Heres my 8.8 build

Donor was a 94 Ranger with a 28 spline differential and 3.55 gears. I chose this so I wouldnt have to order new axles. 10 bolt donor axle came from a 98-02 Fbody. Friend gave it to me for free because he swapped axles to a posi and this one was leaking from just about everywhere. Total cost was just under $100 for this conversion

Ok, lets get started. Ford on top, 10 bolt on bottom. Notice the obvious length differences


Here it is again with the 10 bolt axles slid in better showing how short it is. Drivers side is approx 3" too short, pass side approx 7"


Next i used some scrap steel to build a simple jig. This located the suspension points and TA bolt holes. I was sure to set the axle tube angle to 0* and yoke to 0* for simplicity. Be sure to measure from the axle flange to the backing plate flange. This will help with finite adjustments so no shims are needed when installing the calipers at the end. For mine the backside of the axle flange to the backside of the backing flange was 2.535" on both sides


Tubes cut and ground down to slide in, trued and welded. Yoke is set to 0*, axle flange is set to 2.535". Tubes trued to 0* in all directions


Notice the TA mount location has to be changed for this axle, the pumpkin is in the way. Eyeballing under the car, there seems to be ample room for the mount to move over 1.5". Also, notice the DS CL peeper is in the same location on the 8.8, so the DS will be in the exact same location


Building the TA mount, almost done. .150" tubing and .25" plate, solid


Reassembled and ready to go in, after the calipers are painted silver. Who thought yellow was a good color? Yuck. Housing is painted with tractor paint, which is essentially brush on powder coating. Its very durable


Cost:

$0 Worn out 10 bolt with disk brakes and usable axles
$75 Junkyard Ford ranger 8.8 housing with diff and cover
$23 New axle seals, gear oil and friction modifier
$0 Jig

Other noteworthy TA mounts
http://i39.photobucket.com/albums/e2...d/IMAG0748.jpg
http://i39.photobucket.com/albums/e2...d/IMAG0749.jpg

http://i150.photobucket.com/albums/s...TAbracket1.jpg
http://i150.photobucket.com/albums/s...TAbracket2.jpg

https://www.thirdgen.org/forums/atta...860altered.jpg
https://www.thirdgen.org/forums/atta...863altered.jpg

http://i455.photobucket.com/albums/q...8/HPIM0755.jpg

 

is the rearend offset in the ranger or why is the axle length different so much?

 

Offset and narrower. The crown vic axles are the only ones remotely close to 3rd gen length. Cant remember if they're centered or not. Makes no difference for this type of build

 

i get it was just wondering why ford did that lol... nice write up tho. thanks!

 

So you are reusing the stock 28 spline axles with the 8.8 carrier? I didnt know that was possible.

 

What's the housing width on the 7.5? I've got an 8.8 from a Turbocoupe I was using towards another project that fell through. Mine comes out to 61". IIRC it's close, but I can't remember.

 

Yes. Reused them to maintain the proper length and wheel bolt pattern. Slid right in, C-clips held properly, pin slid in properly with almost no axle play


Dont remember and dont really care. I slide the axles in and moved the tubes in/out until the flange to flange difference was correct. I didnt know if the internal dimensions changed with the larger carrier so I didnt rely on it being the same between axles

 

Buttoned up the project today

All mounting points were spot on, stock hardware fit fine. Ample clearance full range of motion under the chassis and inf the wheel wells. Since this was a 98-02 axle I was able to drop my 2" spacers to fit my Y2K wheels

 

Im a big fan of the 8.8. like what you did.
Im wondering how durable the TQ arm mount is going to be..

 

Looks good. I plan on doing something similiar to this when I get back stateside.

 

Any part that seems under par? Nows the time to speak up

 

I tried to do my own 9" tq bracket years ago and couldn't quite get it right.
I kept breaking them. Just seems to be a lot of weird forces right there.. I finally got the package from Moser..
I do hope yours works 4 ya 4 sure tho! I'm rootn 4 ya an the ole 8.8

 

We'll find out soon enough I suppose

 

Good work, keep us posted on TA mount and how it holds???

 

Subscribed!

I would like to do something similar with a Dana 44 or 60. I'm also subscribed to see if the torque arm mount on the rear breaks. I have another year or so before I go home so you've got plenty of time to break in hard for me!

On another note; if this works out well, and since you made a very professional manufacturing jig (in need of some of your tractor paint) I am wondering if you plan on offering up for sale any more units? Maybe you could make enough to re-stimulate the economy!!

Just a thought...

Good work!!

 

Also, is the axle shaft spline and diameter the only reason for choosing the 8.8? I'm very curious to know if there is any other reason...

 

If i have any spare time I may build another housing or two

This was a bottom of the barrel budget build so I reused the free Fbody 28 spline axles. A stronger rear would use a 31 spline differential from an explorer, but then new axles would have to be ordered

Also, Im really not seeing how the TA mount can fail. Under load the TA levers down on the nose of the diff, so the support tubes will hold the majority of the weight. Lower tube is in compression and is strong enough to support a house. Upper is in tension, so the strength is in the welds which I was sure to get good penetration for. The loop of plate around the snout acts more as a locator than as strength to the unit. Even if all the load was placed on the upper section of plate alone, its laying flat on the snout with about 2" overhanging. It takes almost a ton and a half to flex that 1.5" x 1/4" plate enough to affect pinion angle which is more than the TA sees total. Then factor in the lower support and the two reinforcement tubes. I really dont this think mount is going anywhere. The 28 spline axles should break first

 

I LOVE budget deals, trust me!

I was just really curious as to the choice of the 8.8 Ford rear end. I am leaning towards a GM 8.5, or maybe a Chrysler 9.25 on the smaller end but I really want a Dana 44 or 60. I think I will at least attempt to do this before I shell out the cash for a new custom jobbie.

Also, what did you do for your driveshaft? The flange is different in the pictures. I re-read this twice to make sure that I didn't miss it!!

 

What would you charge me to do a Dana 44?

Seriously....

 

Process is the same for any center section really. Theres a really old thread on here where a guy built a 9" this method (28 spline axles too)

I havent had the DS made yet. Its really just a matter of choosing the proper yokes/flanges and sometimes cutting the DS to length. A local shop builds all the shafts for the local oval track racers and he's confident he can make something to fit. 8.8 swaps on LS1tech almost always use the stock DS with a new flange and conversion U-joint. I have the fun job of using a 4L80E (different yoke) and a Ford axle flange

 

Any idea if 9 bolt 28 spline axles would fit like the 10 bolt ones?

 

If its 28 spline it should fit. Some 3rd gens, esp the early ones used 26 spline axles which will not fit

Cant guarantee the axle tubes will slide in the 8.8 case either

 

I just bought this rear end from a local guy, didn't have axles brakes or anything just the housing and gears. Only thing that is failing is the top bracket on the tq arm mount but its the metal itself not the weld. I was told that this was ran in a 700hp car before so great job with the build. Im throwing some 4:10's in, 9' ends, axles spool and brace soon. Great build on the rear!!!