Ford 8.8 regearing questions

[coooray619]

im swapping a 2001 explorer 8.8 into my jeep cherokee. i have a friend thats gunna help me install 4.10 gears but i was wondering about wether to get the "master install kit" or not since the axle only has like 25K miles on it? also ive heard i might need a "notched cross-shaft" ... anyone know anything about that? TIA guys

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[johnnyweb]

you can always grind the stock one on one side to clear the ring gear if needed. may sure you grind the right spot so you can turn it to get the set screw in and the un ground sides push the axles out. good luck!

[AaronDixon]

You can also grind the ring gear a little to get the cross shaft past... It shouldn't be much.

Aaron

[grantdcol]

You'd really be better off selling the explorer axle you have (plenty of people want them for their rangers) and buying an axle which already has 4.10 gears.

There shouldn't be much difference in cost, certainly less than the amount you'll spend on swapping to 4.10 gears.

[tre5]

I dont believe you need the notched cross shaft if you are going to be running 4:10s. You only need it if your are going to 4:56 or 4:88.

[coooray619]

cool, thnx for the responses. well i got the axle for $250 and the gears sould be $200 or less... can i get an 8.8, low miles, disc brakes, and 4.10s for less than $450?

and what about the "master install kit"? should i purchase one?

[Jeff_B]

I just finished doing exactly what you are about to do. Except in a Wrangler.

My explorer 8.8 came with 3.73's, I used ford racing 4.10's didn't need to grind or notch anything. I recommend using a master install kit with axle bearings and everything else replaceable, there is no sense spending all that money just to have a bearing go bad and ruin new gears!!

If you need more detail on the install let me know, it's really easy if you have the right tools!

[coooray619]

I just finished doing exactly what you are about to do. Except in a Wrangler.

My explorer 8.8 came with 3.73's, I used ford racing 4.10's didn't need to grind or notch anything. I recommend using a master install kit with axle bearings and everything else replaceable, there is no sense spending all that money just to have a bearing go bad and ruin new gears!!

If you need more detail on the install let me know, it's really easy if you have the right tools!

alright, ill order up a mster install kit too. what did you do about the e-brake? ive heard i can use Grand Cherokee (i think) cables to make them work on my Cherokee...

so far ive just got the perches and brackets grinded off the housing and the diff cover removed, what other tools might i need besides a good welder and basic hand tools?

[Jeff_B]

I have yet to settle the e-brake issue...can't help there. Let me know what you end up doing!

Tool wise you will need a bearing splitter (got mine at Napa $45) you will need this to remove the old pinion bearing and get the stock shim in order to reuse it on the new pinion.

You will need a press to remove the old bearings and install the new ones. Be careful not to press on the cages!

Brass punches work well for installing outer bearing races (if you don't have driver set)

A slide hammer works well for pulling the axle bearings.

You need a dial indicator to set the proper backlash. I set mine at .007". This can be a little time consuming and frustrating but it's crucial for gear life.

You will need a inch lb. torque wrench for setting the pinion preload. While tightening the pinion nut (impact) a little at a time keep checking the preload, if you go to tight you can't just back the nut off a little you will need to replace the crush sleeve and start again.

Aside from standard tools I think that's about it. Have fun!

-Jeff

[zjohnson]

Ok, for a 4.10 gear, you don't need to worry about notching. I put a 4.35 in my ranger and had no problems. Recently, I changed to a 5.13 gearing, and had to grind part of the ring gear to be able to slide in the retaining pin.