RE: rearend
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Will a trak-lok out of a straight axle 8.8 work? I've read that it needs machining to work and that you can put it right in.
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Let's answer one topic at a time.
The differential(trak-lok) from a straight axle 8.8 Ford rear will work with or without modification, you decide.
The Mark VIII halfshaft has a groove cut into the splines of the axle near the end of the shaft that slides into the differential. There is a circular clip(NOT a "C" clip) fits this groove. While sliding into the differential, this clip compresses into the groove as the shaft is slid in until it exits the other side. The "IRS" differentials have the inside edge of the spider gear tapered to allow the same compression of the clip upon removal of the shaft, but it does provide resistance in the shaft removal.
With me so far?
On the straight axle differentials, the inside if the spider gear is not tapered and is square shouldered. If the halfshaft is installed with the circular clip, one of two things happen... either the clip cannot be compressed upon removal because of no taper and the halfshaft cannot be extricated or the clip does not slide all the way through to the inside and it is not holding the halfshaft in the differential.
So if you use the regular 8.8 differential(NON-IRS), technically you need tapered side gears for the halfshafts or you need to modify the side gears by machining a taper on the inboard side...
OR...
you simply remove the circular clips from the halfshaft before installation. What holds the halfshaft in? Examine the complete assembly after the hub is put back on. The hub is attached to the halfshaft with a locking nut. The halfshaft cannot exit the hub. The hub is fixed to the car with the upper/lower control arms. IMHO the halfshaft is not at any risk escaping the differential unless you routinely 'catch air' with the rear wheels.