Finally got the pinion yoke cleaned completely and now its time to set up the diff.
Photos 953 - 956 - Yoke
I decided to go with a solid pinion shim for this application. I measured the old crush sleeve and it was 2.283 - 2.278". I added shims to the sleeve to hit right at 2.282" and left the pinion seal out while I attempt the setup. Overall the carrier shims were 0.242" on the left and 0.063, 0.063, 0.098" on right of the carrier looking at the diff. Overall total was 0.476". the final setup was on the left 0.242 & 0.013" and the right side was 0.160, 0.063" for a total of 0.0478". This put the backlash right at 0.006 - 0.007". These are used gears and do not show the same pattern as new gears but this is an acceptable wear pattern (confirmed by a couple of folks that have experience). Pinion shim could have been a little thicker to deepen the pattern engagement but for all I am happy with the look. Worst case once the car is up and running and if there is a whine on decel then I will go back into it.
Photos 957 - 958 - Pinion installed with the correct resistance on the bearings. I've always gone off of feel and it hasn't failed me yet. Note: the carrier shim photos are not the final shims used for the setup. Just ones I tried using to accomplish the correct backlash.
Photos 959 - 960 - Carrier bolted down using a crossing pattern and then using a magnetic base and dial indicator confirmed the backlash was 0.006 - 0.007".
Photos 961 - 962 - gear mesh
Photos 963 - 965 - Pinion seal, "New" aluminum diff cover, vent and yoke.
Going today to hopefully get gear lube, posi additive and evaporust should be delivered today or tomorrow.
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