8.8 regear to 4.56

[trj360]

I'm regearing the 8.8 i pulled from a 99 ex to go under the jeep...it's an open 3.27 right now and i called up completeoffroad.com to see what i would need to go to 4.56...they say something about a notched cross pin? what is that and do i need it? And i don't need a new carrier do i?

Just to be clear, I have never done a regear before...of course i will have help but i don't really know what's what

 

[IZwack]

The notched cross pin is needed because the ring gear is so thick that you can no longer get the cross pin out (because the ring gear is in the way). So in order to put the axle shafts in, you rotate the cross pin so that the flat side faces the axle shaft then slip on the C-clip. Then you rotate the notched pin 180 degrees so that it faces the other axle shaft and then install the other C-clip. This also means that before you bolt on the ring gear, you must assemble the center section first. In other words, if you're keeping it open, install the spider gears before the ring gear or if you're going to go with a lunchbox locker, then put that in before the ring gear. Note that some people have had problems installing lunchbox lockers due to the cross pin that can not be removed.

Also, its worth mentioning that others have partially grinded down their ring-gear which then allows a stock (non-notched) cross pin to be used. But this can only be done up to a certain ratio and I'm not sure its do-able for 4.56s. I think the user JEFE did this but as I recall, he had 4.33s


EDIT - and no you dont need a new carrier.

 

[trj360]

Note that some people have had problems installing lunchbox lockers due to the cross pin that can not be removed.

Well I am doing an Aussie (or at least plan on it) and if so it will all be going in at the same time. Would I run into problems there?

Edit - I have ordered the stuff already, including the notched pin. So the above question is in that context.

 

[IZwack]

I did a little bit of searching and it seems like people are running the Aussie with 4.56s so I think you'll be just fine.

 

[trj360]

I didn't see much about aussies specifically but some quick searches showed people running 4.56 and various other lunchboxes. thanks for the advice. btw your van thing is awesome.

 

[IZwack]

btw your van thing is awesome.

Thanks! I just hope there will be a trailer behind it with an Explorer sometime in the next few months.

 

[trj360]

Thanks! I just hope there will be an Explorer behind it on a trailer sometime in the next few months.

I hear you on that - I'm trying really hard to get this jeep together before summer. I bought it for trails but it also needs to serve another purpose...

 

[JDraper]

4.56's with a lunchbox locker will work fine, but the cross pin is an issue. Most lunchbox locker rely on the crosspin to help the unit function properly, and they don't work will with a ground or modified cross pin. The best way to do it is to grind the ring gear teeth SLIGHTLY where the pin goes through the carrier. You grind the gear where it doesn't contact the pinion gear near the edge just enough to let the cross pin through.

I know for sure that you can't use the pin IZ posted above with any of the Powertrax lockers. Not 100% sure on the Aussie, but they use the same principle.

BTW, I ran my '94 with 4.56's and a Powertrax, and I ground the ring gear slightly, with no issues at all.

 

[trj360]

How do you go about grinding the ring gear? How difficult is the installation using that method?

 

[trj360]

Ok guys - I've got another thread going on this very subject at jeepforum and got some slightly different advice. JDraper, i quoted your post with the advice to see what somebody else thinks of it.

http://www.jeepforum.com/forum/showthread.php?t=753844

I'm trying to get as many opinions as possible on this, no offense to anybody if they are deemed "wrong" in one thread or another.

I have already ordered the gears and want to order the locker soon as well.

 

[trj360]

Why are you hijacking my thread??

SPAMMER - http://www.rangerpowersports.com/forum/showthread.php?t=234044

 

[ericautopart]

Why are you hijacking my thread??

SPAMMER - http://www.rangerpowersports.com/forum/showthread.php?t=234044

If you let me know what they quoted you on gears and such, I'll beat it.

 

[RockRanger]

I ground the ring gear a bit using a right angle diegrider with a sanding pad. I think I also grond the crosspin a bit. I was going to use an Aussie but was concerned with the cross shaft not letting it work right. So I welded the Spideer gears instead. I just dround a little test fit grind a bit more test untill it fit.

 

[HahnsB2]

I built my 8.8 with 4.56s and an Aussie locker. I clearenced the ring gear just like I did on my 7.5 and it works fine. The part that gets ground off isnt in the gear pattern anyways.
You can see the tip of the tooth has been removed to allow the crosspin to go in.

 

[trj360]

I ground the ring gear a bit using a right angle diegrider with a sanding pad. I think I also grond the crosspin a bit. I was going to use an Aussie but was concerned with the cross shaft not letting it work right. So I welded the Spideer gears instead. I just dround a little test fit grind a bit more test untill it fit.

If this were trail only, I'd save some money and jump all over that - but it's going to see a lot of road miles.

All I really want to know is, does the aussie fit, and does it perform as intended? In the jeepforum thread i linked to above, some guy said this:

u do not need a notched cross pin, just grind the ring gear tooth slightly. u will, however, hate that aussie in the 8.8. works fine, but if u ever break a shaft, good luck getting the c clips out to change it. trust me, u will see what i mean.

Is that a major concern with this setup?

Just to clarify that is only ONE tooth that needs grinding?

 

[trj360]

Ok guys, I just called Aussie and spoke to Bill, I'm pretty sure he's the president/owner/whatever. Turns out you need to grind that part of the gear with any locker. Here's the link he emailed me:
http://www.ringpinion.com/TipOfTheDay.aspx?TipID=7

 

[Rick]

Also, its worth mentioning that others have partially grinded down their ring-gear which then allows a stock (non-notched) cross pin to be used. But this can only be done up to a certain ratio and I'm not sure its do-able for 4.56s.

My 4:88 ring gear is notched for clearance