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  1. #1

    Default Reuse, replace, resurface? Opinion needed.

    So I am rebuilding an 8.8 rear for my 92 with new clutch packs. Everything looks to be in great condition with the exception of one tooth on one of the side gears. The one tooth managed to corrode a bit. I wire brushed it down and cleaned it up but there is still evidence and some texture there. I haven't rebuilt any differentials before and I'm wondering if this is enough to be trouble. Would you reuse this gear? Replace it? Lightly file it down?Name:  20170726_192929.jpg
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    Last edited by NY5speed; 07-27-2017 at 09:52 AM.
    -Randy
    '83 Mustang GL notchback - 351w - T5Z
    '84 Mustang GT350 20th Anniversary Hatch #2808 - 302 - T5
    ''92 Mustang LX Hatch - 2.3t - IRS (in progress)

  2. #2

    Default

    Deffinetly replace it. But the cost of new clutches and gears you can get an entire new differential. Ive seen the 03 cobra spec diffs selling for 200 new, but require 31 spline axles.

  3. #3

    Default

    I was leaning toward just buying a new diff. I can save the carbon fiber clutch pack I bought for my f150 I guess. I really wonder how just one tooth ended up like that.
    -Randy
    '83 Mustang GL notchback - 351w - T5Z
    '84 Mustang GT350 20th Anniversary Hatch #2808 - 302 - T5
    ''92 Mustang LX Hatch - 2.3t - IRS (in progress)

  4. #4
    FEP Member
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    Feb 2012
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    Elizabethton, TN
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    Default

    It kind of looks like there wasn't enough cast material to fully machine.

  5. #5
    FEP Super Member
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    May 2003
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    Roseburg Oregon
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    3,308

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    Run it .
    The load is in the bottom of that gear.
    If it is original to the other 3 spider gears , it will be just fine .
    clowns to the left of me , Jokers to the right

  6. #6

    Default

    Run it. If it was a problem, you'd see damage on the adjacent gears.
    84 Cougar, 90 HO with 700DP, Edelbrock RPM intake, 1.7 RRs, shorty's and SS exh, T-5, KC clutch, Hurst pro billet, line loc, 8.8, 4.10s, suspension mods....blah, blah,blah.

    71 Comet, 289, Liberty TL, 9", 6.00s, 11.9x @ 112.... blah, blah, blah.

  7. #7
    FEP Senior Member BMW Rider's Avatar
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    Oct 2014
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    Calgary, Alberta, Canada
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    949

    Default

    Those gears don't work at high speeds so that probably will have little or no effect on its performance and longevity. If you really are bothered by it, find a replacement. A good used gear is a as good as a new one. They are not matched sets either, so only the rough one would need to be replaced.

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