8.8 diff cross pin retaining bolt broke. Can't remove pin
Thread Starter
|
Logistics Pro
Joined: Jul 2009
Posts: 3,635
Likes: 3
From: Lansdale, PA
8.8 diff cross pin retaining bolt broke. Can't remove pin
I have done what I can to not grab the cutting torch and chop this thing out...
The differential cross pin retaining bolt, has broke in half. I have all the threads, but no pin. The cross pin is snug and I can't move it back and forth with my fingers so it's making this job even harder. I've gotten these out with a magnet or small pick before, but the cross pin always wiggled.
How can I get this out without losing my mind?
I currently have axle out and standing on it's end, hoping gravity would help, but without the cross pin moving freely, it is a little difficult.
The differential cross pin retaining bolt, has broke in half. I have all the threads, but no pin. The cross pin is snug and I can't move it back and forth with my fingers so it's making this job even harder. I've gotten these out with a magnet or small pick before, but the cross pin always wiggled.
How can I get this out without losing my mind?
I currently have axle out and standing on it's end, hoping gravity would help, but without the cross pin moving freely, it is a little difficult.
Lead Driver
Joined: Jan 2003
Posts: 9,893
Likes: 12
From: Ohio
Uggh, the ultimate taboo of working on an 8.8. The dreaded cross bolt.
Try a little heat from torch to open the clearance a bit? Might get a little messy if you get too hot and the oil catches fire.
Try a little heat from torch to open the clearance a bit? Might get a little messy if you get too hot and the oil catches fire.
Lead Driver
Joined: Aug 2006
Posts: 5,670
Likes: 12
From: Sand Lake, MI
Yea that is a problem made worse by a cross pin that won't work with ya a little bit.
Short of getting a line on it so as can drill what's left that torch is probably looking pretty good at this point!
Might try tack welding a nut to the end of the cross pin for something to put a wrench on, or short bolt for something to grab. tacking something to it wouldn't hurt the pin and easily removed after the fact.
Being as its up ended have gravity working for you tap on the carrier causing a little bit of vibration maybe persuade whats left of that little pin to fall out? ....yea you probably tried that though!
Short of getting a line on it so as can drill what's left that torch is probably looking pretty good at this point!
Might try tack welding a nut to the end of the cross pin for something to put a wrench on, or short bolt for something to grab. tacking something to it wouldn't hurt the pin and easily removed after the fact.
Being as its up ended have gravity working for you tap on the carrier causing a little bit of vibration maybe persuade whats left of that little pin to fall out? ....yea you probably tried that though!
Postmaster
Joined: Aug 2015
Posts: 3,146
Likes: 32
From: Maryville, TN
Don't torch it. Get a dremel and cut off wheel. Cut edge of pin straight through the bolt. Then you can pull pin and remove carrier. Once the carrier is out you can get the remains of the bolt out easily. You will get into the carrier some. iTS OK!! I have done this. Had it out in 10 minutes. Rear end still in truck today
Postmaster
Joined: Aug 2015
Posts: 3,146
Likes: 32
From: Maryville, TN
Btw, that bolt is only threaded on the head side. The parts store keep the Dorman brand replacement in stock. If the cross pin has any wear, order a new one. This is the main cause of slack in the differential.(that clang from the rear end when going to drive or reverse)
Trending Topics
Thread Starter
|
Logistics Pro
Joined: Jul 2009
Posts: 3,635
Likes: 3
From: Lansdale, PA
I got a long drill bit and made a drill pilot, now to acquire an easy out and pull the pin out. It's got some pressure on it for some reason.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
10 Most Surprising 2026 Ford Truck Features!
Joe Kucinski
Top 10 Ford Trucks Coming to Mecum Indy 2026
Brett Foote
5 Best / 5 Worst Ford Truck Wheels of All Time
Joe Kucinski
Ford Super Duty: 5 Things Owners LOVE, 5 Things They LOATHE!
Joe Kucinski
Every 2026 Ford Truck Engine RANKED from WORST to FIRST!
Michael S. Palmer
The Best F-150 Deal of Every Trim Level (XL through Raptor)
Joe Kucinski
4th Gear
Joined: Mar 2025
Posts: 4
Likes: 0
This worked
I ended up drilling a piece of rod and the broken off threaded section of the pin, silver soldering the drill bit I used to make the holes in the end of the rod, then threaded the broken pin back in the hole as a guide and drilling about 1/4 inch in and used an ez out. Of course after the fact I found that this Kit from Yukon was available Part # YT BE-01. But, it's out now.
I have done what I can to not grab the cutting torch and chop this thing out...
The differential cross pin retaining bolt, has broke in half. I have all the threads, but no pin. The cross pin is snug and I can't move it back and forth with my fingers so it's making this job even harder. I've gotten these out with a magnet or small pick before, but the cross pin always wiggled.
How can I get this out without losing my mind?
I currently have axle out and standing on it's end, hoping gravity would help, but without the cross pin moving freely, it is a little difficult.
The differential cross pin retaining bolt, has broke in half. I have all the threads, but no pin. The cross pin is snug and I can't move it back and forth with my fingers so it's making this job even harder. I've gotten these out with a magnet or small pick before, but the cross pin always wiggled.
How can I get this out without losing my mind?
I currently have axle out and standing on it's end, hoping gravity would help, but without the cross pin moving freely, it is a little difficult.
Last edited by bbford352; Jun 25, 2025 at 03:06 PM. Reason: left out a detail
Thread Starter
|
Logistics Pro
Joined: Jul 2009
Posts: 3,635
Likes: 3
From: Lansdale, PA
this is exactly what I made for fixing the issue I was having. They didn’t have this 9 years ago when I needed it. LoL
4th Gear
Joined: Mar 2025
Posts: 4
Likes: 0
Mine broke with almost exactly one thread still attached to the pin. I could get a small magnet on it trying to pull it out and see it wiggle as I shifted the pinion shaft back and forth but, it would not pull out even when I drilled it with a left hand bit I still had to use the ez out.
Thread
Thread Starter
Forum
Replies
Last Post
longm
Ranchero & 1961 - 1967 Econoline
3
Sep 27, 2011 07:39 PM
packrat56
1948 - 1956 F1, F100 & Larger F-Series Trucks
13
Mar 27, 2007 05:44 PM
sancochojoe
1948 - 1956 F1, F100 & Larger F-Series Trucks
1
Apr 1, 2004 06:47 PM