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This is a (slightly) deep pattern. I would pull 0.003 and recheck.
thats what i was thinking. i would do this and look again. maybe even pull more than that, like .005-10. if it winds up looking a bit shallow, you can get a rough idea of where perfect is. (in the middle of the 2 shim setups) now, once you know that, if you had to choose between a smidge too deep or a smidge too shallow, i would lean towards the smidge too deep. because there will be a small amount of deflection in the case/bearings/pinion/ etc while under load pushing the gears away from one another.
thats what i was thinking. i would do this and look again. maybe even pull more than that, like .005-10. if it winds up looking a bit shallow, you can get a rough idea of where perfect is. (in the middle of the 2 shim setups) now, once you know that, if you had to choose between a smidge too deep or a smidge too shallow, i would lean towards the smidge too deep. because there will be a small amount of deflection in the case/bearings/pinion/ etc while under load pushing the gears away from one another.
Wanted to type the same about overshooting to the shallow side, but because it's very close I wanted to save him the extra work.
If I can't get a perfect pattern, then I'm also leaning towards slightly deep and toe biased pattern.
This is a (slightly) deep pattern. I would pull 0.003 and recheck.
Thanks for the input! The original pinion shim was .035", and that yielded a pattern that was too high on the tooth.
Here it is, with .005" backlash:
This is the final pattern that I made last night. It's already installed and I drove it to work today; seems fine, doesn't make any noise. I'm not going to f*ck with it unless someone gives me incontrovertible evidence that it's going to explode in action.
This is with the .039" pinion shim, and .008" backlash (I sanded down an old solid shim for the final installation instead of a shim pack; I don't like using shim-packs on the driver's side of the differential. Or at all, if I can avoid it. ).