8.8 Trac loc/ spider gear replacement issue

[Fordtruckfan89]

My 03 sport Trac decided to eat a spider gear, figured while I was replacing them I'd do the Trac loc clutches, at 300k they're shot. Im mechanically inclined but I've never had to mess with a rear axle til now.

I found when I went to install the new clutch packs ( ford carbon fiber versions) I couldn't get the new spider gears to roll into the carrier unless I left the shims out that go between the carrier and outer clutch plate.(Stacked as per the instructions)

One shim is a .025 and ones a .030. Tried taking a bolt and nut to compress the clutches/spread the gears and make it easier. It didnt help. The spider gear set is from Yukon gear. What am I doing wrong? I assembled it for right now without shims but I imagine it's not as tight as it should be.

 

[RangerX]

I haven’t done this, but here’s a link that may help Rebuilding A Traction-Lok Differential

 

[Fordtruckfan89]

I read that before I started,it did help. I've been trying to find some thinner shims. Thinnest I've found are .025. I wonder if the gears will break in (eventually) and maybe that'll let the shims fit? I don't know gears

 

[dvdswan]

Did you measure the old spider compared to the new spider gears? It may also be that the new clutches will make it very tight. I image you did pre-soak the clutches.

 

[Fordtruckfan89]

Unfortunately I didnt think to. I gotta do rear brakes soon so I may tear it apart again and see what I can figure out. I imagine there will be alot of filings from the new gears breaking in?