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Setting up the diff carrier's gears questions??

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TimK1955tr2

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Hi, I have seen info on here and the web on how to set up the pinion and crown gears but none on setting up the smaller gears inside the diff carrier itself. For a Tr2/TR3 differential...

The planet and sun gears inside the carrier each have thrust washers but no mention of specs in either the factory manual or Haines.

These gear's teeth are much deeper and "sharper" compared the crown/pinion gears so I am not sure what mesh pattern I should look for.

If anyone has any thoughts or info, it is greatly appreciated!! Thanks, Tim
 
These are not nearly as critical as the ring and pinion. In fact, I have never seen any mesh specs. The differential gears do not turn in the straights when the power is on, and they turn very little in the corners when the power is off. So they do not wear unless the oil in the case is contaminated with sand, metal, etc.

Rebuild encompasses replacing the washers if they are scored or obviously worn. Look over the gears closely for cracks, broken teeth, or other very obvious damage. Then put it all back together and drive!

John
 
Aloha Tim,

I needed to replace the clunking differential in my TR6 daily driver. I got the whole rear drive set-up real cheap and disassembled and reassembled the diff. The front bearing and one carrier bearing were bad, and the planet gear thrust washers were loose, badly scored, and thinner than normal.

While there's a lot about the other aspects of the diff, I only found one sentence on sun/planet gear specs at 51.25.19 in the TR6 factory manual, Step 38: "Select and fit planet gear thrust washers as required to obtain zero backlash." The washers are brass and available in several thicknesses to suit.

The sun gears also have thrust washers, but don't seem to wear much, and fixing the planet gear washers will take up minor wear there. Here are the measurements I got for the carrier gear set-up:

Planet gear measured gap as found: .024 (feeler gauge)
- Planet gear washer thickness as found: .032 & .021
- Planet gear washers fitted: .056 (no sun-planet backlash; turns smoothly)

1,000 miles and so far so good. I used the same rear (pinion) bearing, and all the other specs (backlash, mesh pattern, etc) were OK. This was on a TR6, but a TR3 should be basically the same, just longer output shafts!

Jeff
2 x TR6
Mele Kalikimaka!
 
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