got to thinking, and maybe the 31spline axles from the explorer will be overkill, so i could use an fox mustang rear end, convert it to 5 lug, and have something 57" overall, with 28spline axles and a posi, should be good enough for what kind of power i'd be throwing down in the end. It would likely end up needing some fender rolling, but should be up for whatever i can throw at it. It's just so much more work to use the explorer axle and i probably don't need it....

Why not a 240 rear end? Should be good to hold 250 hp. Swap the front hubs to later 1800 hubs to match the 5X108 bolt circle and you're off to the races...

there's a few reasons i'd prefer the ford rear end,

a) The wheel options it gives (5x108 stuff is tough to find in any real width, and i do plan on autoXing/racing this car a fair bit)
b) The aftermarket support for the axle, (Think cheap LSD's and all kinds of possible gear ratios)
c) The fact that if i get a jig built up to shorten it, it will cost ~~200$, the cost of the axle is the same as a 240, and i don't need to beef up the axle with a LSD/locker like i would the 240. And then i can shorten axles for a few other projects in the future (the other 122, the 960 [which has a 1041L that's on borrowed time], and a few friends with nifty projects).
d) The brake options there are for it. I could easily size the entire system up so that it's got great pedal action and feel. plus, parts for the rear ford stuff is mega cheap, and there's a lot of aftermarket available again.
e) The fact i've killed a few volvo axles in the day through only moderate levels of abuse, and having to jig up one with new bracketry every time that happened would suck, i'd may as well go big, do it right the first time, and end up with something i can use for a long time.

Don't get me wrong, the most logical thing to do is to use a 240 axle, and using an 8.8 is just an added level of complexity.

One more thing i have to consider now is the diameter of the axle tubes, i may be better off shortening a crown vic or ranger rear end. to save on weight. aftermarket axles are surprisingly cheap, and the jig to shorten isn't prohibitavely expensive either.

bit the bullet and bought a narrowing jig, 280USD + shipping.

looks like i'll have about 750$ into this rear end by the time it's done. i've got 2k budgeted for front/rear brakes and a driveshaft. I should be good.

More information on the jig??

ebay special, it's a 48" 1.500" diameter precision ground rod, and a bunch of aluminum pucks set to what is hopefully the proper diameters of the bearing races, so the bar goes through the two carrier bearing holes with pucks and then into the wheel bearing with a third to keep the tube jigged straight whilst welding. Probably would have been a bit cheaper to put together myself after the 85$ it cost to ship.

but, it should work, and should make life easy.

One thing to note, there are stock ranger axles that are inthe 26" range, that means an 8.8 with 28 spline axles could be made (out of a crown vic rear end, lighter/slightly thinner tubes and stuff) in the 54-55" range WMS to WMS out of junkyard parts, and it would hold decent power all day long with no worries.

There are so many different stock length axle shafts available too, so it would be easy to custom fit.

Another thing i'm reading up on is the ford 7.5" since the 122 is an awful light vehicle, and there are guys pushing 300hp through them, and the fact it weighs a whole whack less than the 8.8" (Explorer has 1/4" axle tubes) and uses the same axles as the 28 spline 8.8 stuff.

I'm having a VERY hard time resisting the urge to chop out the tranny tunnel and drop in the b21f (taking off the +t for now) and using the t5 setup from the get go. i need someone to slap some sense into me. I guess the big thing will be seeing if the rear end is salvageable or not for the time being.

I have had no trouble with mine....4yrs and 20xxxkms of 300hp(sometimes more) and still good(oops...shouldnt have said that) It is all the FORD stuff that lets go.

Sort of the point I was making. Matt's, Ian's, Alex's...they've all survived some healthy horses...

To be fair, it's been G80 locker rear ends that died twice and one set of spider gears. Still, a ford rear end designed for a vehicle twice the weight should hold up a fair bit better.

For the price of a proper LSD for a Volvo rear end and 1800 front hubs, with the brake stuff to convert everything (or at the very least some front adapters), I'd think you could get an LSD-equipped 8.8 and the modification jig and still have some change left in pocket, get the exact width you want, and have your pick of wheels in the more popular 5x4.5" bolt pattern.

I've got no doubt that the 1031 can take a certain amount of punishment, but if you're swapping things over anyway, might as well do it right the first time. Doesn't make as much sense in a 240/740 unless you plan on abusing it, as they already have plenty of rear ends in the JY to choose from, and lots of ratios to boot.

I'm with Matt - you don't want 1800 hubs as they are usually 5 X 108 - stay with 5 X 4 1/2 and enjoy the wheel selection.

Thanks guys. That's what I figured. It was only slightly more for an 8.8, but since I've for two cars that need diffs and likely the 960 too, It'll save in the long run. Still gonna try to run stock drivetrain for the time being. Also got a LH2.4 turbo harness, sensors and 563 ecu for a case of beer . May do the swap after paint (so I can paint the enigne bay. When I get the axle shortened up and T5 clutch bits.

finished patching, seam sealing, the drivers side floor today. a lot more rust than i had though, also, pulled out the panel over the A pillar support under the floor and cleaned it out/wire wheeled it/ tremclad'd the f*ck out of it.

jacked up the car, the rear end makes a bit of noise when i turn it by hand. feels like there's a little bit of play too.

looks like the 8.8/t5 will be going in asap.

that means next time i'm in town i'll have my narrowing fixture, and i'll have to find a rear end, maybe i'll get it shortened in time.

hmm.... if i WANTED to i could fit the 9" wide mustang rims on the back... just barely... for only 400$ in custom axles added to the price.... or use two short side 83-92 8.8" or 7.5" 28spline ranger axles..... oh the options! The possibilities!



(same cost as getting aftermarket axles anyways)....

edit edit:

fired up the motor, RMS has a MASSIVE leak, yoinked it out, popped off the pan, looks like i can bolt the lower section of the b20 oil pump straight to the rebuilt 79' b21 motor i've got

so... i did it.

looks like motor mounts are going to be dead simple to make as well. and dug out the 8v header flange i got..... hmm...

Mission for this weekend:

Build motor mounts
Build tranny xmember.
Weld drain onto oil pan.

Finish passenger side floor pan
cut out tranny tunnel
finish stripping and sanding interior.


hoping to find a 240 or other tunnel that will work at a yard and a good rear axle (i'm thinking crown vic or aerostar for now w/discs) and the couple of ranger axles. since i'll be using an 87' tbird w/ the 0.85 5'th and the 3.97 first, i'm probably going to opt for 4.10 gears. since i am liable to offroad some and use the crawler gear, and it'll hit around 30mph in redline in first and around 50 in second.

the whole B20 pump works too. That's what I did.