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With 2 tenths of clearance I'd be more concerned about thermal expansion being the issue more than torque causing movement. Ok its not going to get as warm as the rear as it's not in a constant work condition but it will still get warm eventually.
Temeraire (2018 quasar grey automatic)
One of the last 200ish of the gen3s, probably.
ADOS Attention Deficit Ooooh Shiny!
As the housing will be heated by the hot oil inside the diff, the heat expansion will mostly be the same on housing and gears. Could be a problem when going thru a stream or driving in cold and wet weather. Easily calculated though, I can check when I get back to work.
Small gaps between rotating parts will also increase temperature and in worst cases make the oil foam and deteriorate.
I wonder if the 10 bolt front will have the same issues? Owners of older Jimnys may be better off buying that and sourcing a 10 bolt third member.
Anyway, I hope it all works out for you. A front locker is a great thing to have. Great traction without the loss of agility.
Another point comes to mind. Our cousins across the pond do not like the collapsible spacer on the pinion shaft and neither do I. The reasoning is that if the tube will collapse to give you the degree of pre-load required, then it can easily collapse a bit more and induce bending in the shaft and that could be the answer. So I bought a solid spacer and fitted it into the back axle of my LC. Now I hadn't had a problem before and the mod. didn't give me one after I fitted it as there was sufficient clearance but on the diff. in question with an obvious problem, it is something to think about.
Also what is the crown wheel contact patch like, could it be a pinion depthing issue?
I have to admit I didn't check. I didn't touch the pinion and I doubt if Suzuki got it wrong originally. I'm pretty confident it's never been taken apart before.
I left the clearance as tight as it is because under load the pinion should be pushing the crown wheel away so if anything the clearance should increase. Oh well, the only way to find out is to run it for a while and see what happens.
I wonder if the 10 bolt front will have the same issues? Owners of older Jimnys may be better off buying that and sourcing a 10 bolt third member.
To be honest, looking back that's what I should have done. The 8 bolt doesn't fill me full of confidence. The bolt sticking through the side of the housing to control the ring gear flex really doesn't give me a warm and fuzzy feeling. By the way, does anyone know the correct adjustment of that bolt? I just left it alone in the hope that the clearance was already correct. I couldn't find any reference to it in the online manual.
As far as I know the 10 bolt is basically the same as the rear just with smaller splines so clearance should not be an issue.
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