8.8 swap commences.

[Rommel]

8.8 swap commences

Now it is time for bearings and seals. The pinion seal was really ugly, but when I removed it the bearing looked ok, dry but ok. Since I drive this car so much, I leaned to the side of caution and replaced the outer pinion bearing and seal just to be sure. The outer axle bearings were pulled and replaced with an integral bearing and seal assembly. They are normally used on worn axle shafts because the bearing is designed to ride on the journal surface closer to the end of the axle. Because the bearing is further out, the seal is integrated into one unit. I thought it was a good idea and the unit itself looked well made and functional. When I installed the axles into the tubes, there seemed to be very little contact between the axle seal journal and the lip seal. Having done this in the past with the normally separate seal and bearing I wondered if this was going to be enough. I crossed my fingers and hoped this was the way it should be. The seals didn’t leak when I filled the diff, but leaked immediately on my first test drive. I had to pull the axles, pull these very expensive bearings out (about $29 each), and install the standard separate bearing and seal. Live and learn. I may have damaged them when they were installed, but upon comparing them with a standard seal, there was an obvious difference in diameter. The standard seal fit much tighter to the axle then the fancy one did. Plus, the standard separate bearing and seal set up cost less than half of what the fancy ones did. Attached is a pic of the offending unit

[Rommel]

8.8 swap commences

Here is another picture of the integral bearing/seal next to the separate bearing and seal installed.

[Rommel]

8.8 swap commences

If you ever wondered what the difference between the SVO axle out of a 7.5 diff compared to the standard 8.8 axle, here it is.

[Rommel]

8.8 swap commences

No, nothing was bent, not that I could tell anyway. The axle on the left is the SVO axle; the right is the 8.8 TC axle. Things may look bent in the picture, but I think it’s just an illusion. I took the picture against the siding to give a display of the difference in length.

[indiana dave]

You've inspired me!

Not to swap rearends, but to pull mine and detail it.
In doing so, I found one of the shocks to be dented, and it wouldn't extend by itself. I had to pull it with all my strength to extend it. I'll be looking for some Koni sports eventually.
I also found a pinched brake line to the drivers side. Yikes!
It's a wonder my car handled as good as it did!
BTW, how is the big weight thing on the front of the driveshaft connected? I know people have removed it, but I can't see how. Maybe they were refering to not reinstalling it with an aluminum driveshaft.
I'm also going to dump that weight on the front of the axle snout.
I am pulling mine out, degreasing it, wire-brushing it, and going to prime and paint it with metalic gray like my trim along with the driveshaft, control arms, etc. I'm going to do the rear cover in silver for contrast. I'll also get a new gas tank when the job situation allows.
Yea, it's not concours, but I don't care.
Eventually the whole undercarriage is getting repainted body color, and it is going to look sweet!

[Rommel]

8.8 swap commences

Good on you for detailing the underside of your car. I’m still working on keeping mine on the road, so the beautification phase will have to wait. As for the weight on the driveshaft, I’m not sure what its porpoise was but my car already had a standard Mustang driveshaft installed when I got it. If yours is not worn or causing vibration, than leave it alone, otherwise the standard driveshaft is a quick and easy install and they can be found for cheap!

[Rommel]

8.8 swap commences

Now that I have a good set of seals in there, it’s time to bolt the rest of the system together. This is the time to take care of things like brakes and shocks. I had already replaced my Konis a year ago so I was good there. Brakes on the other hand needed to be done. New calipers, pads and turned rotors and I’m good to go.

[Rommel]

8.8 swap commences

I have the 8.8 swap completed and it is a success. The whole job was very straightforward and with a little common sense, a good jack, and a box of common hand tools, anyone can do it.
First ride: Seat of the pants feel displays slightly better pull throughout all of the gears. This was expected with the lower gear ratio but what I noticed immediately was how much smoother the car rode at all speeds. Before, with the ailing 7.5 there was a vibration (both audible and felt) starting at about 55 MPH and lasting through 80 MPH with the worst noise coming in between 65 and 75 MPH. This was cause by a worn pinion and pinion bearings. I have to give this rear end credit though. I got this car with 80,000 miles on it and it made these noises from day one. I currently have 279,000 on it and the rear end held together. If parts availability and price were reasonable, I would have fixed the 7.5. Overall though, I think I will be happier knowing the 8.8 will take anything I throw at it. I would recommend this swap to any SVO owner.
Now I can drive my car without my eyeballs vibrating. Now with a smoother quieter rear end, I’m hearing a bunch of stuff I never heard before.
I know this thread was not all conclusive, so if there are any questions on something I didn’t cover, just ask and I’ll tell ya what I know.

[QWKSNKE]

Re: 8.8 swap commences

Originally posted by Rommel
No, nothing was bent, not that I could tell anyway. The axle on the left is the SVO axle; the right is the 8.8 TC axle. Things may look bent in the picture, but I think it’s just an illusion. I took the picture against the siding to give a display of the difference in length.

So the TC (and 93 cobra) rear ends are narrower than the SVO? For some reason I was thinking the TC and 93 cobra rear were wider than the SVO

[SVOeric]

Rommel --
Just wanted to say THANKS very much for posting that writeup -- Very informative..

[Eyelawdoc]

Re: Re: 8.8 swap commences

Originally posted by QWKSNKE
So the TC (and 93 cobra) rear ends are narrower than the SVO? For some reason I was thinking the TC and 93 cobra rear were wider than the SVO

No, actually the width of the rear axle housing is the SAME for all three cars. It is the length of the axles inserted into the housing that varries. Since the SVO (and the Lincoln Continental and Mark VII from which the SVO setup is derrived) has the longest axles, the assembled SVO unit is the widest.

[QWKSNKE]

how much longer are the axles in a SVO?

[indiana dave]

Has anyone weighed the 7.5 vs. the 8.8? I'v eread that the 8.8 wasn't put into SVO's because it was heavier, and wasn't necessary with the torque of the 2.3T.

[tonye]

very nice

i will doing the swap in the future and this helps alot

thanks

[SVOhNo]

What did you do as far as gears are concerned, leave them alone? How did you make sure they were ok? Not questioning your work, wondering what to do with the rear I just got.
Matt