C&P set to my diesel carrier with a RD132 locker, There is a bearing size, possibly you have used the wrong bearings?

hilux have lots of differnt gear sets some have biger bearings and some have a biger pinion hight