crosspin problems (56k no)

[t5cents]

can anybody help me with this im still waiting for info on RF. here is the thread over there..ill copy and paste the original post and u can read the others..thanks for all ur help

http://www.ranger-forums.com/forum2/f6/f37/93316-crosspin-problems-56k-no.html

ok so last weekend i took the truck up to some local mountains and was pushin the truck pretty hard. well on the drive home i started hearing this clunk at random times....somtimes when i hit the brakes, when i pushed in the clutch, when i gave or let off the gas and somtimes when i was just driving at a constant speed and throttle it would do it. so ive been driving it for the last couple of days cause i couldnt figure out where it was happening from...couldnt tell if it was the t-case or the rear or front end...and since it was so random i couldnt listen for it. so today i jacked up the rear end and put it in 1st and let it spin and went out and listened to it...definatly some clunking coming from the rear end. so i pull the inspection cover off and look around. firs thing i notice it that the cross pin is all chewed up (from hitting the ring gear)...then i scoop out the botton of the pan...i get a bounch of shaving and about 5 or 6 pieces of metal a little bigger than a BB. so i spin it around and none of the teeth are messed up at all. then i look at the other side of the cross pin..i notice it is loose and there is a crack going through it...so i pulled the bolt that holds it in, out. then i pull the 2 pieces out and try to then push the rest of the pin out...but it cant go out the side thats mauled up cause it hits the ring gear...its notched on the side that broke so im assuming it is supposed to come out that side...but it wont come out..i think it might be cause the other side is to mauled to fit through the hole....any way what to u think...why do u think it broke..is somthing else messed up do u think, could i just put a new cross pin in and call it good for a wile..at least until i get my 8.8? thanks

pix (sorry some are crappy cause it was dark out)

 

[Hahnsb2]

The biggest downfall of the 7.5 is the weak crosspin, it's what broke for me and most others and it doesn't help that the 3.73 and 4.10 7.5s have a notched crosspin making them even weaker. Basically to get the crosspin out the ring gear needs to be removed, at least that's how ford would like you to do it. My preferred method is to take a dremel and clearance the ring gear tooth that's in the way, this allows the use of a full crosspin and makes it's much easier to work on by not having to remove the ring gear and carrier.
Only the very edge of the ring gear is affected and it's not in the contact pattern anyways. Here's a pic of the clearance ring gear on my 8.8 (4.56s and numerically higher on the 8.8 need it).

A full crosspin will make it much stronger too, I really had to try to break mine with a 4.0, 4.10s, 33s and a locker.

 

[AllanD]

I'm going to say the words, the words that an ER Doc uses to tell you you're having a really bad day....


Awwwww.... NEAT!

Never seen THAT before....

Looks like you need a new pin.

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[dangeranger01]

Mine only broke the cross pin once. The other two times it broke the side gears. Just step up to an 8.8 with a Detriot and dont worry anymore.