Ford 8.8 Eaton eLocker build and install

[dit]

Picked up an 8.8 from an 89 F150 4x4- $75

New brakes, drums and wheel cylinders were a bonus and made up a bit for the fact the axles were trash.

first thing was to gut it and strip it. Trick to easily remove wheel bearings and seals (with center removed): 6' long pipe or bar and a hammer from opposite side; several blows and they're out.

I'm thinking it a good idea to hold onto these parts for now.

[dit]

While waiting for parts, it's a good time to brush up on ring and pinion install and make up a pinion set-up bearing. I did a complete write up on this in 2008 on the old site; http://astrosafarivans.org/bb2/viewtopic.php?f=59&t=8715&p=86141&hilit=photo_van#p86141 so I'm not likely to get into that here. There is also an infinite amount of info on the web, some of which is correct.

Ring and pinion set up is no big deal as much as legend suggests: it's just numbers and a pattern that can be accomplished with $25 worth of special tools from Harbor Freight.

A set-up bearing and trimmed pinion nut will save you a lot of time and anguish. Use the old pinion bearing. Measure the thickness of the bearing (including the outer race). If that measurement is different than the new bearing you will need to adjust the pinion shim accordingly; this one measured the same as new. Go light with the Dremel as you still want the bearing to fit snug. Just remove what is needed on the inside of the inner race so it slips easily over the pinion.

[sixsix]

...Go light with the Dremel as you still want the bearing to fit snug. Just remove what is needed on the inside of the inner race so it slips easily over the pinion.

I kept this up for a few days till I could get back here.

Am I reading this correctly... that IS a precision ground ID, is it not ? Hand grind, should we not be horrified ?
Did I miss a year that day...?

If OK - I'll go back to the "Mainstream Media Pandemic Fear Shelter". It's a room w/ no tv and cable.

[Rod's Trucks]

"...it's a good time to brush up on ring and pinion install and make up a pinion set-up bearing."
With the information taken slightly out of context, it was obviously misleading Sixsix.
The post was in reference to making tooling to set the pinion depth, using a bearing with a slightly relieved ID ( only takes a few minutes for the minimal amount of modification) to allow easy bearing insertion and removal, for setting the pinion shim pack as needed.
Then a new bearing and nut are to be installed...Easy Peasy...and works great.

Rod J

[dit]

Sorry guys, I guess throwing that in at that point was misleading. Yes, old bearing for setup purposes.

While I have your attention, anyone out there have an Astro rearend they might be able to measure the pinion angle on? Pinion in relation to the spring perches. I finally got some parts. Want to weld up the perches but I'm having a hard time pulling angles with the diff still in the van. Thanks in advance!

Master rebuild kit, 4.10 gears, wheel bearings and perches. Axles on the way. Unfortunately the eLocker is still a couple weeks out.

[dit]

I got the angle ~10°

It you just want to put an 8.8 in your van; no rebuild, no new gears, no new diff, these are the parts you will need: 1"- 5x5.5 to 5x5 wheel spacer (unless you have 6 lugs), spring perches, travel stop mounts (fabricated from old perches), re-worked shock mounts and a conversion u-joint. The only machining that will be required is drilling a 5x5 pattern in the passenger side axle and drum and turning the axle center hub down to 77.8mm to accommodate the center bore on the stock rims. If you want disk brakes it looked to me that the assembly from an Explorer (unknown year) will bolt right up.

[dit]

weld three mounts each side and you have an Astro/Safari 8.8 rear axle housing

[dit]

New axles finally arrived from Summit

[markmitch]

Nice write up! I am not ever going to do this mod but I still like to learn new things. My van is modified but not to the extent I will need a beefer rear axle. However if you ever have the chance to rebuilt a GM 7.5 rear axle and have some tricks to do it I would love to know them. Someday I wish to rebuild my factory rear axle with a new GM G80 set up.Mark

[dit]

I really didn't *want* a beefier rearend, this entire project is so I can put in a selectable locking diff. With the COVID the project is really getting backed up. Eaton keeps putting off their 8.8 production a month at a time. I may have to go with an OX locker instead.

The 7.5 is fine for my application but no options for a selectable locker. As for the G80, I'm not sure I'd take the time and money. They often fail; mine blew up first time I took it off road....

I will likely have a complete 7.5 truTrac with 4.10s available when the time comes.

[markmitch]

Oh ok Understood, mine is an RS and came with the 3:42 with G80 but after so many miles the G80 quit working all together. I have another g80 with 3:42 that came out of an 88 Safari but I have never done a rear end and if I pay someone to do it and the G80 is no good then I gain nothing.

[AstroOafAdventurer]

I really didn't *want* a beefier rearend, this entire project is so I can put in a selectable locking diff. With the COVID the project is really getting backed up. Eaton keeps putting off their 8.8 production a month at a time. I may have to go with an OX locker instead.

The 7.5 is fine for my application but no options for a selectable locker. As for the G80, I'm not sure I'd take the time and money. They often fail; mine blew up first time I took it off road....

I will likely have a complete 7.5 truTrac with 4.10s available when the time comes.

Thanks, I'd been curious as to the reasoning behind modding/adding the 8.8.

[M_a_t_t]

Adding a bigger rear end is on my list of eventual mods. I suppose I like to torture my vehicles. Last time I towed something heavy (yes I know... exceeded capacity) I ruined my wheel bearings. Plus I wouldn't mind a disc upgrade.

[dit]

The explorer disk setup looks like it will bolt up. I was tempted but not sure about the master cylinder proportioning. Also the clearance between the calipers and leaf springs on the drivers side would be tight. I will gain the f150 11” drums over the Astro 9.5”.

[TowVan]

From what I've read on the "net," (so it must be true!) the 8.8 is an almost direct copy of a chebby design - just changed enough to not be sued. Haven't heard if that's a 10 bolt, or 12 bolt, but I always assumed a 10 bolt. I know its not as strong as a 9'', but not as much parasitic loss as a 9" either. 'Course I know there are some versions of a 10 bolt that are stronger than others...
But it doesn't surprise me to hear that the 8.8 has better aftermarket versatility!

[dit]

From what I've read on the "net," (so it must be true!) the 8.8 is an almost direct copy of a chebby design - just changed enough to not be sued. Haven't heard if that's a 10 bolt, or 12 bolt, but I always assumed a 10 bolt. I know its not as strong as a 9'', but not as much parasitic loss as a 9" either. 'Course I know there are some versions of a 10 bolt that are stronger than others...
But it doesn't surprise me to hear that the 8.8 has better aftermarket versatility!

Yes I've read that also and having had both the 7.5 and the 8.8 apart, there are similarities; i.e. the pinion and carrier setup will be identical and the axles and bearings are very similar but beefier. The latter I appreciate as I just ate up an axle bearing surface for reasons unknown. I also like that the 8.8 is fairly small so as to only loose ~1/2" of ground clearance.

[dit]

Got some shop work done on the new axles. We made them hub centric to the Astro wheels but still allowing for the considerably larger center on the Ford brake drum to be indexed. Also drilled the flanges to 5 on 5 pattern.

Turning an aluminum center for the drivers side wheel spacer/adapter.

Turning the passenger side axle hub

Finished Driver side adapter/spacer

Turned PVC bushing to allow for rotary indexing of axle on drill press

Jigged up and ready to drill. ***note that only the psngr side will need to be drilled as the drivers is taken care of by the adapter

[dit]

If you don't have access to machining you can buy custom axles to these specs for ~$400.

index drilling pilot holes using the Astro drum as a pattern.

The holes for the Ford lug studs are of a somewhat odd size of 19/32. Lacking that drill size and living 25 miles out of town which likely didn't have one anyway, we followed with a 1/2 in twist drill then used a cutting tool mounted on a half inch boring tool in the drill press to open up the holes to 19/32.

Finished 8.8 Astro axles: drivers left, psngr right.

[CopperFiremist]

GEEZUS! NICE WORK!

[WinnieVan]

Love a good machine shop.. well done.