8.8 cross pin will not fit back in after Aussie install.

[Harry]

Putting an Aussie in Reid's TJ. Reused the thrust washers. The cross pin makes it past the spacers and JUST BARELY hits the the axleshafts. I mean like by thousandths. Shafts are slid outboard as much as possible. I'm hesitant to remove the thrust washers and have too loose a setup. I bet we could grind a few sheets of paper's thickness off the ends of the shafts and it would slide right in, but this doesn't seem right.

Anybody got any ideas or run into anything similar?

[hoggie101]

I think you need a notched cross pin that might just be for a gear size I'm not 100 percent sure

[kracker]

sometimes ya have to grind the crosspin when reinstalling....if you have the correct(hardened) crosspin this shouldnt be an issue...but make sure ya only grind a little bit at a time until it fits...thats what i had to do when i dropped an aussie in my 8.8

[customcreationsllc]

or grind the gear teeth search Randy's ring and pinion they tell you to grind the gear teeth.

[Harry]

or grind the gear teeth search Randy's ring and pinion they tell you to grind the gear teeth.

Do you mean the ring year teeth or the Aussie gear teeth? no issues getting past the ring gear just to be clear. It slides in nicely until it hits the ends of the shafts that just barely protrude.

[customcreationsllc]

Ring gear teeth

http://www.ringpinion.com/TechnicalH...y.aspx?TipID=7

[customcreationsllc]

But I'm not exactly sure what you are talking about.
Is something else in your way?

[Harry]

The cross pin slides in the carrier, past the spacers. The ends of the axleshafts just barely stick inward (in the path of the crosspin) and the cross pin hits them and stops.

[Harry]

sometimes ya have to grind the crosspin when reinstalling....if you have the correct(hardened) crosspin this shouldnt be an issue...but make sure ya only grind a little bit at a time until it fits...thats what i had to do when i dropped an aussie in my 8.8

Interesting. What is different dimensionally about this hardened cross pin? Is it notched? Is grinding the cross pin something that you had heard of other people having to do? This is my first time doing a C-clip Aussie install, I'm used to the D30s just falling together.

[customcreationsllc]

Interesting. What is different dimensionally about this hardened cross pin? Is it notched? Is grinding the cross pin something that you had heard of other people having to do? This is my first time doing a C-clip Aussie install, I'm used to the D30s just falling together.

They sell notch cross pins but not recommended for lockers as the locker really abuses the cross pin.




So you are saying the cross pin hits the axle shafts?
You need to make sure the C is in the correct spot I know it is hard with lunch box lockers.

[Harry]

They sell notch cross pins but not recommended for lockers as the locker really abuses the cross pin.




So you are saying the cross pin hits the axle shafts?
You need to make sure the C is in the correct spot I know it is hard with lunch box lockers.

I guess that's something we'll have to check. I figured the spacers wouldn't even be close to seating correctly if the c-clip wasn't in all the ways since they have to slide over them.

[konastinky1234]

not sure if this could be your problem.....but when i did my aussie in the 8.8 my c clips were ground down around the edges a bit from a mini spool so make sure those clips seat down real snug. i've taken my 8.8 apart too many times and it's a bitch with how tight it is in there so everything has to be int he perfect place and that may gain you that little bit. then i just keep playing with it like a rubix cube you'll get it eventually.

[kracker]

Interesting. What is different dimensionally about this hardened cross pin? Is it notched? Is grinding the cross pin something that you had heard of other people having to do? This is my first time doing a C-clip Aussie install, I'm used to the D30s just falling together.

some crosspins are notched and hardened...thats the way to go...but if you grind the ring gear just a tad you ll be okay too, but just dont take too much off....the hardened x pin is to take the abuse of the locker...regular crosspin is not nearly as strong...

but ideally what ya should do is get the hardened,notched cross pin and depending on clearance ya might not even have to grind the crosspin...every carrier is slightly different as far as tolerances....but grinding the ring gear is really the right way to go if it wont fit...

[Harry]

no issues getting past the ring gear just to be clear. It slides in nicely until it hits the ends of the shafts that just barely protrude.

I think we're going to pull it apart and check the tolerances.

[Crazy Reid]

I grinded the pin so i could make it wheeling this weekend. Let's see how she holds!