Ford 8.8 Assembly & Set Up (Part 1) #FairmontProject

Here’s (Part 1) of the Ford 8.8 differential assembly and set up. This took a little longer than expected, hence the need for a 2 part video.

Link to (Part 2): https://www.youtube.com/watch?v=npUBF9Wj1Iw
Link to (Short Version): Link Posted when video becomes available
Link to (Final Assembly): Link Posted when video becomes available

Link to previous video in series: https://www.youtube.com/watch?v=il8nDlCepyc

Differential Basics video: https://www.youtube.com/watch?v=0Y6vOwiCe1U

This is a complete overview of how to assembly and set up a Ford 8.8 differential. It shows how to assemble the differential, set backlash, and set up the gear tooth pattern.

The best place for answers to your automotive questions: http://www.ericthecarguy.com

Camera: Brian Kast

Thanks for watching!

Discussion about this video: https://www.ericthecarguy.com/kunena/18-The-EricTheCarGuy-Video-Forum/64579-ford-8-8-assembly-set-up-fairmontproject

Special thanks to

Kings Ford: http://kingsfordinc.com

Ford Performance techline: https://performanceparts.ford.com/contact-us/

Additional info and links

Ford 8.8 PDF: https://performanceparts.ford.com/download/instructionsheets/FordInstShtM-4209-8.pdf

Gear tooth pattern guide: https://www.ringpinion.com/Content/Book/Reading-and-Adjusting-Ring-and-Pinion-Tooth-Patterns.pdf

Dana Differential assembly guide: http://www2.dana.com/pdf/5717.PDF

Ford differential identification guide: http://www.fordification.com/tech/rearends_ford09.htm

Article on the 8.8: http://www.hotrod.com/how-to/transmission-drivetrain/116-ford-8-8-rear-end/

Parts

My differential: https://lmr.com/item/M4204F318C/Mustang-88-31-Spline-Traction-Lok-Differential-With-Carbon-Fiber-Clutch-Disks

My gear set: https://lmr.com/item/LRS-4209FRA-K/Mustang-88-355-Rear-Gear-Kit

My differential cover: https://lmr.com/item/M4033G2/Ford-Mustang-FRPP-Rear-Differential-Girdle

My 5 lug conversion kit: https://lmr.com/item/SVE-2300DK-B/1993-Mustang-Black-SVE-5-Lug-Conversion-Kit-31-Spline

Pinion head bearings: https://www.ringpinion.com/b2c/Search_Results.aspx?Requery=True&SortBy=Yukon&SearchType=Part&SearchPhrase=m802048

Pinion head bearing races: https://www.ringpinion.com/b2c/Search_Results.aspx?Requery=True&SortBy=Yukon&SearchType=Part&SearchPhrase=m802011

A great place for differential parts: https://www.ringpinion.com

Pinion flange sleeve Federated 99181: https://www.amazon.com/SKF-99181-Speedi-Sleeves/dp/B000EPTAPW

Ultra black RTV: https://www.amazon.com/Permatex-82180-Maximum-Resistance-Silicone/dp/B0002UEN1U

Gear Paint: https://www.amazon.com/Ratech-500-Marking-Compound/dp/B001P2D27U

Tools

Differential Shim Installer: https://www.summitracing.com/parts/yga-56077?seid=srese1&cm_mmc=pla-google-_-shopping-_-srese1-_-yukon-gear-axle&gclid=CJ6Dj-DSxc0CFQgaaQodKbgFjA

Pinion Flange Holder: https://www.summitracing.com/parts/aaf-all68372?seid=srese1&cm_mmc=pla-google-_-shopping-_-srese1-_-allstar-performance&gclid=CPjuvYjTxc0CFQYuaQodvNEKQg

Bushing Driver Kit: https://www.jbtoolsales.com/astro-pneumatic-7824-bearing-race-and-seal-driver-set#oid=1002_1

Dial Indicator: https://www.jbtoolsales.com/central-tools-3d102-dial-indicator-set-with-on-off-magnetic-base#oid=1002_1

Digital caliper: https://www.jbtoolsales.com/general-tools-1478-8-digital-fractional-caliper#oid=1002_1

Inch Pound Torque Wrench: https://www.jbtoolsales.com/precision-instruments-d2f150hm-torque-wrench-dial-with-memory-needle-3-8-dr-150-in-lb#oid=1002_1

Long breaker bar: https://www.jbtoolsales.com/k-tool-23081-chrome-breaker-bar-1-2-drive-24-long#oid=1002_1

Sunex Press: https://www.jbtoolsales.com/sunex-tools-5720-manual-shop-press-20-ton#oid=1002_1

**Answers to your automotive questions found here: http://www.ericthecarguy.com/faq

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Stay Dirty

ETCG

Due to factors beyond the control of EricTheCarGuy, it cannot guarantee against unauthorized modifications of this information, or improper use of this information.  EricTheCarGuy assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. EricTheCarGuy recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video.  Due to factors beyond the control of EricTheCarGuy, no information contained in this video shall create any express or implied warranty or guarantee of any particular result.  Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained in this video is the sole responsibility of the user and not EricTheCarGuy.

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27 thoughts on “Ford 8.8 Assembly & Set Up (Part 1) #FairmontProject

  1. I thought of and discovered a really cool trick when installing races on a sport bike I was rebuilding. Take all the races and put them in the freezer for a few hours beforehand, then take them out one at a time as you need them. You'll find that the races shrink enough that they literally just drop in, maybe sometimes needing a little tap. It was a whole lot easier than having to press them all. A thicker bearing might take longer to shrink, might not work at all, but it's worth a shot.

  2. Would you have been ok if you made sure to get the same pinion bearing that you took off to have a setup bearing? Great info man. I really enjoy your videos you really explain what n why you're doing what you are doing. Thanks n keep it up Todd

  3. You have convinced me to get a 9" with a third member. If looks like you are not gonna do any quick gear changes with an 8.8" if you drag race. And the cost to go to 9" does not seem to be much different. I realize I am looking at if from a drag racing viewpoint.

  4. Eric, I love your videos man, but being a diff specialist this video had me yelling at the screen. That was a solid effort though, your persistence is something to be admired.

  5. I bought a 2000 expedition 5.4 engine but i have a grinding sound in the differential when i turn left or right it sounds like thats where its coming from i have a feeling the old owner changed something in there I see silicone on the rear diff.my question is this , is that what I'm hearing or not

  6. Great video. Very informative. I just picked up an 8.8 core that i am stripping completely and building a 4.10 trac loc for my 2010 crown vic. These video sets are how I am going to build mine, really appreciate the detail and information you provide.

  7. Have to swap my rear diff and pinion. 1997 Ford Ranger. Old one ran dry, tore up pinion carrier bearings, chipped some teeth. This series is my primary source of learning. I think I get it now. Thank you!

  8. I know you have to be very precise in setting up your differential but how did Ford mass produce so many vehicles if you have to spend so much time tweaking each individual differential I wonder how they did it so quickly to mass produce so many vehicles

  9. I have never had to do this before but i have listened to friends talk about doing this and with this video i understands allot more then ever before thank you

  10. hi to you, great video with lots of explanations.
    Today I am replacing my differential but I cannot read the setting value on the pinion.
    How to get your opinion, a photo where?
    thank youps : (my car is a 1995 Cherokee Jeep)

  11. Again, my FIRST CAR was a 1978 Fairmont Sedan in Metalic Brown powered with an Inline-6 200 Auto.

    As with watching your video series, I have been trying to find another one to "Modify" and use as a Daily Driver…

    Sadly, they are either too expensive ($2,500 to $1,750), or WAY out of my Region… I have even expanded my search for either a Futara Coupe, or a Wagon. NO LUCK!😿

    My only complaint I had with my (5) previous Fairmont's/Zepher's was the Aluminum Bumpers.

    Looking forward to seeing you have your Fairmont Sedan back on the road!😎

    Take care,
    🤓 -Thomas
    Western Washington State

  12. How do you know if you have your pinion depth correct? I've noticed on most pinions they have a measurement on the backside of the pinion that tells you the pinion depth. I didn't hear anything about pinion depth.

  13. Well my 355 gears 8.8 differential broke that pin thats like 3 quarters of an inch think and i was wondering do i have to pull the entire differential like you did but leave the axle and all of that on the truck

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