The rear end of our AE86 was showing its age. It was really rusty and crusted over from almost 40 years of neglect. We were really worried that the axle housing was close to rotting through, so we disassembled it and had the housing and third member sandblasted and powder coated. After sandblasting, we were able to see that the rust was not yet structural and that the housing was good to reuse. The cost was around $400, which was kinda a bummer, before COVID our powdercoater would have only charged $200 for the same thing. We had also told them to mask off the interior of the housing to keep the sand out, but this was ignored and we spent hours with a pressure washer trying to get all of the sand out. Finally, our rear end was ready to put together, and Battle Garage and OS Giken came through with the parts for us to build our rear end back better.
We got a NOS Genuine Toyota 4.55 ring and pinion for Battle Garage and had it WPC treated to reduce friction. Since our 4AG isn’t going to produce much power, we are staying with the OEM size 6.7″ diff to keep friction and rotating weight down.
We got this billet pinion spacer from Battle Garage as well. This will prevent the crush collar from deforming during hard use, which destroys the ring and pinion.
Battle garage produced this parts group that has every part needed to rebuild the rear end. Where the factory Toyota parts are no longer available, Battle Garage substitutes quality proven aftermarket parts. This saves tons of time tracking down rare parts on ebay and specialty stores around the world to find the stuff needed.
Howard set up our third member doing and shimming for pinion depth, backlash, and rotating torque. Now our rear end with the OS Giken differential and lower final drive was ready to drop in.
