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I installed 4.88s in my Son's 86 F150 4X4 back in August. The 8.8 in his truck has a Trac-Loc carrier in it. We also replaced the clutches with carbon fiber clutches from Ford Racing. Well, he split the carrier completely in two last week (built 351W, 35" tires, and a lead foot). When I installed the gears originally, I purchased a notched cross pin that is designed for 4.88 gears and up (he has the older style with a 3/4" cross pin rather than the newer 7/8" cross pin). The notch in the pin allows the cross pin to clear the thicker ring gear. I stopped by the local 4X4 shop (very reputable in this area, over 20 years in business), and the owner advised me that he never uses the notched shaft, because it's weak, and he believes my Son broke the cross pin, and when it spun around it caught the housing, causing the carrier to split (I can believe this to be true). My question is, the 4X4 shop sold me a used Track-Loc unit, that has the 7/8" cross shaft, and he says he uses his die grinder, to bevel one of the ring gear teeth to gain clearance to allow the stock cross pin to be installed. Before I start grinding away on the ring gear, anyone ever run into this?. I also posted in the axle section
I installed a lock right in my buddys ranger, had a 7.5" with 3.73s, I ground down one tooth on the ring gear to clear the new un-notched shaft with the lock right. The truck had 235 street tires on it, but it weld up through many smoke shows, he would hold it wide open, drop the clutch, and hit the brakes right away to get em roastin, then go for second and let em cook a little more, then let off the brake and do doughnuts until everyone in the truck wanted to puke, yes we were in high school at the time haha. We would do this on bone dry pavement without bleach, water or gravel, the slave cylinder bit the dust but the rear end was still good, he just sold it, the current owner is still driving it.
Edit: when I say "ground down" I mean like not much at all just one tooth, a little bit
Judging by the condition of his rear tires, I don't believe the problem is off road related. It definately looks "pavement related". In other words, he wore out the rear 35" Procomp MT's in less than a year (under 10k miles). His cousin told me one day that that he's famous in high school for the best burnouts, along with participating in truck pulls on the asphalt parking lot (we actually took the truck away from him for 4 months when he put a nylon strap completely through the tailgate). Anyway, this repair's on his dime, so maybe he'll chill out a little because it's costing him $$$, and he's having to bum a ride to work right now, as I won't let him use my wife's car (I did give in and buy him 2 new 35" BFG MT2s as an early X-mas present). I think the 8.8 should survive, as long as he doesn't drive like an idiot, but like my wife tells me, "what did you expect when you handed a 17 year old a built and lifted 4X4????". If you look in my gallery, you'll see what the truck looked like when I finished building it for him (gallery = father/son project).
I installed a lock right in my buddys ranger, had a 7.5" with 3.73s, I ground down one tooth on the ring gear to clear the new un-notched shaft with the lock right. The truck had 235 street tires on it, but it weld up through many smoke shows, he would hold it wide open, drop the clutch, and hit the brakes right away to get em roastin, then go for second and let em cook a little more, then let off the brake and do doughnuts until everyone in the truck wanted to puke, yes we were in high school at the time haha. We would do this on bone dry pavement without bleach, water or gravel, the slave cylinder bit the dust but the rear end was still good, he just sold it, the current owner is still driving it.
Edit: when I say "ground down" I mean like not much at all just one tooth, a little bit
That's exactly what the shop owner advised, 1 tooth, possibly 2 depending how the ring gear teeth lined up with the hole for the cross pin.
I have 4.56s in my 8.8. I ground 2 teeth down just a bit. Fits perfectly. I also have 4.56s in my other truck it has a 7.5" rear axle. Has the notched pin, no problems with 33's and a 4 cyl. 33's can supposibly snap a 7.5 I let the smoke roll and give it hell, holding up good.
I HAVE 4.88's in my old half ton axle that I ran 38.4x14.5 swamper sx's on and had no problems. I ground down 2 teeth as well to run the stock pin. The one thing that you might be running into is one of the weak parts of the 8.8 is the main caps. They have a tendancy to give alittle under high stress, letting the ring gear to deflect back and cause breakage. They make diff covers that preload the main caps that I had on mine and never had a problem on or off road. Hell even did some burnouts with the bias plys