Chrysler 8.25 regear to 4.54 pinion depth

[1986goose]

How’s my pattern boys? 
 

I’m putting Yukon gears into a Chrysler 8.25 I pulled from the junkyard so I can put that into my 86 MJ. Right now I’m running an open diff 4.10 D35. Any recommendation on how many shims I need to set pinion depth? I’m guessing at least 0.004” lol. It’s really bad maybe I should jump to 0.006” I only want to put it back together once. 
 

Thanks, 

[derf]

That's way off.  And you don't show the other side of the teeth so we can't see the other half of the pattern.

 

And I know you don't want to take it apart multiple times but you will very likely have to.  It's part of the process.

[89 MJ]

[1986goose]

12 minutes ago, 89 MJ said:

Ok but if you had to guess

[derf]

Need to see the other side of the teeth to know what to recommend.

[ghetdjc320]

I’m a little confused here. The 8.25 doesn’t use any shims. It has side adjusters and a crush sleeve. 

[1986goose]

3 minutes ago, ghetdjc320 said:

I’m a little confused here. The 8.25 doesn’t use any shims. It has side adjusters and a crush sleeve. 

You can put shims beneath the race for the pinion inside (larger) bearing.

 

I did some research and I need to use a caliper to find the difference in depth from the old pinion to new pinion. I’ll start there 

[ghetdjc320]

I’d completely ignore any old settings. Yukon presents its own machining variables anyways. From the looks of your pattern, you’re missing backlash

[1986goose]

For reference, I have added 0.004” (four-one thousandths) to the pinion depth. I’m going to remove 0.0005” (I have 0.0015” shims) to bring it to the middle of the tooth. 

[derf]

What is your backlash?

[1986goose]

14 hours ago, derf said:

What is your backlash?

0.005”

 

 

[1986goose]

Just now, 1986goose said:

0.005”

 

 

Final result: 

 

Total shims added: 0.0035”