Mini spool install

[jtaborsky]

8.8 from a ~2000 Explorer and a G2 mini-spool.

I'm putting in a mini spool. I thought it would be easier, but nothing fits together! I had to grind the c-clips to get them to fit in the grooves, then I had to grind the mini spool blocks because they were too wide to fit between the axle shafts. Now the cross pin won't slide back in easily. Should I grind that too? Should I coerce it with a hammer?

Is this much difficulty normal? What am I doing wrong?

I thought this would be easy, but I need help!

Thanks.
- Joe

 

[mkyhmltn]

The mini spools for the 8.8 are designed for an open carrier. If you have a limited slip the easiest way is to change out the carrier or rebuild the limited slip.

 

[jtaborsky]

I have an open carrier, but these pieces just don't fit!

 

[Big Jim M]

From memory

8.8 from a ~2000 Explorer and a G2 mini-spool.

I'm putting in a mini spool. I thought it would be easier, but nothing fits together! I had to grind the c-clips to get them to fit in the grooves, then I had to grind the mini spool blocks because they were too wide to fit between the axle shafts. Now the cross pin won't slide back in easily. Should I grind that too? Should I coerce it with a hammer?

Is this much difficulty normal? What am I doing wrong?

I thought this would be easy, but I need help!

Thanks.
- Joe

I installed a mini of another brand once in a Chevy. I remember the instructions telling me to grind the blocks so the clips would fit. Perhaps you have not ground enough?
I also remember having trouble getting the holes to line up for the pin. I think I had to turn the carrier over and over and it finally allowed the holes to align and the pin slipped right in.
Whatever else you do positively don't use your hammer on that install! I know everything in there looks heavy and strong but you don't want to force anything as the results can be unfavorable quickly!
As a last resort I'd be calling the manufactory for better instructions.
Big Jim

 

[jtaborsky]

I wound up grinding two sides of the pin flat so it could fit past the axle shafts. Cross your fingers for me!

- Joe

 

[killj0y]

I wound up grinding two sides of the pin flat so it could fit past the axle shafts. Cross your fingers for me!

- Joe

You generally do not want to grind the cross pin. It will cause premature failure as most of the pressure of the diff and spool in this case is on it. I would contact the manufacturer and find out what's wrong before catastrophic failure.

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