Ford 8.8 w/5.13's and Aussie issues ! ! Question ! ! - Great Lakes 4x4. The largest offroad forum in the Midwest

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Old April 13th, 2007, 01:20 AM   #1
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Default Ford 8.8 w/5.13's and Aussie issues ! ! Question ! !

I googled for at least an hour and couldn't find an answer or even a comment regarding this. Here's the situation.

I had 4.10's in my 8.8 with an aussie. I'm regearing to 5.13's right now. 5.13's in an 8.8 require the use of a notched cross pin or trimming a tooth. It would require alot of tooth trimming so I choose the notched pin. When using a notched cross pin, you put the internals in the carrier and then put the ring gear on. Later after everything is set and you're ready for axles, you turn the crosspin to one side so you can slide the axle in to install the c-clip and then turn the other way for the other one.

THIS IS WHERE THE PROBLEM LIES.

I can install the aussie but, when you open the cam gear up to slide the c-clip in, it opens enough but the spacer is in the way....



My spacers look slightly different than the pic above. The are more cup shaped and are not solid meaning that the inner part is machined out some to provide a place for the c-clip to ride in.

HERE ARE MY OPTIONS AS I SEE THEM.
1. Grind the notched crosspin wider to provide enough space for the spacer to slide into.
2. grind the the spacer enough to allow the c-clip to slide through it.
3. grind a ring gear tooth enough so that I can install the cross pin after the ring gear is on the carrier.
4. buy a c-clip eliminator kit ($160 more than I want to spend)
5. sell the aussie and weld the 8.8

I'm looking for thought's on this just in case I'm missing something. I can't be the only person who has tried to solve this issue....
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Old April 13th, 2007, 01:43 AM   #2
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I guess it depends where your pattern is on the gear set weather or not I would grind the teeth down to be able to pull the pin out.

I like welded rears (or selectable) personally. The Aussie is a good locker (I run one in my d44), but I don't know if I would run one in a rear application with low gearing and big tires.
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Old April 13th, 2007, 01:45 AM   #3
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Yeah... I wouldn't be grinding this. That is a lot of grinding.

how much more room do you need to install the clips?

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Old April 13th, 2007, 08:44 AM   #4
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So by turning the pin you can't get the spacer to slide far enough to the drivers side to reveal the slot in the passenger side axle?

Is there a gap between the spacer and the side gear half?

Did you get the drivers side C-clip installed? (or did you install it while installing the Aussie?)

Got pics?
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Old April 13th, 2007, 08:52 AM   #5
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Quote:
Originally Posted by Jeeperz Creeperz View Post
So by turning the pin you can't get the spacer to slide far enough to the drivers side to reveal the slot in the passenger side axle?

Is there a gap between the spacer and the side gear half?

Did you get the drivers side C-clip installed? (or did you install it while installing the Aussie?)

Got pics?
What I get from it it, the notch in the cross pin is wide enough for the shaft to fit inside of it. The spacer in the aussie is quite a bit larger diameter, so it won't fit inside the notch at all.
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Old April 13th, 2007, 09:05 AM   #6
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Quote:
Originally Posted by Jeeperz Creeperz View Post
So by turning the pin you can't get the spacer to slide far enough to the drivers side to reveal the slot in the passenger side axle?

Is there a gap between the spacer and the side gear half?

Did you get the drivers side C-clip installed? (or did you install it while installing the Aussie?)

Got pics?
I don't have pics right now (wife left the digi at grandma's on easter).

As for the notch in the pin, I'd have to enlarge the grind in it at least a 1/2" wider overall. That's alot and then there would be the heat issues unless I went really slow.

There is only a gap in the spacer and side gear half when the cross pin is out. You have to have the pin out to slide the spacer over to open the gap for the c-clip to slide into.

I can't get any c-clips in at all, I can get them started in the locker but then the spacer is in the way.

I got the question into the techs at aussie but I don't think they'll have an answer other than it wasn't designed for that type of application.
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Old April 13th, 2007, 09:18 AM   #7
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Dumb question, but where'd you get the pin?

Is it notched in the center only, or is half the pin shaved (so that you can pull it out past the ring gear)?
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Old April 13th, 2007, 09:27 AM   #8
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The pin came from complete offroad and it's only notched in the center, and only a slight bit wider the the axle shaft's diameter. I'ts cross section looks like this

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Old April 13th, 2007, 09:30 AM   #9
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I'd have to cut at the red lines to make it wide enough to slide the spacer over. about a 1/4" wider on each side.

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Old April 13th, 2007, 10:20 AM   #10
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Originally Posted by sodapop View Post
I'd have to cut at the red lines to make it wide enough to slide the spacer over. about a 1/4" wider on each side.

It's probably heat treated as well. I would have a machine shop do it if you decided to.

I can toss it in the mill if you mail it here if you want to go that route.
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Old April 13th, 2007, 11:35 AM   #11
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Well after consultation and partial assembly, very little material had to come off the ring gear. Only a small portion of the toe of one tooth had to be ground down. I don't think it will be enough to make a difference. I also took it very slow so that it stayed cool to the touch at all times too. When I set the gears up, I'll also do my best to get the contact patch outside of the grind spot. When I get the digi, I'll post pics for future reference.

Thanks for you're help guys (Monkey, Jeepers, and Ken [junk90xj] @ All Pro Automotive)!
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Old April 13th, 2007, 10:02 PM   #12
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done yet?

let me guess you screwed off all day with rims that wont work too?
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Old April 14th, 2007, 11:28 AM   #13
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done yet?

let me guess you screwed off all day with rims that wont work too?

Why yes I did, then I had to stop on the corner of Grand and washington waiting for a few tricks to pay for those rims.

seriously though, the gears are set, just have to finish final install with new bearings and crush sleeve. I'm going out to do that now.
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