Transfer lever jumping back into 4WD

I see, great catch, thanks again!

What would it take to sort this out tho?
I assume I would have to replace the pinion and ring?
If the installed e-locker is 10 bolts, I would have to stick to 10 bolts ring right? Is there such thing as 10 bolts with the same ratio as my other diff so they can match or will I have to also replace the locker? it’s alot of money and I don’t trust that guy ever touching it again.

He didn’t mention anything about grinding the axle case and I doubt he would if I asked, I guess the only way to find out is taking it out.

What damage could I cause if I keep driving like this? 4WD

With it being 1/4 turn out, I'd have thought the front was an auto 4.090 and the back manual 3.909

3.909/4.090 x 5 turns = 4.75 turns.

Or, the front could be a late manual 4.3 and the back an auto 4.090

4.090/4.3 x 5 turns = 4.75 turns

I chose 5 turns as if one was a 4.3 and the other 3.909  10 turns would be near enough one turn out and you wouldn't see anything, but 5 turns would put it half a turn out.

3.909/4.3 X 5 turns = 4.54 turns  1/2 turn out over 5 turns.

Whichever, the 2 diff are different ratio and that is the cause of the problem.

Pull the rear diff and count the teeth, then either get a front that matches and transfer the locker, or pull the front and count the teeth, then get a rear that matches it, BUT this will alter the speed in gears, unless you fit larger tyres that bring the overall ratio back to original.


Now you see why I don't trust anyone else to work on my car...


 

Wish I had as much knowledge as you guys, thanks alot, now I understand better what ratios mean.

So basically now I need to match the count of the teeth on the pinion ring in both diffs, is that correct?

I think the challenge will be finding a pinion ring with the same ratio as the rear one and 10 bolts so the locker fits, I don’t even know what fits and what doesn’t, would really appreciate some tips.

Sounds expensive as I’ve already paid too much on the front axle so I’m wondering, will something break if I drive like this (sometimes offroad so I need 4WD)  until I find a better diff? 
 

You work out the diff ratio by dividing the number of teeth on the crownwheel by the number of teeth on the pinion.

Probably the pinions are the same and the crownwheels are different, which is why the 4.3 diff is larger diameter (it has more teeth) and won't go in the axle case without grinding the case a little.

If you use 4wd something will definitely break if the surface is grippy, whatever you tested it on was too grippy as it caused all that wind up.

 

I see, thanks for explaining the whole ratio thing.

I will remove the rear diff and count the teeth on the crown wheel, then do the front one which will be different, if I understand correctly, the only piece that I need to replace is the crownwheel as the pinion is identical, correct?

Does the transfer box have anything to do with this?

Thanks

If yours is a 2001 manual, and the rear diff hasn't been changed, you need a front diff from a 2002-2005 (non-vvt) manual. They will be the same ratio but with the 10 bolt ring gear.