I'm looking for a replacement diff for my "other" truck that is fairly strong (9" or 8.8), 4.10 ratio and correct width (@60") with 5 lug pattern. Explorer is close but the ratio seems hard to find or very expensive.

 

I had a 4.10 Trak-Loc in my '89 EB, but they're a 7.5" and definitely not strong. The Trak-Loc version tends to oval one of the spider shaft bores in the ring carrier and you get a rattle. And mine had significant decel pinion bearing noise at around 300k miles.

Is the 8.8" from a 4.0l 2WD Aero available in 4.10 ?

[later]

I don't think so. The only 4.10 ratios I see are for the 7.5" diffs in Aeros, according to this list I got from somewhere years back. The comments are not mine:

 

Gee, did some Aerostars actually come with aluminum rear axle housings? I know the front axle on my AWD is a Dana 28, and I think it is aluminum. But I don't think I've ever seen one with an aluminum rear axle housing.

Previously I had looked for LSD 8.8" axles with 3.73 ratio, and could not find any. If your list is all-inclusive, that explains why. I was hoping to replace the 7.5" rear axle with an 8.8" of the same ratio, and with a LSD.

 

I got that list -- with the comments attached -- off the internet, it's not my quote or research.

I don't think the Dana 30 is a rear diff.

 

The 8.8 3.73 LSD can be found on the Explorer D4 axle, and mine is still waiting for adaption to the Aero.
Comes with disc brakes too.
Project delayed until early 2015, to be usable by summer.

 

I knew they must exist somewhere.

How are you planning to make the adapting?

 

Yes, I'm an engineer with a welder, and my Exp front brake adaption is still working flawlessly.
The big-tube 8.8 w/discs is way heavier than the Aero 7.5.
From lifting just one end, I expect the total to come in at around 250lbs.
Surprise, this '97 example needs to be widened, not narrowed, to match the Aero track.

If and when, the project will go into the Built-to-tow thread.

 

Maybe you've posted this before, and I missed it, but can you describe your front brake modification? Or provide a link to anything you've posted before?

 

I'm sure you'll remember Explorer Brakes On An Aerostar.
Fronts currently overshadow the weaker (10") rear drums.
The inbound rear discs will then become too strong with the stock MC and need the Exp MC to balance correctly.
And one Exp MC has bias adjust.

 

Thanks Rojo, I can't believe I forgot about that. (and I've commented on it as well).