Ford Differentials: Rebuild 8.8 & 9 Inch: How to Rebuild the 8.8 and 9-inch

by Joe Palazzolo

Overview

The Ford 8.8- and 9-inch rear differentials are two of the most popular and best-performing differentials on the market. While the 8.8-inch differential is commonly used in late-model Mustangs, the 9-inch is the more popular and arguably the most dominant high-performance differential for muscle cars, hot rods, custom vehicles, and race cars. Built from 1957 to 1986, the 9-inch Ford differential is used in a huge range of high-performance Ford and non-Ford vehicles because of its rugged construction, easy-to-set-up design, and large aftermarket support. The 9-inch differential effectively transmits power to the ground for many classic Fords and hot rods of all types, but it is the choice of many GM muscle car owners and racers as well. These differentials have been used extensively and proven their mettle in racing and high-performance applications.

The Ford 8.8- and 9-inch must be rebuilt after extensive use and need a variety of different ratios for top performance and special applications. This Workbench book provides detailed step-by-step photos and information for rebuilding the differentials with the best equipment, installing the gear sets, and converting to Posi-Traction for a variety of applications. It describes how to disassemble the rear end, identify worn ring and pinion gears, other damage or wear, and shows step-by-step rebuilding of the differential. It also explains how to select the right differential hardware, bearings, seals, and other parts, as well as how to set ring and pinion backlash so that the rear end operates at peak efficiency.

Aftermarket 9-inch performance differentials from manufacturers including Currie, Moser and Strange are reviewed and you learn how to rebuild and set up these high-performance aftermarket differentials. In addition, this book provides a comprehensive identification chart to ensure readers properly identify the model and specifics of the 9-inch differential. Chapters include axle identification, inspection, and purchasing axles for rebuilding; differential tear down; ring and pinion gear removal; inspection and reassembly; drive axle choices; and more.

Product Details

ISBN-13:	9781613250389
Publisher:	CarTech
Publication date:	04/23/2013
Series:	CarTech Series
Pages:	144
Sales rank:	708,755
Product dimensions:	6.86(w) x 10.20(h) x 0.40(d)

About the Author

Joe Palazzolo is currently the Global Engineering Director-EV System Solutions at Dana Incorporated. His resume includes employment at Ford, Magna Powertrain (formerly New Venture Gear), Warn Industries, GKN Driveline and GETRAG Corporation. He has also supported numerous race teams as well as building and maintaining his own motorsports and powersports vehicles. Joe is an ASE Certified Master Technician, holds a Bachelors Degree in Mechanical Engineering, and a Masters Degree specializing in Automotive Engineering. He has been a member of the Society of Automotive Engineers (SAE) for more than 18 years and is active in developing SAE standards. He has been teaching Drivetrain seminars for more than 10 years and a recipient of the Forest R. McFarland Award for distinction in professional development and education. He has received numerous patents for his innovative work and creativity in advancing vehicle mobility systems.

Table of Contents

Acknowledgments

Introduction

What is a Workbench® Book?

Chapter 1:

Axle History and Identification
8-Inch
9-Inch
8.8-Inch
Front Axle Applications
93½8-Inch
Part Numbers

Chapter 2:

Axle Removal
Safety Equipment
General Procedures
Brake System Removal
Leaf Spring Removal

Chapter 3:

8.8-Inch Axle Disassembly and Inspection
Optional Upgrades
Disassembly Preparation
Axle Housing Disassembly
Traction-Lok Differential Disassembly

Chapter 4:

8.8-inch Axle Assembly
Traction-Lok Differential Assembly
Axle Housing, Wheel End Bearing and Seal Assembly
Ring and Pinion Gear Set Assembly

Chapter 5:

9-Inch Axle Disassembly and Inspection
Physical Differences
Strength Differences
Axle Shaft Splines
Disassembly Procedure
Brake Drums and Axle Shaft Dissambly
Third Member and Pinion Cartridge Removal
Summary

Chapter 6:

9-Inch Axle Assembly
Open-Differential Assembly
Traction-Lok Assembly
Third-Member Assembly
Axle Housing Assembly

Chapter 7:

Ring and Pinion Assembly
Face-Hobbed Gears
Face-Milled Gears
Break–In Procedure
Gear Ratio Selection and Tooth Combinations

Chapter 8:

Performance 9-Inch Axle Installation
Vehicle Acquisition and Inspection
Drivetrain Upgrades
Transmission Installation
Spring Pocket Kit Installation
Wheel Tub Installation
Axle Ratio Selection
Summary

Appendix: 9-Inch Axle Identification Codes

Source Guide

Editorial Reviews

"Within the 144 pages of this softcover book is everything you need to know about rebuilding Ford's 8.8 and 9-inch differentials. In fact, the information is so well presented with understandable, concise writing backed by hundreds of clear, detailed photographs, that you'll be able to rebuild most other differentials too, as they are all basically the same by design. Here the author guides you through each and every step of the rebuilding process, details the tools needed, explains how and why each part works, and shows you how to set the pinion angle and other critical dimensions." -Hemmings Classic Car, September 2013

Hemmings Classic Car

"... an essential reference on the subject." -tkc magazine, January/February 2014

tkc magazine

"It can't make you an expert, it can't even stop you getting things wrong, but it can definitely stop you from falling into the elephant traps that await the novice, and help you decide whether you should attempt the job yourself or just call the speed shop.... definitely recommended." -American Car Magazine, November 2013

American Car Magazine

Ford Differentials: How to Rebuild the 8.8 and 9 Inch provides step-by-step disassembly and assembly instructions for any auto technician who wants to identify and work with the best differentials for Ford. From high-performance setups and installation specifics to the internal components of different assemblies and tricks and tips of installation, this is a workshop manual highly recommended for any working with Ford differentials who want a series of color step-by-step photos and rebuild specifics for the 8.8 and 9 inch assembly.

Midwest Book Review - James Cox

"... an essential reference on the subject." -tkc magazine, January/February 2014

Old Cars Guide to Auto Restoration - Angelo Van Bogart