Now I know why v8's are full time 4wd!

If I learned anything by actually being an engineer who engineers things that actually work, I can tell you that you definitely cannot "guarantee" anything at any time. It could have literally been a management decision to just use the cheapest possible gear that they could find laying around from the previous production run of forklifts. There is no way you know anything more than me about the design of the 4th generation 4runner rear differential unless are the person who stamped the engineering document and released it to production. I guess you might be the person who designed the rear differential and sat in meetings while bean counters grilled you in Japanese on how to make it cheaper while avoiding lawsuits, but I find that possibility remote.

Toyota is a first echelon engineering company. So was Hewlett-Packard in the 70's, 80's, and 90's, and Agilent after they spun off from HP. I spent 44 years doing engineering for those companies in that environment. Companies like that do not put untested and uncalculated stuff in their product designs just because it was "laying around from the previous production run of forklifts". Every design gets engineered, prototyped, and tested. At that point a decision will be made as to whether or not it meets product expectations. Management may get involved to adjust expectations for economic or schedule reasons, and Toyota's expectations may be different from yours, but don't for a minute believe that they just guessed and hoped.
[MENTION=100496]blackworks[/MENTION] is correct in that, based on this forum, there are not a great number of stripped ring gears from behind V8's. Yours is the first I can remember. And, you still haven't addressed the question I asked as to whether it was properly set up. The fact that you had a locker installed back there means someone besides Toyota has been into it, which raises possible doubts about the gear setup. As I said in my first post in this thread, the most likely cause for ring gear tooth failures is too much space between the ring gear and the pinion. If the side adjusters were too loose on the carrier bearings, the ring gear could push sideways away from the pinion and cause the mayhem you experienced.
 
I won't say the 8" rear diff is a bad design, only that I have seen first-hand and heard numerous "offroaders" on the forums break their 3rd member, with the V8 or V6 on the 4th gens or the V6 FJ's. One thing they have all had in common; extra weight and larger tires (usually 35's) Most of the time they have a rear locker as well though most FJ's do stock and they come down off a rock with a rear wheel spinning or are trying to pull somebody out. I can't recall anybody breaking theirs on the street while never being wheeled previously.

In fact I'm pretty confident mine will eventually break once I get 35's and a rear locker with the rocks I drive over, even while driving carefully.

But like I said, I don't believe the 8" rear diff is a bad design or Toyota was wrong to put it on our trucks, it just has its limits like everything else. 35's, lockers, and climbing rocks push it, Toyota doesn't care about those of us that throw on heavy/huge tires and add 1000lbs over stock while climbing boulders, they just care about durability for the other 95% of people and in that role the axle is perfectly durable.
 
:popcorn:

So, if it quacks like a duck...sounds like a duck...must be a duck...

Or some fat guy behind the bush with a duck caller...
 
As I said in my first post in this thread, the most likely cause for ring gear tooth failures is too much space between the ring gear and the pinion. If the side adjusters were too loose on the carrier bearings, the ring gear could push sideways away from the pinion and cause the mayhem you experienced.


I believe Zuk applies additional pre-load to the carrier side bearings in order to minimize this ring gear deflection. He talks about it in one the installation he did but I can't find which one. He calls this "CBPL" Gear Install Harrop
 

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