Spider gear crosspin removal?

[Geeshik]

I realize this is a bad time to post a 'need an answer now' post because it is so late (early) in the day, but if someone, anyone is out there with some info, I would greatly appreciate it.

First, I have a 93 ranger with the 7.5 open rear and 3.73 gears. The crosspin is worn to the point that the axle 'clunks' when a load is applied (starting from a stop). The little 8mm bolt that secures the pin came right out, but I am not having any luck with the pin itself.

I noticed in the Tech Library that someone had a writeup on installing a Lock-Right and it says to just remove the pin, but it does not clear the ring gear no matter which way I turn it. I don't want to force it past the ring gear and damage the gear or the pin. What should I do?

[Geeshik]

Never mind. I searched for crosspin on the site and I think I need to go get a dremel and have at it. I hope it doesn't weaken the ring gear.

I see marks on my crosspin, but I'm wondering if maybe the spider gear housing is worn also. Does anyone have the hole/shaft sizes on these parts?

[Geeshik]

I figure I'd let you know I did because it says we should say if the issue is resolved.

I ended up filing a little bit off the corner of two of the gear teeth near the pin, but not in the contact pattern of the pinion gear. The pin came straight out. It was worn. I installed the new pin I picked up from ford. It was solid and did not have a giant chunk ground out of it like the other one, but it was cheaper and still fit well. I figure that with those teeth filed, I could take the pin out any time to change axles, bearings, or seals. So I replaced the bearings and seals and the leaking rear cover. It had a small rust hole in the top that was leaking. I figured the axle girdle would be less likely to rust through.:D

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[88_Eddie]

i took out the screw that holds it in and hit it with a punch in my 8.8, came right out, glad to hear you got it tho. nice diff cover btw

[adsm08]

Usually jacking the rear end up and rocking the wheels back and forth will knock the king-pin loose.

[Geeshik]

I found out that the 3.73 and higher (4.10, 4.56, etc) gears have a larger peak on them than the lower ones in the 7.5 axles. They cause clearance issues with the pinion shaft (crosspin). Ford notched some of the crosspins so you could still get your axles out without completely removing the pinion shaft. That's all well and good until your crosspin needs to be replaced. I was getting a constant 'pinging' sound when accelerating from a stop, so while it was apart, I checked things out and found out mine was pretty worn out.

The 'proper' way to remove this shaft is to pull your carrier and remove the ring gear. I found out through some other guys on here that you can 'clearance' the gear by filing it or using a dremel tool to take the slightest amount off.

I ran it to work today, and everything was perfect. Thanks again for the great site and all the help.