Jeeeeez....why me. Full Size Bronco

[flintknapper]

Trying to put new a new ring and pinion in my 8.8 today, all is going well until I go to remove the cross shaft retaining pin/bolt.

Naturally, it twists off leaving about one or two threads in the bottom. So everything comes to a screeching halt!

Wanting to make certain there were some threads left...I ever so gently tap the pin/bolt with a punch. Well...CRAP that is just enough to shear the the last thread (or two) and drive the remaining part into the very bottom of the bore.

Hopefully Napa with stock the Fabbi-Assoc. removal tool so I don't have to wait days and days to get one.

Even then...with the remaining portion of thread (albeit damaged) it is going to take a small miracle to get it drilled (without it spinning) and then get an extractor on it.

Assuming that happens (yeah right), nothing short of a complete alignment of the heavens is going to let me back that thing out and hit the threads of the carrier.

Sheeeesh!!!!!!!

Wouldn't you think Ford could make the retaining pin/bolt out of something harder than "pot metal" so this doesn't happen. Someone at Ford needs to be kicked in the nuts.

[lingo]

Flintknapper, I hate to say it but those pins break all the time. When I was working at the stealership we always tried to sell a new pin when ever we sold a gear set. i think that they bind between the carrier and the center pin and break. Best of luck man

[flintknapper]

Originally Posted by lingo

Flintknapper, I hate to say it but those pins break all the time. When I was working at the stealership we always tried to sell a new pin when ever we sold a gear set. i think that they bind between the carrier and the center pin and break. Best of luck man

You are correct, its quite common...and a new pin should always be installed.

I think the normal small movement of the cross shaft from the pressure of the spider gears eventually breaks them.

If that were to happen at the juncture of the CS and the carrier, then the CS would be free to drop down and wreak havoc on the rest of the internals. At least that didn't happen.

Its just going to be royal pain to get it out.

[Gumby]

I'd say it's gonna be a royal pain to get out.

I wonder if you could get a stud gun from a body shop and weld a stud on there?

[flintknapper]

Originally Posted by Gumby

I'd say it's gonna be a royal pain to get out.

I wonder if you could get a stud gun from a body shop and weld a stud on there?

The problem with mine is that it broke off with part of one thread remaining. Of course...when I lightly tapped on the pin to see if there were any threads left or not....it went down into the bore past the threads.

All efforts at drilling it out resulted in the part just spinning.

I almost got it out using super glue and a small drill bit. But the glue gave way before I could get it to take a thread.

As long as it breaks off and some of the pin stays threaded...you can drill it and use an easy out (there is a removal kit made for this). Or if the pin breaks off (below the threads) any number of remedies are available.

BUT...if it breaks off with part of a thread left, and the pin then goes below the threaded bore you're screwed! Naturally...that is what happened to mine.

I ended up grinding out a "window" in the end of the cross shaft that exposed the upper part of the pin. I then drilled that part with a million holes, took a punch and broke it up until just the smooth pin remained. I could them use a sharp pick to push the remainder out.

Sacrificed the cross shaft ($12.00) but saved the carrier ($60.00). Took all damn morning...but I got it done.