OK guys I figured out my problem with the BP diff not fitting in the GH bulk.
I was using some honkin' 6x15x.2mm shims to shim between the bearings and the outdrives. The bearings sit very squarely and snug up against a little wall in the alloy bulks, and when I would go to close the bulk cases there was no room for a 15mm O.D. shim beside them, so they would protrude and make it so the case would not close all the way.
Lucky me, I brought home a file and an oil stone today from work, just for this job. Well I did not use them on the aluminum bulkhead like I figured i would. I ended up filing down the 15mm O.D. shim to match the O.D. of the outdrive so it wouldn't interfere with the bulkhead. Problem solved! (Yes, i filed down a shim
)
Now I have a new problem.. I finally got a perfect shim set-up so the diff spins freely and there is just a hair of play between the pinion and the ring gear. To achieve this though, I now have NO shim between the bearing and the ring gear. As soon as i put a shim there, the pinion/ring are louder when spun and just overall dont sound right.
The bearing in use is a metal shielded Boca bearing and it
is the beefier of the two (8x16x5mm) for what its worth.
Will this set-up work or is the bearing going to blow out? Is there a way to get the ring gear away from the pinion
without removing this shim?
Thanks a lot guys!