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Old 03-29-2013, 01:11 AM
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Ford 8.8 Posi disassemble questions

I am trying to take my Ford Explorer 8.8 Posi unit apart to replace the clutches and cannot get the locking bolt out so I can remove the spider gear pin. Does anyone have some tricks for removing this bolt?

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Old 03-29-2013, 06:39 AM
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What is the problem? Why can you not get it out?
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Old 03-29-2013, 08:13 AM
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I had a good 'ol time with that recently, but finally got it after having a tug-of-war with the old Loctite. Gotta use a six-point tool, not a twelve...sometimes on one of those bolts with tiny heads, if I don't have a six-point wrench and a ratchet won't fit I'll take a six-point socket and weld a handle onto it, and just call that a dedicated tool then.
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Old 03-29-2013, 08:36 AM
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If the pin/bolt is broke, you can drill a small hole at the other end and probably blow the broken part out with air (after the bolt part is removed).
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Old 04-01-2013, 04:22 PM
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If you have not rounded off the bolt head yet, here is what I would recommend:
Take a hand held propane torch and heat the carrier up right where the threads are. This will "release" the loc-tite temporarily. While it is still hot, using the CORRECT socket and maybe an extension so as to move your impact gun away from the carrier, hit it with a good 3/8" impact gun and it will come right out. If you have rounded the head of the bolt off already.. Well.. Break out a cold chisel and try and move the bolt head in a counter-clockwise direction. Order new bolt. Problem solved.

If you think getting that bolt out is fun, wait until you try and roll the side gears w/clutch packs out of the carrier. That's REAL fun! The FERD 9.75" are great fun to learn on.. Just saying. I can't count how many Ford diffs I've had to replace the clutches on because of groaning when turning sharp corners.
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