Ford 8.8 re-gearing issues

[3ncrypt3d]

Trying to figure out all I need to do to swap gears on a 97 ranger with 3.27 gears in a L/S 8.8. I’m wanting to switch to 4.88 gears since I have a 4 banger and 32 inch tires. I read on some forum (I think and explorer one) that is need a notched center pin. Would it be better just to get 4.56 gears? Or would I run into the same issue there. I believe a 4.10 would be enough to get those tires moving, but I do go wheeling quite often. Mostly dirt/mud trails. Any help would be appreciated!

 

[4x4junkie]

I don't use notched cross pins, they've been known to break occasionally (they also don't function correctly with some drop-in style lockers).
Instead what I do is simply grind a tiny amount from the tip of the interfering gear tooth (usually between 0.5-2mm), just barely enough so that you can slide your original solid pin past it.

If grinding gear teeth makes you cringe... Don't. It's actually a common procedure (google ring gear tooth grinding, your should find plenty of info out there about it). The portion of the tooth to be ground away never contacts the pinion gear, and so does not affect strength or operation in any way.

I did this on mine 15 years ago with 5.13 gears.

 

[Captain Ledd]

I notched the very tiny tip of a tooth when I did my 4.56 gear install. But under abuse ( ) from a 4 whizzer, I don't think you'll run into cross-pin breakage issues. I have 4.56's and 29's, 4.88's would probably be better for a 32" tire. Mine's technically a little on the steep side, but I love them. %100 glad I did it.

Ultimately, as long as the ground spot is outside of the contact patch, grind the tooth. The outer part of the tooth doesn't take any load, it's only there because it technically needs to end somewhere.

 

[Curious Hound]

I Ground the teeth on mine. (8.8" 31 spline w/ 4.56 gears and Aussie Locker)