Has anyone re-gear their differential?

[Hitchhikingmike]

I know there has been lots of talk about it on here before, but has anyone actually every re-geared their differential on a 3rd generation explorer before? Let alone, has anyone ever even installed a locker in their 3 gen?

Its been talked about a lot before, but I was just wondering if anyone has ever modified their differential before.

I've never had the funds (college student). But I would love to lower my gearing so I can get bigger tires.

It would just make me feel good if I knew that other 3gen people have done this sort of stuff before.

Please chime in...

 

[IZwack]

I'm pretty sure setting up the 3rd gen's ring and pinion will be pretty much like the other 8.8s, including the awful crush-sleeve design:

But if you're a college student, forget regearing until you graduate. Regearing front and back will run about $1k (parts+labor), or about $650 (parts only) if you have the tools and know-how already.

 

[Hitchhikingmike]

I'm pretty sure setting up the 3rd gen's ring and pinion will be pretty much like the other 8.8s, including the awful crush-sleeve design:

But if you're a college student, forget regearing until you graduate. Regearing front and back will run about $1k (parts+labor), or about $650 (parts only) if you have the tools and know-how already.

what's so awful about the crush sleeve design?

like I said, I know people keep saying the "the 3 gen shares the same 8.8 differential" so its possible. But who all has actually done it?

 

[IZwack]

what's so awful about the crush sleeve design?

Well the only problem with it is that you'll need to start hitting the gym 6 months before because you'll need Super Massive strength to crush that thing even with a 6 ft cheater bar added to a breaker.

I've done this before to a 97's 8.8 and I think a newborn infant shot out from under me as I was trying to crush the sleeve -- yeah, its that intense!

 

[Drewstang]

Wow. A trip to Pull-A-Part will net you the front and rear ring and pinions for less than $200. The Mustang guys usually sell 8.8 gears cheap. You can buy new gears from Summit front and rear for about $300. You should do some basic maintaince while you're at it, like bearings, seals, and trac lok rebuild for the 8.8.

 

[IZwack]

Wow. A trip to Pull-A-Part will net you the front and rear ring and pinions for less than $200. The Mustang guys usually sell 8.8 gears cheap. You can buy new gears from Summit front and rear for about $300. You should do some basic maintaince while you're at it, like bearings, seals, and trac lok rebuild for the 8.8.

Got a link to that Summit gearset (front and rear) for $300? The front axle isnt just a regular Dana 35 -- I believe its called an "M35". Also add in an install kit to each differential -- ~$80 per axle.

I wouldnt trust buying a used gearset for a daily driver -- who knows if the previous owner set it up properly and/or abused it. The 8.8 lacks a third pinion support so naturally, the pinion deflects under high torque.

 

[Drewstang]

Got a link to that Summit gearset (front and rear) for $300? The front axle isnt just a regular Dana 35 -- I believe its called an "M35". Dont forget to also add in an install kit to each differential -- ~$80 per axle.

And I wouldnt trust buying a used gearset for a daily driver -- who knows if the previous owner set it up properly and/or abused it. The 8.8 lacks a third pinion support so naturally, the pinion deflects under high torque.

Rear gears:
http://store.summitracing.com/partd...=SUM-748802&N=700+4294918962+115&autoview=sku
Front gears:
http://store.summitracing.com/partd...918962+4294902533+4294780410+115&autoview=sku

My service manual has a Dana 30 listed as the front axle. It could be wrong I guess.

Gear mesh patterns can be corrected with shims as well as pre-load. I've personally witnessed 800hp Mustangs run 10 second quarter mile times with an 8.8 and upgraded half shafts, so I know the 8.8 will hold a 245hp 4.6 SOHC or a 200hp 4.0 V6 with ease.

 

[IZwack]

Gear mesh patterns can be corrected with shims as well as pre-load. I've personally witnessed 800hp Mustangs run 10 second quarter mile times with an 8.8 and upgraded half shafts, so I know the 8.8 will hold a 245hp 4.6 SOHC or a 200hp 4.0 V6 with ease.

Thats cool but I still personally would not run a used gear set on a daily driver. I'd probably run it on a trail rig cauz the vehicle can always be limped back to the trailer with the other axle, but I personally opt for a new one on a DD.

 

[helmsa]

I've never had the funds (college student). But I would love to lower my gearing so I can get bigger tires.

Just wondering what size tires you are planning on running. I considered regearing mime right after getting tires, but after running somewhere in the neighborhood of 1000-1200 miles, I'm rethinking the idea.

On the highway I'm running about 1900 RPM at 70 MPH and have only lost 0.3 MPG (adjusted for tire size) with the tire upgrade from 235/70R16 to 265/75R16 (9.3% larger tires) and to be honest with you, the driving conditions have been worse since I bought the tires.

Please keep the discussion going, but is it worth $1K+ to regear when you could get more HP, great sound, a sweet tune (programming), and possibly better MPG out of the same money to compensate for the larger tires? Even running 285/75R16 tires, you are only looking at the 1800 RPM range with 3.55 gears, which is actually a really good place to be for MPG.

 

[Hitchhikingmike]

Right now I'm running on stock tires: 28"ers. I would love to go up to 31-33"ers. I could put on bigger tires now, but just don't want to experiment with it all. I'd rather re-gear the first time and get it right. I'm also riding on 3.55:1 gearings for now too, so I'm on the high end of the gear ladder (bad).

I want to keep my truck as a daily driver too. So i don't want to be limping around the city with big tires on 3.55 gears. Plus I don't want to lose the ability to tow crap too.

Its just on my wish list of things I would love to do one day, hopefully I will be able to. I'm already reading some good articles about re-gearing too:

http://www.explorerforum.com/forums/showthread.php?t=144780
http://www.corral.net/tech/drivetrain/gears.html
http://www.drivetrain.com/noslipinstallationinstr.html

lots of good info on the web!