THE UPDATE WE'VE ALL BEEN WAITING FOR!! (Part 1 of 2)
Toyota incorrectly set backlash on the rear differentials in a good amount of FJ Cruisers. This causes the differentials to howl. What does someone do with a brand new car that makes noise? Warranty. The dealership will replace the 3rd member under warranty. Many of these 3rds are the coveted e-Locker. On most warranties, Toyota Motor Company will call back the old parts for inspection. The 3rd members cost too much for Toyota to ship, so they don't get called back. Instead the dealerships are told to throw them away, many get sold to a scrap guy.
Enter my friend Mike. If you've seen some of my picture threads from wheeling trips, you'll see a white and black fully locked and SAS'd 1st Gen. That's Mike. He's a technician at a local Toyota dealership. He replaced e-locker 3rds in two consecutive FJs. He had the parts manager hold both of them, as he was gonna swap out his LockRight lockers for a pair of e-lockers. Mike was nice enough to give me one of them and buy an ARB instead.
So with new locker in hand, I logged onto East Coast Gear Supply, located in one of the Carolinas (not sure which). If you are in need of any gears, lockers, t-case parts or really anything Toyota or Suzuki, these guys are top notch. Highly Recommended! Anyways, I ordered from them a Ring and Pinion set by Precision Gears in the 4.88 ratio, along with the triple drilled flange, solid spacer and e-locker gasket*. I got a call from them an hour later, they didn't have the Precision gears in stock, but they'd give me Nitro Gears instead for the same price! That's a $255 gearset for $159!!
Upon reciept of the parts (super fast shipping) I ran down to East End Transmissions in Westhampton Beach, Long Island (also highly recommended!) and they tossed the diff together with the new gears for a mere $150.
My next problem was wiring. I have a 2001 so it never came equipped with the locker harness/ECU or anything. So I looked towards 12voltguy.com for a standalone wiring/switch setup. The only ties to the vehicle on this kit were power and ground. The rest of the wiring was independent and ran from the switch all the way to the differential.
I'm so lucky to have had so many cool people help me get everything together and also with the install. There were hiccups and my Runner ended up sitting at my friends house for about 3 weeks, and in between running around like crazy and muscling through the CO Police Academy, he helped out a ton.
Okay enough of the sappy love story, you want the writeup! Here's the writeup I was following throughout my build:
Retrofit Electric Locker
The only thing we did different was leaving the housing installed in the truck, and we drilled the holes unsing the 3rd member itself, not the gasket.
In the garage and sittin' on jackstands

Jacked up, pulled axle shafts out

before...

Driveshaft dropped and fluid drained...say goodbye to this silly open diff with 3.90 gears pfft!

it's about time I did this...

and the part numbers for anyone looking to buy the seals from the dealer

A diff doesn't get much more "open" than this

Who wants an open differential with 3.90 gears?...<crickets>...yeah me neither

Marking out the notch for the cut...scariest part of the build- cutting into a perfectly good housing :cry2:
