So I got this 8.8 from a member on this forum, and it was already chopped and rewelded for my 66 Dart. The pinion was not removed, but the carrier was when I got it. New bearings and seals have been installed.
The problem I'm having is when I go to put it back together. I got a shim kit that uses a couple of thick shims and several thin ones. No matter what I do with the shims, the same thing happens. When I tighten down the right side carrier cap, the carrier still spins. When I even get the left carrier cap snug, it locks up and the carrier won't turn at all. I'm assuming this is bad.
I have the feeling like the pinion isn't shimmed correctly and the ring gear is being pushed down into the pinion gear too much when I tighten the left side (which is the side with the ring gear on it).
Does that sound right? What else might be going on?
1- remove the carrier and get the pinion to turn freely -- back off the pinion nut and then tighten it just enough to remove any end play in the bearings and still have a slight turning drag on the bearings. but still turns freely
2- load your carrier into the housing --
3- your shim selection for the carrier determines the backlash and preload on the carrier bearings.
4- 8.8 carrier shims total thickness is in the .540-.550 range when preload and backlash are correct.
5- to start select a shim thickness of say .265 and place it on the right side bore ( opposite side from ring gear ) of the carrier.
6- now take a screw driver and pry against the left bearing race which forces the carrier against the right side shim pack -- check to see if you have any backlash in the gears -- if no backlash increase the thickness of the right shim pack say in .005 increments ,if to much backlash remove shim-- then repeat the above step.--- try for .010 backlash initially.
7- once you have backlash -- measure up a shim pack for the left side which will give you a total shim pack figure as stated above -- say you have right side shim of .265 thickness,,, install a shim totalling .275 on the left -- making sure you still have backlash in the gears .
8- install your bearing caps -- arrows on the caps face to the outside of the housing when oriented properly --- < left side -- > right side. snug them down to 50 ft/lbs
9 - check to make sure you have a backlash of .008 -.010 -- if not you will have to adjust your shim selection -- remove or add shim to decrease or increase backlash in steps of say .005 -- usually what ever you remove from one side add to the opposite side.
10 -- now time to do a pattern check on you gears -- paint 4 teeth with gear checking compound and rotate the assembly-- this determines if your pinion shim selection is correct -- if the pattern checks out -- disassemble everything keeping track of your carrier shims to install them back on the correct sides -- set you pinion bearing preload 20-25 in/lbs for new bearings 8-15 in/lbs for used bearings --- reinstall your carrier and torque the caps to 80-85 ft/lbs
11 -- one other thing the carrier should have to be pried out of the housing when correctly installed with the right amount of preload on the bearings .-- they have come to me for repair from shops that should know better and literally fall out of the housing--sad
it can be tedious but you want the gear to live so a correct set up is necessary. close does not count .
