Member - Alan H (QLD) replied:

My 1994 80 series with 270 on the clock has excessive backlash.

It seems to have been there forever and I have got used to it and passed it off as inherent to having the three diffs. I think it has slightly got worse over the years and this may be wear over this time.

The clutch has the usual 80 series shudder. The clutch is original and I tow a trailer on most trips.

Ian from Thermoguard Instruments replied:

Hi Brett,

AFAIK, 'clunky' diffs are usually due to excessive crown-wheel to pinion backlash, rather than lash in the differential gear cluster. And, of course, the centre diff has no crown-wheel and pinion.

At 280,000km, I'd say you've well and truly had your money's worth out of that clutch. Why not drop the transmission to replace the clutch plate (and pressure plate and bearing, while you're at it) and, if the old clutch plate DOESN'T have shot springs, then have a think about delving into the transfer box.

By the way, you say the uni joints and splines are OK, but have you checked how much backlash you have in the front and rear diff pinion shafts? Also, remember that after 280,000km, all the splines and gears in the clutch, gearbox, transfer box, prop shafts, both diffs and axles will have worn to some extent - maybe it's just the cumulative total adding up?
Ian

STEVE069 replied:

Hi Big Woody have you checked the front drive flanges and CV splines?
Steve

120scruiser replied:

Hi big woody
Most of the early 80 series clutches only had a damper rubber in it and no spring.
My 8/92 80 series only had this and when I removed the clutch the damper rubbers were totally gone. I put a new daiken clutch in and had nothing but noises so after 12 months pulled it out and put a genuine toyota clutch in.
With the toyota clutch the rattles were gone and there was smooth engagment of the clutch again.
If you put yours in 1st gear and then slowly take off and let it idle along in first, see if you have a rumbling sound around the gearbox especially in low range. If you do you need a new clutch. The worst thing is the clutch friction surface is probably fine but the dampers will be gone. The 1hz series of engines puts out alot of engine vibration and the clutch soaks this all up and totally destroys the dampers.
The new clutch that goes in from toyota still has the rubber dampers but they have also installed a damper spring which should make it more tolerable.

Bear in mind that if you have a little bit of wear in the rear diff, a little bit in the transfer case, a little bit in the centre diff, a little bit in the front diff, a little bit in the drive shafts, a little bit in the front hubs it all adds up. There may be no excessive backlash in any one part but you may have little bits in several parts. This is normal for an 80 and the problem is where do you start to rectify it. If you wanted to rectify all the little bits you would be up for thousands.
I have always said it takes 100 000 km to learn to drive an 80 series gently.
My recommendations would be to put a new genuine clutch in and you will find it will be significantly better.
Cheers
120scruiser

streeter replied:

big woody
had the same in my 93 i changed the clutch which it needed doing any way but noise and backlash was still their put new swivel hubs and cv joints in and its now running smooth as a babys bum and now clunking
cheers
streety

streeter replied:

oops should read no clunking

Billowaggi replied:

Hi All , as said above the clunk is not just the centre diff but accumulated wear throughout the entire drive train front and rear it is usual in high k constant 4x4's [take an old Range Rover for a spin sometime!.]
Regards Ken.

udm replied:

We have 2 80´s, they both had the same problem, it´s gotta do with worn splines in front diff/front axles/front wheel flanges and worn cv´s. Did I forget something lol?

Ulises