Serious Explorations Ford Explorer and Ranger Message Board
#1 Resource for Ford Explorer and Ranger Owners - By Enthusiasts, for Enthusiasts.


Ford Explorer Generation Guide

EF Swag Store 2015 Ford Explorer Forums Elite Membership Chat Room My Posts Reviews Explorer Photo Gallery
Go Back   Ford Explorer and Ranger Forums "Serious Explorations"® > Ford Explorer Ranger Repair - Troubleshooting - Modifications & Detailing Forums > Explorer & Ranger Transmissions, Transfer Cases, & Differentials

Notices

Explorer & Ranger Transmissions, Transfer Cases, & Differentials Transmissions, Transfer Cases. A4LD, 4R70W, 4R44E, 4R55E, 5R44E, 5R55E, M5OD, BW 1354, Control Trac, GEM, AWD. Ford 8.8", Dana 35

8.8 Axle Facts and Swap info

Reply
 
Thread Tools
Old 01-25-2009, 09:42 PM   #1
Tbars4
Offroad/Fitness Moderator
anaheim hills,california
 
Tbars4's Avatar
95 ranger 4x4/ 91 X 4x4
 
Join Date: Mar 2007
Posts: 25,407

Vehicle Specs

Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 170 Post(s)
(Original Poster)
8.8 Axle Facts and Swap info

...I found this on a Heep Forum and thought it would answer some future swap questions...
http://209.85.173.132/search?q=cache...lnk&cd=7&gl=us

...The Original and full thread can be found here...
http://www.jeepsunlimited.com/forums...d.php?t=371713

...Note to all newbies..
..When you see Dana 35 mentioned in this information it is pertaining to a J**P rear axle and not a Ford front axle...
___________________________________________________________________________________

There are many different variations of the Ford 8.8 axle. One of them is best suited for the use in a Jeep and that would be the Explorer (or Mountaineer) 31 spline 8.8. If you have found one off a Aerostar, Mustang, F-150 etc, you should really pass it up and look for a Explorer axle if you wish to retain a similar track width on your Wrangler. Trying to start your build-up with the wrong axle will be frustrating and expensive although you may have picked it up for cheap in the beginning.

Ford 8.8 assembly specs:
Cover bolt 28-38 ft.lbs.
Pinion bearing preload 16-29 in.lbs.
Pinion bearing preload 8-14 in.lbs (used)
Ring gear backlash .008-.015
Ring gear bolt to case 70-85 ft.lbs
Side bearing caps 70-85 ft.lbs.


Explorer 8.8 Measurements:
Weight (complete assembly w/ brakes etc.): 174 lb.
O.D. of tubes: 3.250".
Tube thickness: .250" (some are .188”!)
Ring gear diameter: 8.800".
Ring gear bolts: 7/16" dia. (qty. 10).
Pinion diameter/splines: 1.625 / 30.
Axle shaft/splines: 1.320 / 31.
Rotor thickness (where it mounts to axle is .250").
Overall width 59.625" (the F8.8 is .950" narrower then a TJ Dana 35).
(The F-150 8.8 is drum brake and width WMS to WMS is 65.5”.)
Hole diameter for ABS sensor in top of housing: .811".
Bolt size (U-joint flange to yoke) is: 12 x 1.75 x 30 mm
Centerline of housing to C/L of pinion difference is 3.875" toward the P/S.
Pinion offset: P/S to C/L of Pinion, 27-3/4" (no rotor on axle), D/S to C/L of Pinion, 31-5/8" (no rotor on axle). (this measurement is 2.5" more offset to the P/S then a TJ Dana 35).

Specs:
Code Capacity Ratio
43 Open 3200 3.08
41 Open 3200 3.27
42 Open 4.10
46 Open 3.73
45 Open 3200 3.55
D4 Limited Slip 3200 3.73
D2 Limited Slip 4.10
L73 Limited Slip 3.73
L - Limited Slip Differential
C - Conventional Differential

How many splines are the axle shafts?
drivers side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 30-1/2 inch length - 5 X 4.5 inch lug pattern.

passenger side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 27-5/8 inch length - 5 X 4.5 inch lug pattern

Can I get 35 spline shafts?
Yes, with a little searching I found 28 and 33 splines too. Remeber 8.8 axles are used on many different Ford rigs. Mustangs, Rangers, F150s, Aerostar etc... different axle lengths than the Explorer so if you are looking for aftermarket products make sure you are not looking at something for a Mustang that might not fit an Explorer.

Can I use my drive shaft that I bought for my SYE/Dana 35 set-up? Yes

Is the 8.8 narrower than a Dana 35 rear axle?
Yes but not enough to make a difference when running most aftermarket wheels.1.5" shorter or so. It doesn't matter unless you try running stock rims w/12.5 or wider tires.

Are the 8.8 shafts stronger than Dana 44 shafts?
Yes, also the bearings, pinion and ring gear are also much larger.
Axle shaft Strength and output torque rating by Warn and 4 Wheeler

The axle shaft strength tested by Warn Ind:
F8.8= 6,500 (lb. ft.)
D44= 4,600-5,000 (lb. ft.)
D35C= 4,000-4,300 (lb. ft.)
-------------------------------
COT: Continuous output torque rating
MOT: Maximum output torque rating

(Numbers from January edition of Fourwheeler, page 60.)
Dana 35 rear axle COT: 870 MOT: 3480
Dana 44 rear axle COT: 1100 MOT: 4460
Ford 8.8 28spline COT: 1250 MOT: 4600
Ford 8.8 31spline COT: 1360 MOT: 5100
Dana60 semifloat COT: 1500 MOT: 5500]

Will I need that brake proportioning valve from a Rubicon? Probably not

Does the 8.8 offer more ground clearance over the Dana 35 and 44? Not under the differential but the bigger axle tubes lift the rig about 5/8 ".

Is there welding involved? Yes, but the new brackets you put on are much stronger than stock Dana’s. Not a good idea to re use your old Dana 35 brackets

Where do I get brackets?
4x4 Group Buy has Rubicon Express for.
Bob Supplee has Tera.
DC4WD has Tera.

Carolina Rock Shop (call or email for price quote)
TeraFlex TMI-ABK-TR
M.O.R.E. Dana 35 bracket (sku:MORE98700)
Rubicon Express RE9969 TJ Axle Bracket Kit Rear
MAD 4WD

The list above should get you headed in the right direction as far as brackets go. Look around and compare prices as the brackets can be found for $200.00 or less shipped sometimes. Keep this in mind when shopping for any item for your build-up,if you do, you will save a bundle.

Can I reuse my Dana 35 brackets? Yes, but it is not recomended. The stock Dana 35 brackets are sort of flimsy compared to the beefy aftermarket versions. Some of the brackets available are in fact for Dana 35 axles to replace the weak ones that come factory. Reusing the D-35 brackets is time consuming even if you have the right tools, not a good idea IMO

Should I weld the axle tubes to the cast housing? I would if it had been salvaged from a wrecked rig. If it is new on a crate (in my opinion) don’t bother.

Will my stock sway bar work? Yes, with a minor modification to a passenger side pinion gusset.

Do all 8.8s come with a limited slip? No, read the tag on the housing or remove the cover. 3L73 = 3.73 gears witha "L"imited slip

Where is the gear break for lockers? There is no break. Same locker for 3.73 to 6.14

Do I need a notched cross pin? Yes for 4.56-6.14 to clear ring gear, or notch a gear tooth.

More cross pin info
The 3/4 inch cross pin only fits those rears with the 28 spline count period!
Therefore, the 7/8 inch crosspin is what we are concerned with and it fits Explorer, Mountaineer, F150, and Expedition's with the 8.8 ring gear and 31 spline axles. It also come in those special Mustangs that have the 31 spline axles i.e. Cobra, Steeda, and Rousch.

The axles for Jeep conversion we are keen on are the 96 through 2001 Ford Explorer and Mercury Mountaineer with disc brakes and all that fall into this category with or without limited slip have the 7/8 inch cross pin.


Convert from a 28 to a 31 spline??? Need bigger axle tubes too! The bearing on a 31 spline is much bigger than a 28 spline bearing.

What year ford explorers do I look for as a donor for 31 spline and disc brakes? To get rear disc brakes and 31-spline axle, you need to look for a 1995 to 2001 Explorer or Mountaineer. Earlier years use drum brakes and may be 28-spline. Different vehicles may have the wrong bolt pattern, width, spline count, or brakes. A 2-door Sport Explorer may be a donor past the 2001 cut off. Also, Explorer SportTracs with production dates of August 19, 2002 through June 29, 2005 are equipped with 31-spline axles and rear disc brakes and are exactly what was in the previously listed 95-2001 Explorer. Before Aug 19, 2002, the Sport Tracs were equipped with the smaller 28-spline 8.8 axle shafts and used drum brakes. After June 29, 2005, Sport Tracs were produced with an Independent rear as found on 2002 regular Explorers.* Sport-Trac

What is so great about 8.8? Parts are everywhere, as in axle shafts, covers, brake parts etc..

What's not so great about the 8.8? Weak stock carrier, replace with a carrier type locker like ARB or Detroit (not a lunch box type) this will cure the problem.

Spun axle tubes: Simply weld the tubes into the diff housing before they spin. You are welding to cast steel so now would be the time to ask for a professional's opinion. I have heard of guys tossing the works in a oven before welding, some just go at it cold. Both say their way is right.

Thin stock diff cover: Get some armor.


What kind of locker can I get? Thanks Joe
ARB SELECTABLE AIR LOCKER
AUBURN GEAR - ECTED ELECTRIC LOCKER
AUBURN GEAR - HIGH PERFORMANCE LIMITED-SLIP DIFFERENTIAL
AUBURN GEAR - PRO SERIES LIMITED-SLIP DIFFERENTIAL
Aussielocker.com
DETROIT LOCKER
E-Z LOCKER - FITS IN FACTORY NON-POSI CASE
EATON - ELOCKER SELECTABLE LOCKING DIFFERENTIAL
EATON - POSI LIMITED-SLIP DIFFERENTIAL
FULL SPOOL - 31 SPLINE - STEEL
MINI SPOOL - 31 SPLINE - C-CLIP COMPATIBLE - STEEL
ORIGINAL STYLE POSI - COMPLETE
POWERTRAX - LOCK-RIGHT LOCKER - FITS IN FACTORY NON-POSI CASE
TRUTRAC LIMITED-SLIP


What is the bolt pattern? 5 on 4.5” just like stock TJ/YJ wheels.

Will my Jeep lug nuts fit the 8.8? In most cases, yes.

What do I do with the speed sensor? leave it in place.

Where to buy?
Car-part.com
www.ok4wd.com
wallysheata, Ariel Performance
www.alljeep.com
http://www.rockequipment.com
to name a few.

How much do they cost? Free to $1500.00 but you can find them new for around $500.00 in their stock form complete disc to disc.

What do I need for a swap into a tj?
Here are some things I used:

-TeraFlex Bracket kit
-ARB
-U.S. Gears 4.56
-Master install kit (Timken)
-Crane diff cover
-Napa brake line kit P/N 380528 (x2)
-T-hose NAPA P/N 380889
-ZJ E-brake cables (drivers and passenger side)
Mopar P/N 52008904 & 52008905
NAPA P/N 95342 (right) 95347 (left). (not for YJs)
-Driveshaft adapter: Spicer 2-2-1379
-Flange bolts Ford P/N N800594-S100 (x4)
-'03 TJ Rubicon (w/disc) proportioning valve P/N 5083808AA
-3/16" hard brake line about 40" & 18"

HELPFUL SITES be sure to check these out:
Stu-Offroad
Dome & Detour
8.8 Swap
J.E. Towle / DPG Offroad
Chris Overacker / CODE 4x4
Stormtrooper
4x4 Wire Links
The Ranger Station Tech Library
The Ranger Station Tech Library 2

YJ & XJ STUFF:

From M.O.R.E.
-XJ Installation Kit P/N 98600 84-2001 XJ
-XJ E-Brake Cable Kit P/N EB3 Disc Brake F8.8 Only
-Special Yoke P/N 221379 F8.8 to 1310 U-Joint

From Dealership:
-Mopar spring perches
-Tabs for shock mounts
-ZJ ebrake cables from the dealer (for XJ install)
-Flange from spicer dealer $30 (have seen this go from $20-$50)


HELPFUL TIPS:

Stock brake cables won't come off bracket at tub. Pound a deep 13mm socket on the cable end to compress the fingers holding it in place.

Add gear oil through the abs sensor hole at the top. With an 19 degree pinion angle, I just pour three quarts in and call it full.

To replace axle seals, use the end of the removed axle shaft to pry the seal out.

Axle shaft bearings...remove the seal first as above, then slide hammer the bearings out.

Parking brake shoes can make rotor removal a pain after rust sets in, I always machine the inside lip of the rotor (drum section) about 3/8 inch from the edge to the edge about .030 deep so rust won't interfere by dragging on the shoes.

Old parking brake shoes can have the lining come loose from the metal part of the shoe...reglue with two part epoxy if new shoes not readily available...(it's only a parking brake). Parking brake shoes from Ford...$115 set! Autozone...about $20!
BENT SHAFT????


8.8 PART NUMBERS:
-8.8 rear parking brake star wheel adjuster. Ford p/n F58Z 2041 A @ 22.98 each.
Left and right are same part number. (1/08)
-Rear Caliper Bolts p/n N606046-S60 List $4.10 each (9/06)
-Flange bolts P/N N800594-S100 $1.29 (x4) (5/05)
If you have some Ford part numbers you want to ad just pm me.




__________________
I have Rocks in my head. What's in yours?
'95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel
'91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List
How to: Wheels,Tires, & Lifts...
Buy Explorerforum.com Items here

Last edited by Tbars4; 02-26-2009 at 02:54 PM.
Tbars4 is offline   Reply With Quote
( Join the Elite Explorers )

For only $20 per year you can become an Elite Explorer member. Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose and fix problems yourself, and learn which modifications really work without having to experiment on your own. Elite Explorer members can change the forum "styles" to eliminate most ads, including blue underlined links, and no ads on photos. Other benefits include the ability to store 1000 Private Messages, upload photo attachments directly to your posts and to our Photo Gallery and more. Join the Elite Explorers today.


Old 01-25-2009, 10:31 PM   #2
Stic-o
Elite Movie Star
Tujunga, CA
 
Stic-o's Avatar
'99 XL 4x4 & '06 XLT 4x2
 
Join Date: Sep 2002
Posts: 12,244

Vehicle Specs

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 77 Post(s)
Ted, if you feel like going through some of my old threads, there may be some useful info about swaping Full size 8.8's in




__________________
The JP Mobile ~'99 Explorer XL 4X4 * The Mall Crawler ~'06 Explorer XLT
The Tow Rig ~ '01 F250 Crew Cab 4X4 * The Commuter ~ '10 Focus SES

See the JP Mobile Movie HERE

Stic-o is online now   Reply With Quote
Old 01-25-2009, 10:41 PM   #3
IZwack
Moderator Emeritus
Germantown, MD
 
IZwack's Avatar
1998 Ford Explorer
 
Join Date: Feb 2003
Posts: 21,834

Vehicle Specs

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 1 Post(s)
Ted I think you should include a link to the forum where you got this info from .. just so we're playing this by the book.




__________________
»»»»»...how'd the moon get there, how'd the moon get there?
IZwack is offline   Reply With Quote
Old 01-25-2009, 10:48 PM   #4
Tbars4
Offroad/Fitness Moderator
anaheim hills,california
 
Tbars4's Avatar
95 ranger 4x4/ 91 X 4x4
 
Join Date: Mar 2007
Posts: 25,407

Vehicle Specs

Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 170 Post(s)
(Original Poster)
...I thought i did, but it is included now...

...I will edit this more later...




__________________
I have Rocks in my head. What's in yours?
'95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel
'91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List
How to: Wheels,Tires, & Lifts...
Buy Explorerforum.com Items here
Tbars4 is offline   Reply With Quote
Old 01-31-2009, 12:00 AM   #5
mrboyle
I Drive By Brail
Fruita, CO
 
mrboyle's Avatar
'96 XLT '80 Toy
 
Join Date: Feb 1999
Posts: 4,156

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 7 Post(s)
Just a FYI, the forum you got that from just coppied the origional thread from JeepsUnlimited. http://www.jeepsunlimited.com/forums...d.php?t=371713




__________________
Mike Boyle
ASE Certified Master Tech.
'92 XLT(RIP) 1980 Toyota PU
Quote:
Originally Posted by DiffWackDaddy
Some people go looking for God, others get broadsided by them
mrboyle is offline   Reply With Quote
Old 02-06-2009, 09:48 AM   #6
Tbars4
Offroad/Fitness Moderator
anaheim hills,california
 
Tbars4's Avatar
95 ranger 4x4/ 91 X 4x4
 
Join Date: Mar 2007
Posts: 25,407

Vehicle Specs

Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 170 Post(s)
(Original Poster)
...MrBoyle, thanks for the heads up and link...Some of the stuff I edited out due to no refferencing found, now makes more sense...




__________________
I have Rocks in my head. What's in yours?
'95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel
'91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List
How to: Wheels,Tires, & Lifts...
Buy Explorerforum.com Items here
Tbars4 is offline   Reply With Quote
Old 02-13-2009, 07:57 PM   #7
xseekanddestroyx
92
 
Join Date: Feb 2009
Posts: 1

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
i just got a 8.8 rear end out of a 2002 ford explorer sport i was told it was 31 spline but im not sure since its not on the list can anyone help thanks
xseekanddestroyx is offline   Reply With Quote
Old 06-08-2009, 11:37 AM   #8
pirate72
FROM Chicago. Live in Terre Haute, IN
1996 XLT
 
Join Date: Feb 2009
Posts: 17

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quick dumb q...I swapped my 8.8 out of my 96 Ex into my 94 YJ...I'm looking to regear, and I'm wondering if I can use a ring/pinion set that is classified as being out of a Mustang 8.8? I know it says not to use the whole axle, but are the gears pretty much the same?
pirate72 is offline   Reply With Quote
Old 06-16-2009, 05:16 PM   #9
trj360
1999 XLT SOHC
 
Join Date: Oct 2007
Posts: 1,215

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by xseekanddestroyx View Post
i just got a 8.8 rear end out of a 2002 ford explorer sport i was told it was 31 spline but im not sure since its not on the list can anyone help thanks
Yep, it's the same as the 95-01 axles, I've noticed that the people on Jeep forums have a lot of bad or just plain wrong info.


Quote:
Originally Posted by pirate72 View Post
Quick dumb q...I swapped my 8.8 out of my 96 Ex into my 94 YJ...I'm looking to regear, and I'm wondering if I can use a ring/pinion set that is classified as being out of a Mustang 8.8? I know it says not to use the whole axle, but are the gears pretty much the same?
If I were you, I'd call a place like Randy's Ring and Pinion and ask them. As far as I know, companies sell all gears based on the axle, not what vehicle it came out of. A quick phone call should answer your question.
trj360 is offline   Reply With Quote
Old 06-16-2009, 08:24 PM   #10
cybergasm
B
Humboldt Ks
 
cybergasm's Avatar
1997 Mountaineer 5.0
 
Join Date: Jan 2006
Posts: 6,531

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by trj360 View Post
Yep, it's the same as the 95-01 axles, I've noticed that the people on Jeep forums have a lot of bad or just plain wrong info.
and some of that bad info has been reposted in the first post in this thread
cybergasm is offline   Reply With Quote
Old 06-17-2009, 12:01 AM   #11
trj360
1999 XLT SOHC
 
Join Date: Oct 2007
Posts: 1,215

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by cybergasm View Post
and some of that bad info has been reposted in the first post in this thread
I had people on another forum telling me it was impossible to get 3.55 gears out of an explorer sport 8.8.
trj360 is offline   Reply With Quote
Old 06-17-2009, 10:43 PM   #12
Tbars4
Offroad/Fitness Moderator
anaheim hills,california
 
Tbars4's Avatar
95 ranger 4x4/ 91 X 4x4
 
Join Date: Mar 2007
Posts: 25,407

Vehicle Specs

Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 170 Post(s)
(Original Poster)
...Post up any and all errors and I'll edit them in bold print...

...I just got that info for umm, , a friends future project...




__________________
I have Rocks in my head. What's in yours?
'95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel
'91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List
How to: Wheels,Tires, & Lifts...
Buy Explorerforum.com Items here
Tbars4 is offline   Reply With Quote
Old 06-18-2009, 09:33 AM   #13
cybergasm
B
Humboldt Ks
 
cybergasm's Avatar
1997 Mountaineer 5.0
 
Join Date: Jan 2006
Posts: 6,531

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Dunno seems to me that the info you got Ted seems centered on the Explorer/Mountaineer axle mostly but who ever wrote it seems to be lumping in the rest of the 8.8 Axle family in there with all the references to the earlier 28 spline axles that came in the Ranger and other Ford models.
cybergasm is offline   Reply With Quote
Old 06-18-2009, 07:44 PM   #14
cybergasm
B
Humboldt Ks
 
cybergasm's Avatar
1997 Mountaineer 5.0
 
Join Date: Jan 2006
Posts: 6,531

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
corrected copy IMO

Quote:
Originally Posted by Tbars4 View Post
...I found this on a Heep Forum and thought it would answer some future swap questions...
http://209.85.173.132/search?q=cache...lnk&cd=7&gl=us

...The Original and full thread can be found here...
http://www.jeepsunlimited.com/forums...d.php?t=371713

...Note to all newbies..
..When you see Dana 35 mentioned in this information it is pertaining to a J**P rear axle and not a Ford front axle...
___________________________________________________________________________________

There are many different variations of the Ford 8.8 axle. One of them is best suited for the use in a Jeep and that would be the Explorer (or Mountaineer) 31 spline 8.8. If you have found one off a Aerostar, Mustang, F-150 etc, you should really pass it up and look for a Explorer axle if you wish to retain a similar track width on your Wrangler. Trying to start your build-up with the wrong axle will be frustrating and expensive although you may have picked it up for cheap in the beginning.

Ford 8.8 assembly specs:
Cover bolt 28-38 ft.lbs.
Pinion bearing preload 16-29 in.lbs.
Pinion bearing preload 8-14 in.lbs (used)
Ring gear backlash .008-.015
Ring gear bolt to case 70-85 ft.lbs
Side bearing caps 70-85 ft.lbs.


Explorer 8.8 Measurements:
Weight (complete assembly w/ brakes etc.): 174 lb.
O.D. of tubes: 3.250".
Tube thickness: .250" (some are .188”!)
Ring gear diameter: 8.800".
Ring gear bolts: 7/16" dia. (qty. 10).
Pinion diameter/splines: 1.625 / 30.
Axle shaft/splines: 1.320 / 31.
Rotor thickness (where it mounts to axle is .250").
Overall width 59.625" (the F8.8 is .950" narrower then a TJ Dana 35).
(The F-150 8.8 is drum brake and width WMS to WMS is 65.5”.)
Hole diameter for ABS sensor in top of housing: .811".
Bolt size (U-joint flange to yoke) is: 12 x 1.75 x 30 mm
Centerline of housing to C/L of pinion difference is 3.875" toward the P/S.
Pinion offset: P/S to C/L of Pinion, 27-3/4" (no rotor on axle), D/S to C/L of Pinion, 31-5/8" (no rotor on axle). (this measurement is 2.5" more offset to the P/S then a TJ Dana 35).

Specs:
Code Capacity Ratio
43 Open 3200 3.08
41 Open 3200 3.27
42 Open 4.10
46 Open 3.73
45 Open 3200 3.55
D4 Limited Slip 3200 3.73
D2 Limited Slip 4.10
L73 Limited Slip 3.73
L - Limited Slip Differential
C - Conventional Differential

How many splines are the axle shafts?
drivers side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 30-1/2 inch length - 5 X 4.5 inch lug pattern.

passenger side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 27-5/8 inch length - 5 X 4.5 inch lug pattern

Can I get 35 spline shafts?
Yes, with a little searching I found 28 and 33 splines too. Remeber 8.8 axles are used on many different Ford rigs. Mustangs, Rangers, F150s, Aerostar etc... different axle lengths than the Explorer so if you are looking for aftermarket products make sure you are not looking at something for a Mustang that might not fit an Explorer.

Can I use my drive shaft that I bought for my SYE/Dana 35 set-up? Yes

Is the 8.8 narrower than a Dana 35 rear axle?
Yes but not enough to make a difference when running most aftermarket wheels.1.5" shorter or so. It doesn't matter unless you try running stock rims w/12.5 or wider tires.

Are the 8.8 shafts stronger than Dana 44 shafts?
Yes, also the bearings, pinion and ring gear are also much larger.
Axle shaft Strength and output torque rating by Warn and 4 Wheeler

The axle shaft strength tested by Warn Ind:
F8.8= 6,500 (lb. ft.)
D44= 4,600-5,000 (lb. ft.)
D35C= 4,000-4,300 (lb. ft.)
-------------------------------
COT: Continuous output torque rating
MOT: Maximum output torque rating

(Numbers from January edition of Fourwheeler, page 60.)
Dana 35 rear axle COT: 870 MOT: 3480
Dana 44 rear axle COT: 1100 MOT: 4460
Ford 8.8 28spline COT: 1250 MOT: 4600
Ford 8.8 31spline COT: 1360 MOT: 5100
Dana60 semifloat COT: 1500 MOT: 5500]

Will I need that brake proportioning valve from a Rubicon? Probably not

Does the 8.8 offer more ground clearance over the Dana 35 and 44? Not under the differential but the bigger axle tubes lift the rig about 5/8 ".

Is there welding involved? Yes, but the new brackets you put on are much stronger than stock Dana’s. Not a good idea to re use your old Dana 35 brackets

Where do I get brackets?
4x4 Group Buy has Rubicon Express for.
Bob Supplee has Tera.
DC4WD has Tera.

Carolina Rock Shop (call or email for price quote)
TeraFlex TMI-ABK-TR
M.O.R.E. Dana 35 bracket (sku:MORE98700)
Rubicon Express RE9969 TJ Axle Bracket Kit Rear
MAD 4WD

The list above should get you headed in the right direction as far as brackets go. Look around and compare prices as the brackets can be found for $200.00 or less shipped sometimes. Keep this in mind when shopping for any item for your build-up,if you do, you will save a bundle.

Can I reuse my Dana 35 brackets? Yes, but it is not recomended. The stock Dana 35 brackets are sort of flimsy compared to the beefy aftermarket versions. Some of the brackets available are in fact for Dana 35 axles to replace the weak ones that come factory. Reusing the D-35 brackets is time consuming even if you have the right tools, not a good idea IMO

Should I weld the axle tubes to the cast housing? I would if it had been salvaged from a wrecked rig. If it is new on a crate (in my opinion) don’t bother.Here the author counterdicting himself with this statement sincew later in this acticle he recommends welding the tubes

Will my stock sway bar work? Yes, with a minor modification to a passenger side pinion gusset.

Do all 8.8s come with a limited slip? No, read the tag on the housing or remove the cover. 3L73 = 3.73 gears witha "L"imited slip

Where is the gear break for lockers? There is no break. Same locker for 3.73 to 6.14 i think this needs to changed since we know that explorers came 3.08 and up from the factory.

Do I need a notched cross pin? Yes for 4.56-6.14 to clear ring gear, or notch a gear tooth.

More cross pin info
The 3/4 inch cross pin only fits those rears with the 28 spline count period!
Therefore, the 7/8 inch crosspin is what we are concerned with and it fits Explorer, Mountaineer, F150, and Expedition's with the 8.8 ring gear and 31 spline axles. It also come in those special Mustangs that have the 31 spline axles i.e. Cobra, Steeda, and Rousch.

The axles for Jeep conversion we are keen on are the 96 through 2001 Ford Explorer and Mercury Mountaineer with disc brakes and all that fall into this category with or without limited slip have the 7/8 inch cross pin.
The year here needs to be changed to 95


Convert from a 28 to a 31 spline??? Need bigger axle tubes too! The bearing on a 31 spline is much bigger than a 28 spline bearing.

What year ford explorers do I look for as a donor for 31 spline and disc brakes? To get rear disc brakes and 31-spline axle, you need to look for a 1995 to 2001 Explorer or Mountaineer. Earlier years use drum brakes and may be 28-spline. Different vehicles may have the wrong bolt pattern, width, spline count, or brakes. A 2-door Sport Explorer may be a donor past the 2001 cut off. Also, Explorer SportTracs with production dates of August 19, 2002 through June 29, 2005 are equipped with 31-spline axles and rear disc brakes and are exactly what was in the previously listed 95-2001 Explorer. Before Aug 19, 2002, the Sport Tracs were equipped with the smaller 28-spline 8.8 axle shafts and used drum brakes. After June 29, 2005, Sport Tracs were produced with an Independent rear as found on 2002 regular Explorers.* Sport-Trac I think this statement is completely wrong.

What is so great about 8.8? Parts are everywhere, as in axle shafts, covers, brake parts etc..

What's not so great about the 8.8? Weak stock carrier, replace with a carrier type locker like ARB or Detroit (not a lunch box type) this will cure the problem.

Spun axle tubes: Simply weld the tubes into the diff housing before they spin. You are welding to cast steel so now would be the time to ask for a professional's opinion. I have heard of guys tossing the works in a oven before welding, some just go at it cold. Both say their way is right. Here is the statement i noted about earlier

Thin stock diff cover: Get some armor.


What kind of locker can I get? Thanks Joe
ARB SELECTABLE AIR LOCKER
AUBURN GEAR - ECTED ELECTRIC LOCKER
AUBURN GEAR - HIGH PERFORMANCE LIMITED-SLIP DIFFERENTIAL
AUBURN GEAR - PRO SERIES LIMITED-SLIP DIFFERENTIAL
Aussielocker.com
DETROIT LOCKER
E-Z LOCKER - FITS IN FACTORY NON-POSI CASE
EATON - ELOCKER SELECTABLE LOCKING DIFFERENTIAL
EATON - POSI LIMITED-SLIP DIFFERENTIAL
FULL SPOOL - 31 SPLINE - STEEL
MINI SPOOL - 31 SPLINE - C-CLIP COMPATIBLE - STEEL
ORIGINAL STYLE POSI - COMPLETE
POWERTRAX - LOCK-RIGHT LOCKER - FITS IN FACTORY NON-POSI CASE
TRUTRAC LIMITED-SLIP


What is the bolt pattern? 5 on 4.5” just like stock TJ/YJ wheels.

Will my Jeep lug nuts fit the 8.8? In most cases, yes.

What do I do with the speed sensor? leave it in place.

Where to buy?
Car-part.com
www.ok4wd.com
wallysheata, Ariel Performance
www.alljeep.com
http://www.rockequipment.com
to name a few.

How much do they cost? Free to $1500.00 but you can find them new for around $500.00 in their stock form complete disc to disc.

What do I need for a swap into a tj?
Here are some things I used:

-TeraFlex Bracket kit
-ARB
-U.S. Gears 4.56
-Master install kit (Timken)
-Crane diff cover
-Napa brake line kit P/N 380528 (x2)
-T-hose NAPA P/N 380889
-ZJ E-brake cables (drivers and passenger side)
Mopar P/N 52008904 & 52008905
NAPA P/N 95342 (right) 95347 (left). (not for YJs)
-Driveshaft adapter: Spicer 2-2-1379
-Flange bolts Ford P/N N800594-S100 (x4)
-'03 TJ Rubicon (w/disc) proportioning valve P/N 5083808AA
-3/16" hard brake line about 40" & 18"

HELPFUL SITES be sure to check these out:
Stu-Offroad
Dome & Detour
8.8 Swap
J.E. Towle / DPG Offroad
Chris Overacker / CODE 4x4
Stormtrooper
4x4 Wire Links
The Ranger Station Tech Library
The Ranger Station Tech Library 2

YJ & XJ STUFF:

From M.O.R.E.
-XJ Installation Kit P/N 98600 84-2001 XJ
-XJ E-Brake Cable Kit P/N EB3 Disc Brake F8.8 Only
-Special Yoke P/N 221379 F8.8 to 1310 U-Joint

From Dealership:
-Mopar spring perches
-Tabs for shock mounts
-ZJ ebrake cables from the dealer (for XJ install)
-Flange from spicer dealer $30 (have seen this go from $20-$50)


HELPFUL TIPS:

Stock brake cables won't come off bracket at tub. Pound a deep 13mm socket on the cable end to compress the fingers holding it in place.

Add gear oil through the abs sensor hole at the top. With an 19 degree pinion angle, I just pour three quarts in and call it full.

To replace axle seals, use the end of the removed axle shaft to pry the seal out.

Axle shaft bearings...remove the seal first as above, then slide hammer the bearings out.

Parking brake shoes can make rotor removal a pain after rust sets in, I always machine the inside lip of the rotor (drum section) about 3/8 inch from the edge to the edge about .030 deep so rust won't interfere by dragging on the shoes.

Old parking brake shoes can have the lining come loose from the metal part of the shoe...reglue with two part epoxy if new shoes not readily available...(it's only a parking brake). Parking brake shoes from Ford...$115 set! Autozone...about $20!
BENT SHAFT????


8.8 PART NUMBERS:
-8.8 rear parking brake star wheel adjuster. Ford p/n F58Z 2041 A @ 22.98 each.
Left and right are same part number. (1/08)
-Rear Caliper Bolts p/n N606046-S60 List $4.10 each (9/06)
-Flange bolts P/N N800594-S100 $1.29 (x4) (5/05)
If you have some Ford part numbers you want to ad just pm me.
cybergasm is offline   Reply With Quote
Old 10-14-2009, 01:40 AM   #15
gman1234
 
Join Date: Dec 2004
Posts: 45

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
I would like to know some more info about swapping rear axles. The donor is a 1999 ex, 8.8, 31 spline axle with discs and 4.10 gears. The patient is my 94 ex, currently running the stock 8.8, 3.27 gears. I am going to re gear very soon here and one option I found was this axle completed and ready to go for about the same price as gears, kit and labour. Figured I could bolt in the 99 axle and have the disc brakes and the 4.10 gears in one go. Then just get the front done to match

Does the existing brake setup work from the drum setup to using a disc setup? I would think the proportioning may be an issue, or the master cylinder but would like some info from someone who might know more than myself.

Was hoping someone around has done this, Blacksheep Josh I believe I saw that you did something similiar to this?

Cheers

Last edited by gman1234; 10-14-2009 at 01:56 AM.
gman1234 is offline   Reply With Quote
Old 10-14-2009, 10:15 AM   #16
Tbars4
Offroad/Fitness Moderator
anaheim hills,california
 
Tbars4's Avatar
95 ranger 4x4/ 91 X 4x4
 
Join Date: Mar 2007
Posts: 25,407

Vehicle Specs

Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 170 Post(s)
(Original Poster)
...I had heard that you want to get and swap the whole parking brake cable...I also heard there was something up with the proportioning valves...

..This is from Paul Gagnon, let me know if it answers your questions...
http://www.geocities.com/pg4x4/rearendswap.html



...and this thread has some info too...
http://www.explorerforum.com/forums/...rear+axle+swap




__________________
I have Rocks in my head. What's in yours?
'95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel
'91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List
How to: Wheels,Tires, & Lifts...
Buy Explorerforum.com Items here
Tbars4 is offline   Reply With Quote
Old 10-14-2009, 10:46 AM   #17
joecrna
Las Flores, CA
98 XLT 4X4 sohc
 
Join Date: Oct 2006
Posts: 599

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 1 Post(s)
Ted,

You mentioned lockers for the 8.8. How about a torsen diff., any idea of availability and functionality? The stock limited slip heats up and starts to slip very easily.




__________________
Joe
98 XLT 4X4 sohc
TT, Custom Deaver leafs, 31x10.5 BFG's
Custom skid plates, recovery shackles
Defender rack, Warn transformer mount
and winch
joecrna is offline   Reply With Quote
Old 10-14-2009, 11:27 AM   #18
Tbars4
Offroad/Fitness Moderator
anaheim hills,california
 
Tbars4's Avatar
95 ranger 4x4/ 91 X 4x4
 
Join Date: Mar 2007
Posts: 25,407

Vehicle Specs

Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 170 Post(s)
(Original Poster)
...Here is a good place to get basic torsen info...
http://torsen.com/

...As for the Torsen and myself......This is just my opinion and I know people who just love theirs...

..I think the idea and concept is great as a limited slip (LS) but, swapping a used Torsen in the rear axle and from what I have seen, there could be some problems...They had a bad batch of them run and you would need to search on here for the run numbers...I think I posted some a couple years back...

...From what I have seen and heard, I myself would not take the time to install it over choosing a good locker...

...There is also rumor that Torsen should be releasing this fall a T-2 for the front Dana 35 on 98 and newer Rangers/Explorers...For more info their Tech Support can be reached @ (585) 464-5000...

..But they have been releasing it for years...
http://www.explorerforum.com/forums/...p/t-65548.html




__________________
I have Rocks in my head. What's in yours?
'95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel
'91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List
How to: Wheels,Tires, & Lifts...
Buy Explorerforum.com Items here
Tbars4 is offline   Reply With Quote
Old 10-14-2009, 12:38 PM   #19
gman1234
 
Join Date: Dec 2004
Posts: 45

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Thanks Tbars, lots of good info there. None of the info specifically quotes 99 axle but its the same gen so I would assume it would be ok. From what I can see it will bolt up, no worries. Slight modify to some brackets and the cables and brake lines. No worries there. Still a bit vague on the brake system, sounds like some have used a different master cylinder from the second gen. From the couple threads there I think it will work ok. I just done want my brakes out of wack. Just want to know if a brake system upgrade (master cylinder, valves or whatever) is needed or if its ok to use it with my stock system without complications. I have 6 days to figure it out, the fellow selling this axle will be in the area for a short time only.
gman1234 is offline   Reply With Quote
Old 10-14-2009, 02:06 PM   #20
Tbars4
Offroad/Fitness Moderator
anaheim hills,california
 
Tbars4's Avatar
95 ranger 4x4/ 91 X 4x4
 
Join Date: Mar 2007
Posts: 25,407

Vehicle Specs

Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 170 Post(s)
(Original Poster)
...Off the top of my head, this guy had did the swap to his first gen...he may be able to answer the brake question ...
http://www.explorerforum.com/forums/...d.php?t=151352




__________________
I have Rocks in my head. What's in yours?
'95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel
'91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List
How to: Wheels,Tires, & Lifts...
Buy Explorerforum.com Items here
Tbars4 is offline   Reply With Quote
Reply



Suggest this thread to friends:



Join the "Elite Explorers" Today!



Search Explorer Forum


Top of Page

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 01:27 PM.



US Flag
We Support Our Troops!

Explore the site!


Copyright 2014 - 1996 Rick Horwitz Photography



Ford Motor Company is not involved in the management of this site in any way.



All tips on this site are for use at your own risk and discretion.

Modifying the suspension on any vehicle will cause changes to its handling characteristics.



Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.