FD Explorer 8.8 Diff Kit

[Jordan Innovations]

Has anyone tested this yet?  The 4.10s are starting to get to me and was hoping this would be sorted out soon so I can get a 8.8 with more reasonable ratios in there.

I've got mine in, just finishing up the build of the diff itself (bought a new housing and it's been an experience).  Mount fits wonderfully, axles went together easily, very pleased.
The problem I have stems from the fact that the new diffs (everything made in the last couple years) have these incredibly large bearings right behind the pinion gear - an extra 1/2"+ bigger than the "old" 8.8 pinion bearings... this means that if you buy a new diff - even if it's a replacement for a 2006+ 8.8 - it'll need the new bearing.

That bearing is a dealer-only part, and costs $110+.

We missed an event this weekend because I couldn't get that bearing until Friday afternoon, and we're having the damnedest time shimming this thing.  With the power that we're making, the gear pattern has to be pretty spot-on, and whenever we get a pattern that's close (meaning tips of the edges) and shim to get it better, it seizes.  It's going to Performance Gearing tomorrow to get handled.

As far as the swap kit, it's wonderful.  The bars are close to the chassis, but with a minute of work, I was able to get my 10an/8an fuel lines in between with some hose to damp vibrations


We made these delrin bushings for the front, they're a light press fit and include the 60* taper as well as the chamfer at the bottom.  Pinion angle will be set and future sets will be lathed with the correct spacing up top.  I thought I took pics but I guess I'll have to find them - I'm sure my machinist or myself will sell them if people need them.

[frijolee]

FYI: Jeff volunteered his car to save us some time in taking Anthony's car apart every time we were doing a design session.  As such, he's now running the first article, and his is the only kit which has been "released" to date.

In terms of status for everyone else, I updated the plate design after we got final fitment info from Jeff, all piece parts have been cut, machined sleeves delievered, the weld fixture is built, and we're now starting the full up fabrication.  I expect the first batch of tester kits to be done in about two weeks.

-Joel

[Jordan Innovations]

Picking up my diff right now, should have "driving impressions" (aka burnouts on R-comps) soon.   

[Schitzo]

edit

[Exidous]

WTB an update. It has been what like two whole days? OMG :-p

[Jordan Innovations]

Got the diff in with our machined delrin bushings and a 1/4" aluminum spacer above the bushing for pinion angle adjustment.  I think this'll be perfect, it looks amazing.  The axles are the same length, so the diff sits centered and the driveshaft (a Driveshaft Shop/Jordan Innovations TR6060 CV shaft in our case) kicks to the passenger side a tiny bit which is great to keep the universals healthy.







Rear cover juuuust about touches stock subframe, but misses.  Awesome!


One of the coolest things for me is that our same Driveshaft Shop shaft worked for the Explorer setup just by changing universal and flange!  The CV measurement is tight, but within tolerances by 1/8" or so.  AWESOME.

Bleeding brakes again and going to test drive today if all goes well.

[orion4096]

Looks good.  Is there room to completely remove the diff cover without dropping the whole diff?

[frijolee]

Looks good.  Is there room to completely remove the diff cover without dropping the whole diff?

I don't know, but to be honest I'm doubtful you'd really want to try.  The practical part of your question requires two considerations: can you get the cover bolts out (I'm not sure) and can you slip the cover down out of the way (it's spaced back so you have better odds than you might think at first glance).

However the reason I think it's not a great idea is that the 10 cover bolts also sandwich in the rear support cradle so once you pull those bolts out there's nothing but RTV holding the rear of the diff to the stock mounting points.  This actually isn't a lot different than a stock explorer.  The mounting is integral to the cover and there really isn't an "inspection plate" anymore.

[Jordan Innovations]

Looks good.  Is there room to completely remove the diff cover without dropping the whole diff?

I don't know, but to be honest I'm doubtful you'd really want to try.  The practical part of your question requires two considerations: can you get the cover bolts out (I'm not sure) and can you slip the cover down out of the way (it's spaced back so you have better odds than you might think at first glance).

However the reason I think it's not a great idea is that the 10 cover bolts also sandwich in the rear support cradle so once you pull those bolts out there's nothing but RTV holding the rear of the diff to the stock mounting points.  This actually isn't a lot different than a stock explorer.  The mounting is integral to the cover and there really isn't an "inspection plate" anymore.

Exactly - I don't think I would, even if you could. 

[MoparX]

Looks good.  Is there room to completely remove the diff cover without dropping the whole diff?

No, the ring gear would stop the cover from sliding out.

[wickedrx7]

Thanks for the updates, Looks great!!!  Can't wait to get my kit!

I picked up an '08 Open 3.73 today with only 39K and one Axel.  I compared it to the Cobra dif I still have and they are actually pretty different. The spline on the axle is different as well as the axle seal on the '08 is a lot larger than on the cobra.  I can post some pics if people are interested. 

Next step is to order a traction lok, cobra spec and install that?  Any tips/Instructions? LOL

[Exidous]

I really need to start looking for a diff. If anyone goes to a junk yard and they have two I'll buy the other. :-) Seriously. Finding an explorer diff in Europe is damn near impossebre. I have a US Mail box too.

[frijolee]

Next step is to order a traction lok, cobra spec and install that?  Any tips/Instructions? LOL

My recommendation: Pay someone to do it.  Details on what my DIY install took are here:  http://www.norotors.com/index.php?topic=1274.msg226366#msg226366  (starts in post 286 if the link misbehaves). Mine's a truetrac but the short version is that at the end of the day there's too much time and too many specialty tools needed to make this economical to do yourself.  In hindsight I should have just paid someone.

[markfluko]

Do you have any places to recommend to do something like that? I still need to find an Explorer diff.

I am just trying to find out who would be competent enough to do the install correctly. If I had someone lined up to install a Eaton TrueTrac then it would open the options of finding an Explorer diff up greatly as I could just use any housing... Rather than finding a mystical 2006+ 3.73 Locker or 3.55 Locker.

4wd/ mudding/ big ole truck shops to install a TrueTrac?

[largeorangefont]

You just need to go to a shop that is familiar with using a case spreader. This is needed for the Ford aluminium housing so you don't damage the housing when the shims are inserted. It really should not be a huge deal, you will just want to find a competent rear end shop in your area. There is nothing really exotic to it. Truck shops, and/or specific rear end shops should be able to do the job.

Just tell them what you are doing, and it is not going in an Explorer with bigger tires.

For So Cal guys, I went to Hoopers rear end exchange in Sun Valley. They did a great job, and offered to turn it around in the same day. I believe I paid $150 and brought all the parts in.

I am with Joel. I did the math, and the expense of the tools and time investment to do the diff change process only once may not be economical.