The 4.57's are made different than the Mazda sourced J's 4.77's.

The 4.77's are an OEM gear in some applications, and are set up the same as the 4.10's.

You shouldn't have to unbolt the gear from the differential carrier to reset up the clearances.

You may want to look for a heavy truck/equipment shop that has experience setting up differentials.

 

As you requested

#10 41271-PCZ-003 - Collar/distance piece
#28 91001-PCZ-003 - Bearing
#29 91002-PCZ-003 - Bearing
#11 9XXXX-PCX-001 - Shim (Part number varies with size)
#23 90201-PCZ-003 - Lock nut
#31 91201-PCZ-003 - Pinion Seal

 

I don't know if it's still true but Honda only used to sell shims in a set for a lot of dollars. The same shims are available through Mazda individually.


fltsfshr

 

I finally found a couple of pics of all the bits i supplied for the installation:

Here they are in a gallery:

http://img182.exs.cx/gal.php?g=foto0492zn.jpg

I see "only" 5 items:

91001-PCZ-003 - bearing
91002-PCZ-003 - bearing
90201-PCZ-003 - lock nut
91201-PCZ-003 - Pinion seal
41271-PCZ-003 - Collar/distant piece

The "only" the shim (Item # 11 on diagram) is missing !!!

The shim was the one piece that was "re-used" by the mechanic from the old stock differential !!! He confirmed that today over the phone.

This had about 30.000Km on...

Do I really need to order this part and have it replaced ???

@Stratocaster: up to you.. which "SHIM SIZE" should be used with the J's 4.77 ???

This result in which Honda part number to be ordered (if needed) ???

Carlo

 

Shim size. OK, this is a tricky one. I can't tell you what size you need, but the installer should know. It is how the pinion depth is set. Since each ring and pinion is differant and so is the diff housing, you have to measure it. There is a process for this in the Helms manual and your tech should have known how. What this tells me that your tech did not know how to install this. You need to find a new tech to install the ring and pinion. Here is what to look for:

1. Older tech
2. GM, Jeep or other non import experience
3. He should know how to set a gear in his sleep
4. He should know how to make a shim if needed. Or have a collection from years of installs.

My local installer only does Diffs and Trannys. He has been doing them for over 20 years. He builds rock crawling Jeeps for fun.

The bottom line here is that you tech messed up. How bad is unknown until you can get the right guy to look at the gears. This is why the installers is most important for a gear installation.

 

Strato...

I totally agree with you...

But my first question is still unanswered: if we "re-used" that shim that came with the original gear... is it bad ?? How bad .. if bad ??

Question is.. since IT IS the original shim from the original 4.1 OEM gear.. is it still good for the J's 4.77 one ???

If not.. why wouldn't J's reccomend a different shim size in order to prevent this kind of confusion ???

Also importanto to understand.... is the original oem shim (item #11) subject to wear with time ??

I ask this cause my mechanic says that this piece (the shim) is only there in order to "keep the right distance" between the other pieces... so up to him there is no need to worry about it being reused (30.000Km old).

Is that right? Or is he bullshitting me ??

The only thing he sais is that maybe we have to try a different setup for the way the pinion and the crown actually "meet together" in order to work.. this setup maybe it's the reason for the wining ...

It this the backlash setting right ??

I will try to look for some more experienced guy..

Problem is .. beleive it or not ... it's going to be quite hard locally.

Car still runs fine in the meantime... (much better than stock 4.1).

I am here...

Carlo

 

"Question is.. since IT IS the original shim from the original 4.1 OEM gear.. is it still good for the J's 4.77 one ???"

It can be the right one. You can only tell by measuring the setup.

"If not.. why wouldn't J's reccomend a different shim size in order to prevent this kind of confusion ???"

You are missing the point. Each gear set is differant. Part of the manufacturing process is to spec the gears. The tolerances differ from set to set, so will the shims. Also when you add the housing, it too is differant from housing to housing.

The botton line is that you need the right shim. New or used is not a factor. But the odds of the shim being the right one in both installs is slim, very slim. But again, it could be.

"I ask this cause my mechanic says that this piece (the shim) is only there in order to "keep the right distance" between the other pieces... so up to him there is no need to worry about it being reused (30.000Km old)."

This is true. But "keep the right distance" is why you are having a sound issue. It is not set right. It should not make any sound at all.

"The only thing he sais is that maybe we have to try a different setup for the way the pinion and the crown actually "meet together" in order to work.. this setup maybe it's the reason for the wining ..."

This is what the shim does!

 

Well.. then i do not understand what kind of test does he (my mecha-fag) wants to try out...

Unless we have a replacement shim (with a different size)... there is not much that can be achieved...

I think I am only wasting my time with my mechanic... I need to find someone else with a different expertize.

In the meantime i have to use the car... I need it. I will try not to stress it too much.

Shit ... I hate this situation

Carlo

PS - Is funny that in the end ... some people say.. "there must be no noise at all.... if noisy then it is not set right".. some other say.. "i get little noise from time to time".. some other say "4.77 gears runs faster so noise is normal".. and again.. "no noise on mine..."... etc etc.

 

I have downloaded the S2000 PDF service manual (28Mb) at:

http://www.streetlegalkhk.nl/multimedia.ph.../HONDA_manuals/

Chapter 15 .. "Rear Differential".

It clearly says that in order to find "the right distance" it is needed to do some measurements ... and according to those numbers whe we'll need to order the right shim.

It's all about this precise measurement...

Service manuals are great because they are meant for the donkey minds... like mine !!! ;-)

Simple as that.... ???

It's obvious that by having re-used the "stock" washer (item # 11) it's it quite hard that it could have worked w/out noise... 4.77 needs different distance...

I am sure all this is in the HELM manual... (downloadable online???).

But some reading it is necessary... right Mr. Honda mechanic ??

IN THE END.... I am finally happy to have understood the way all this works...

I'll keep you informed about the progress...

Carlo

PS - Anything else to add??

 

The pinion depth may be incorrect, but you can still set the gear backlash wrong as well.