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FX4 Lvl II axle swap problems


DHEM

Active Member
Joined
Jun 9, 2011
Messages
39
City
Michigan
Vehicle Year
2005
Transmission
Automatic
Hi me and my friends swapped out the 7.5 axle for a 31 spline 8.8 out of an fx4 lvl II Ranger on my 05 2wd Ranger. The 2 big issues is lots of noise like a semi truck rear end, especially around 40 mph and when you give it gas (Im thinking maladjusted or screwed pinion bearing) and the ABS/Brake light comes on after driving a mile and stays on until your shut the truck off and start it up and drive a mile or so. What I do know about the brake issues is that for one I have a busted adjuster that im already saving up to get. The other known thing is that we needed to get a different brake line due to rust and the new one is a bit to long. I don't think the extra length should be screwing up any sensors but then again I cant be totally sure, maybe one of you know. Then there is the ABS light. Does that just come on and abs shut down by default with a brake fault or does the truck's computer need to be reprogrammed to know its running a different axle with a different ratio? The sensor ring is there and is brand new, I tried 2 different sensors and i'm currently using the one I know works because it did in my 7.5 axle.
I also have another issue, my old axle was missing the filter at the end of the breather tube and the 8.8 didnt have one to come with it. Is this sold at the dealer? I cannot find one anywhere online.

And a short vid, you can barely hear the rear end noise but you can also hear that weird brake noise. You could feel the brake pedal pushing back too.
http://www.youtube.com/watch?v=HdLOA8rElDs
And this one you can hear the rear end noise at 8:40 pretty well.
http://youtu.be/kqWGiWSadVY?t=8m40s

The gears and diff are all new, they were supposedly adjusted correctly the first time, then they got readjusted and re-shimmed and the noise is still there. The brake components are for the most part all new and quite Chinese. New drums and new wheel bearings as well. U-joints have 97xxx miles on them.

So guys whats the damage and whats the deal with the abs :icon_confused:
 
Pull the cover, and inspect the tone ring. I would suggest with pinion bearings and/or carrier bearings bad. Grab the driveshaft at the yoke of the diff, can you move up/down/side/side, if you can, bearings have too much play...

SVT
 
Pull the cover, and inspect the tone ring. I would suggest with pinion bearings and/or carrier bearings bad. Grab the driveshaft at the yoke of the diff, can you move up/down/side/side, if you can, bearings have too much play...

SVT

Thank you
 
Also, with the tires off the ground (or better yet, removed) and the driveshaft disconnected, if it takes more than two fingers to turn the yoke, you have too much preload on the bearings, or another issue. If you have any of these, I suggest a complete teardown and reassembly...


SVT
 
I would run a tooth contact pattern check on it also.
 

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