Front Truetrac / Yukon 4.88 / Driveshaft ftment issue!

[TorqueOfTheDevil]

Hi Guys, I hope someone can help shed some light on an issue I'm having.

I thought this was going to be a nice straight forward install.. but its really not turning out that way! I have searched the forum and google... and found nothing.

I am currently rebuilding my driveline to have front and rear Truetracs with 4.88 gearing.

The kit was all supplied by Randy's Ring & Pinion, and consists of front and rear Yukon gears, the two Trutrac units, and the "USA Standard" master fitting kits. the differentials themselves were assembled by a local axle shop.

The issue I am seing is that the driveshaft does not seem to fit in the differential side (US Driver side) properly.

Firstly there is a lot of play, secondly in its most "inward" position there is a gap.. in its most "Outward" position there is a gap so large you can se the oil seal. (see pics attached)

The circlip / Snap ring has done its job and clicked in place as it shoud. I actually fitted another inner axle part with no clip to see how far it slid in and out, and it is the same.

The Trutrac unit used is part number TT 911A342, which I was assured was the correct one. (It's fitted fine so far).

Has anyone got experience of one of these units in a 3rd gen and can comment on how well the axle fitted afterwards?

It feels like the inner splines start / finish in the wrong place. I'm not sure if its the positioning within the diff unit, or a result of the difference in thickness of the Yukon gears... Either way if anyone has any help it would be hugely appreciated.. I'm pulling my hair out with this latest round of mods.. the V8 was less aggravation and this should be really simple in comparison!

If anyone has any pics of this gap on their 4runner and can share them along with the diff spec that would also be awesome..

The other side (ADD end) where the driveshaft fits into the stub shaft looks perfect.

Thanks!

 

[TorqueOfTheDevil]

Just a quick update on this for the sake of the search....

I have had a response from the supplier and they have told me:

Your setup is completely normal – that is a call we end up taking with some frequency. The amount of dirt that will actually get in is very small. We don’t recommend trying to get anything in to cover or fill that space.

Good news arty:

Other users have confirmed that the amount of lateral play is normal too.

So any future worried Trutrac users can rest assured that all is well..

It still make my blood itch a bit... but I am fussier than most!

 

[ReconCmdr]

This had become quite an issue for me when I installed the TruTrac I purchased from Randys Ring and Pinion. Not that it was Randys fault but the Trutrac is not really designed for our 4runners. I did quite a bit of research after I couldn't get mine to work. I was not doing the install myself but a well respected Toyota 4 wheel shop in Atlanta. I eventually talked with the lead engineer at eaton who designed that trutrac. He stated that it was not designed with the 4 runner in mind but that it could be modified to work if taken apart and milled properly. I eventually found East Coast Gear Supply (ECGS) through the lead engineer at Eaton had worked closely together to make the Trutracs work. So I ended up sending my front end to ECGS and they did the modifications and did the install. ZERO problems since.