Who has done differential re-gears?! Because I need some help.

Re-gearing a Chrysler 8.25 (next is D30 HP) in a 2000XJ, from 3.55 to 4.10, Revolution gears.

I’ve never done gears but with many years of automotive experience I decided to try it myself. I would appreciate some thoughts, opinions and some experience on these patterns please!?

I have a few patterns with different shim thicknesses. The photos are a little self explanatory and if there’s any questions I can help.

Pinion torque (12-15 in.lbs) was always checked when changing pinion shims.
Backlash was always set between .005-.006 with the same procedure.

It’s obvious .027 is too shallow




.030 looks better than .027




While .030 looks better it still seemed a little close to the crown, so I tried .032

 

Dude you got it.

Id run backlash alittle looser like 8ish give gears alittle more oil cushion.

Otherewise you got it. Nothing wring with tighter backlash maybe run thinner oil.

 

So do think the .032 is the winner or the .030?

I run 75w-90 in front and rear. I don't tow anything.
More backlash doesn't seem like a bad idea. (I just read/heard that the closer the backlash the better? Since it wears out over time?) Im not sure if that gear oil weight is acceptable or if I should use 80w-90?

 

The oldtimers say more is better the metal actually doesnt touch with a hydraulic film of oul seperation.

I bet 5-10 in the real worl doesnt.

Ill look your pics over

 

if I had a pattern like the .032 and the backlash is 5-6, I would button up and be done, probably loosen up a thou or 2 when run in

 

Thanks for replying awg. I decided on the .032 as well. Finding accurate specs is frustrating because one source says .005-.008 backlash while the other says .006-.010. I was following .005-.008 but according the gear manufacturer it's .006-.010 so I might shoot for .007

Sorry I just I have to add; ANOTHER frustrating specification are sources saying carrier bearing cap bolts get torqued to 100 ft.lbs while the other says 60 ft.lbs. Same with ring gear bolt torques I've read 55 or 80 ft/lbs.
I feel 100 ft.lbs isn't necessary for bearing caps but what do I know

 

Have you got the FSM?..all specs are in there, free download etc etc

I would certainly use blue loctite on all diff bolts

 

I don't have the FSM and don't know where to find it

 

our esteemed leader cruiser54, go to his icon, then his webpage, or it can sometimes be found on Google, heck, I even have a link to some stuff on my Google drive, search the archibes on this forum, and there are links etc etc

 

Thank you