91 Exploder gears in 94 Ranger?

[Zorro]

2 similar posts tonight, I feel like I'm whoring TRS ...

Quick background. I have a 1994 Ranger, 4.0L 4x4. Bone stock, so open 3.27 D35 and 8.8.

I have found a local Exploder 1991 4.0L 4x4 (have yet to see the truck though), I dunno yet the gearing (emailed the owner), but would the diff internals swap easily? So far I have confirmed that the front is indeed a D35 and the rear an 8.8.
No issues with the front end. If the gears are what I'm after (4.10 or 3.73, worst case), I'll swap gears and/or carrier.
The back is another issue, as my Ranger is 28 spline and the donor is 31. I have nothing against a stronger axle ... but the tech library says it's 1.5" wider, plus fabrication, etc etc etc. Not really willing to go through all that right now.
So what's the easiest way to get those Explorer gears in my Ranger? Can I swap just the gear and pinion? Is the carrier different in that regard?
Let's make it a wee bit more complicated and guess it's a LS ... I'm guessing there's no way to fit it without going 31 spline in my Ranger ... right?

 

[Wicked_Sludge]

the exploders gears and carrier is the same as your trucks. the only difference is the side gears (you can re-use your 28 spline gears).

but, if you do an R&P swap, you need to set the gears up in your new axle housing, which requires use of a dial indicator, a complete set of shims, and knowledge of how to read gear contact patterns. its not something your average backyard mechanic can handle. if you were to swap in the entire 31 spline axle from the exploder, however, you would not only get the huge strength increase, but the 1.5" width increase (thats only 3/4 of an inch on each side) wouldnt even be noticeable to the naked eye. and this way you dont need to set the gears up or swap your side gears.

same goes for the front...just swap in the entire d35 pig out of the exploder (its bolt in) this way you dont need to set the gears up.

 

[rickcdewitt]

you are probably looking at 3.55 or 3.73 in the donor

 

[Zorro]

wicked - I hear ya! I can definitely swap the whole pig up front ... heck if the TTB is 1.5" wider like the back maybe I could change the beams as well, and have a mini-prerunner LOL ... is the front end wider as well? Couldn't find front track width figures ... and would the shock mounts, coil buckets steering etc line up?

I'm not so concerned with setting the gears. A bit of patience and if I'm really lost I have numerous friends I can call to save my arse. However for the back it's the whole fabrication process involved in swapping the axle as a whole that bothers me. But you say I can re-use my side gears ... that's perfect! Thanks for the tip!

rickcdewitt - don't jinx me, man! The guy says he'd bought it for a tow rig ... so perhaps it will have good ratios. Fingers crossed!

 

[Wicked_Sludge]

the d35 only came in one width..so no use in swapping the beams.

to swap the 31 splione axle only requires welding of your trucks spring perches and lower shock mounts. this could easily be accomplished by most machine or automotive repair shops for probably around $100....and its STILL a lot easier then setting up an R&P (do you have a dial indicator, gear marking compound, a micrometer, and a ft-lbs torque wrench at the least?).

http://www.pirate4x4.com/articles/tech/billavista/Gear_Setup

 

[Zorro]

Good to know about the front end. Less hassle.

I do have 2 dial indicators, a micrometer and several "clicker" torque wrenches ranging from the tiny 1/4 to truck sized 3/4. I just need to get some gear paint and I could technically do it all myself.
I'm not good with fabricating (never took the time to learn welding!), but I'm good with mechanical stuff. Have rebuilt several engines ... including a high-strung italian V8 that was sitting 90% disassembled in the trunk. Mechanical stuff doesn't phase me.

But you are right, it is some extra work.

And to be honest ... I could have the axle fabbed for free. It's just the extra width that bothers me. I'm really anal about that stuff, and do not want the front end to be noticeably narrower than the back. Don't really want to put spacers up front either, even if only 3/4" ... those front bearings are weak enough as they stand right now.

 

[Wicked_Sludge]

the front end wont be noticably narrower than the rear..thats my point. check out any stock explorer and you cant tell the difference.

 

[BII302]

The Explorer 8.8 is the same width as the D35. Check your Ranger, the rear is narrower than the front. On Gen.2 rangers the rear was 3"s narrower. On Gen.3s I think the rear is 1.5" narrower.

 

[Zorro]

Back is actually narrower? Well I feel like a jackass now.

Called the guy, ratio is 3.73, he doesn't know if it's LS or not. That's good enough for me! Picking the truck sometime this week. 31 spline FTW.

Thanks for all the great info ... definitely much appreciated!!!!