New pinion gear is thicker than original

[ucs75]

Index - 008
Pinion Shim: .038
Carrier-Left Shim: .223
Carrier-Right Shim: .223
Backlash: Not measurable
Pattern:

The carrier was so tight that I could barely turn it, and it took multiple people to pry it back out again.
This may have part of the backlash issue, but I couldn't feel any.

 

[ucs75]

Index - 009
Pinion Shim: .038
Carrier-Left Shim: .213
Carrier-Right Shim: .229
Backlash: .010
Pattern:

I removed .004 from the total shims to address the issue in index 008. This time it felt better, and I had .010 of backlash.
Feedback on pattern?

 

[CalSgt]

Index - 009
Pinion Shim: .038
Carrier-Left Shim: .213
Carrier-Right Shim: .229
Backlash: .010
Pattern:

I removed .004 from the total shims to address the issue in index 008. This time it felt better, and I had .010 of backlash.
Feedback on pattern?

I like it... I would run with that pattern and backlash if it were mine.

 

[ucs75]

Thanks guys.
I appreciate the advice and feedback. I believe that with this experience, I'll be able to do the rear differential much faster without the back and forth.
My hope is that with all the back and forth, along with measurements and images this will be able to help others.

I've already ordered the new pinion nut for for pickup tomorrow along with the spanner socket for putting the knuckles back on the axle. With any luck, I'll have the diff sealed up with new axles in place tomorrow.
Then I can start fabricating the dust shields to weld back onto the brake backing plates, and might just have wheels/tires on it within a couple weeks.

As you can see, this is a long-term project.
Once the front wheels are on the ground, I'll be able to chock all four, and then I'll be comfortable disconnecting the parking brake (and transfer case linkage) to lift the body up and continue frame cleanup.

 

[CalSgt]

Here's a little trick for bolting up your knuckles if the lower BJ shank starts spinning before you get it tightened to spec:

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