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© 2013 by Joseph Palazzolo

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Edit by Paul Johnson

Layout by Monica Seiberlich

ISBN 978-1-61325-127-0

Item No. SA289

Library of Congress Cataloging-in-Publication Data

Palazzolo, Joseph.

Ford differentials : how to rebuild the 8.8 and 9 inch / By Joseph Palazzolo.

p. cm.

1. Ford automobile--Differentials--Maintenance and repair--Handbooks, manuals, etc. 2. Ford automobile--Axles--Maintenance and repair--Handbooks, manuals, etc. I. Title.

TL215.F7P35 2013

629.2’45--dc23

2012045860

10 9 8 7 6 5 4 3 2 1

Title Page: An assortment of Ford 9-inch axle stampings is welded together to create the housing. The cast-iron third member is installed through the front of the housing. It supports all of the gear and bearings, which allows for easier gear ratio swaps, if you have multiple third members.

Back Cover Photos

Top Left: You need to carefully identify and inspect the differential when you’re in the market to buy one. This case looks like a nodular unit from the front, regarding rib structure, but does not have the “N” on it. When you look on the inside, you see the WAB-4025A. This is not a nodular unit.

Top Right: The 8.8-inch pinion requires some shimming to set the correct pinion depth on the ring gear. Some aftermarket gears are marked; Ford Motorsports gears and original-equipment gears are not marked. In this case, the pinion head markings identify it.

Middle Left: A dial indicator is set up to verify backlash and pattern. Remember to check backlash in at least four different positions; there should not be more than .004-inch variation. Every new gear set should come with a backlash recommendation in the instructions.

Middle Right: The side gears have been installed. Once in place, the washer is set in position and assembly grease is applied to the face of the washer. When all of the differential internal pieces are in place the differential case halves can be closed.

Bottom Left: The ring gear is pulled into position and a couple of bolts are installed. Note the bolts have washers under the heads. These smaller headed bolts with washers are used in Traction-Lok applications only. Open differentials and most other aftermarket differentials use larger headed open differential style ring gear bolts.

Bottom Right: This Ford 9-inch differential assembly is nearly complete. The adjuster nuts need to be set in place. Extra care must be taken to be sure the threads are lined up correctly.

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