Ford 8.8" Gear Teeth Cut Process Differences That Affect Setup

GlassTop09

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Here is a good picture of why you want to check the tooth count ratio of a gear set before purchase to make sure it isn't a non-hunting set if quiet gears are desired:
Drive Side Paint 3D.png
This is the Richmond EXCEL 3.89 non-hunting version of Ford 8.8" 3.90 gears (this set is using the Ford OE 9" 35 ring\9 pinion tooth count ratio) that I bought & had installed. This picture was taken while in process of doing the 500 mi break-in fluid changeout\inspection (gotta just love them Lube Locker diff gaskets......makes this easy) after initial install\2nd realignment.

As you can clearly see, this area is where the installer applied marking compound to check pattern (residue of compound still on tooth crowns). Note how the wear pattern changed on the 2 teeth after the front 2 teeth in the circled area on the ring gear........the clear result of mismatched tooth lapping of ring gear teeth to pinion teeth due to inadvertently being installed out of time (no timing marks on pinion\ring gear teeth to realign the lapping) due to this particular specific gear ratio being a non-hunting gear tooth ratio (description in post #17) thus why this specific 3.89 gear ratio of the "Ford 8.8" 3.90 series" is usually a noisy gear set.......unless you get lucky & unknowingly install into the properly timed tooth pairings of both ring & pinion gears. This could also just be a bad gear cutting as well but if that is so, then Richmond's QA\QC is also poor\non-existent (they claim that EVERY gear set is lapped & checked for proper runout\operation before packaged for sale), so I'll lean on the advent of the non-hunting nature of this 3.89 specific gear ratio as the culprit for the gear whine.

It's getting closer to the weather patterns getting tolerable enough to start the process of pulling these 3.89 specific gear ratio "Ford 8.8" 3.90's" out (Richmond EXCEL series 3.89 9 pinion\35 ring non-hunting gear set) & install the quieter 3.91 specific gear ratio "Ford 8.8" 3.90's" (Motive Gear F888390 3.91 11 pinion\43 ring full hunting gear set) to rectify the gear whine.

You can also see how good this Lucas HP 85W-140 GL-5 dino gear fluid lubricates & holds up to fluid temps (notice on teeth what you see is where the teeth cut thru the phosphorus coating but hardly denting the teeth (had hardly any metal collected on the drain plug magnet.....also shows the advantages of running the Ford Performance Track Pack 8.8" Finned Diff Cover controlling fluid temps) so I reloaded diff w\ some Lucas HP 80W-90 GL-5 dino gear fluid to thin it down some when hot to see if this would help to promote gear teeth to mesh better. Noticed the gear whine did reduce more after fluid changeout so at least it is becoming more tolerable until I change them out.

So, IMHO, you should not lump all 3.90 gear sets for Ford 8.8" axles & label them as bad or noisy.......just know what to look for when considering them to avoid the noisy ones.

Posted for informational purposes.
 

GlassTop09

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FYI.....................

Just to finish this thread up, I've replaced these Richmond EXCEL 3.90 (3.89 actual ratio 9 pinion\35 ring non-hunting) gears w\ a set of Motive F888390 3.90 (3.91 actual ratio 11 pinion\43 ring full hunting) gears & set them up.........they run very quiet overall (have a very slight hum that occurs on decel only between 35-45 MPH, below\above this range are quiet.....most likely due to either me setting these up no-load to favor toe side of tooth center to compensate for BL change during break in when load pattern moves towards tooth center or could also be a symptom of the outer pinion bearing's roller-to-race meshing....I used Koyo bearings from a Motive 8.8" install kit instead of Timken bearings which is the std bearings that all Ford Performance 8.8" install kits use. Have to turn radio off to detect, it's that light) & are vastly improved vs the old Ford 9" 3.89 pattern gears (which is what Richmond uses to make these for the Ford 8.8" axle).

So in closing, if considering 3.90 gears w\ this Ford 8.8" axle, ONLY buy the 11 pinion\43 ring tooth count 3.91 actual ratio full hunting gear sets & make sure that you're using the right pattern checking chart for the gear cut process used (either 2-cut face hobbed or 5-cut face milled). Saves a LOT of trouble\frustration during setup.
 

Dominic Tolerico

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I just had the same issue and lost the same 2 days trying to get the correct pattern on Frpp gears using the manual that outlines 5 cut setup procedures. Very frustrating to say the least. I contacted ford performance and supplied pics and links in hopes that they change the manual to reflect the change in manufacturing. I used the Dana guide to come up with a backlash of .006 to .008 and got a good pattern. That's for posting this, it's nice to know I'm not crazy.
 

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