this is a new one to me, aerostar axles from 86-97 not all the same

old_blue · Nov 19, 2010

Got back from pick a part. both are passenger side axles are same height, 28 spline.....

one is from a 91 I believe and the other is from a 96. I made sure both were in the range of 86-97

The 96 spline area is longer and the area where the c-clip goes is a little different. the earlier one has a raised area in the c-clip are and the 96 does not....

also the end cap that that goes into the ring on the eariler one is flat and solid the 96 isnt solid in the middle. and steps down if that makes any sense.

Does anyone know if this matters? Also when I took the 96 out I did notice the center section seemded a little bigger. thanks for any help

old_blue · Nov 19, 2010

the top left is the 96 and the bottom left is the earlier which I believe to be correct. the top right two show how the earlier axle has the small lip where the c clip goes and spline length although hard to tell as one looks fatter than the other. One was just taken close than the other. the bottom right two just show a better shot of the c clip areas.

I am thinking of taking the 96 back and getting a ranger driver side axle for piece of mind.

The only thing I can guess is that they just changed the astheics of it and the overall function is still the same???

Let me know what you guys think.

BlackGT89 · Nov 19, 2010

Humm, not sure what to make of that larger pocket end on the one. I got my axles from Rangers and didn't notice anything like that. Is there a rubber O-Ring hiding under the grease (in the C-Clip area) on one, and missing on the other ? If you have a pair of calipers it might help to make some comparisons and ease your mind.

old_blue · Nov 19, 2010

hmm they both came out pretty clean. is there suppose to be a rubber o-ring in there? I would think after 10+ yrs they would just wear out.

old_blue · Nov 20, 2010

no rubber rings on it. I thought someone on here had run into this before but I don't remember the outcome.

The yard also had bronco II's which I believe would work too.

The other thing I had a question on was the earlier aerostar did not have the little "S" clip in where the c-clips were but the 96 did. I didn't think it was a big deal as it was just an aerostar. Does this mean anything? any input would be great. I dont want to pull two more axles if I dont have to.

edit-ok the ends of the axles measure as follows-
diameter
96 1.074"
pre 1.024"
c-clip gap
96 .050
pre .045
and the area of the gap
pre .245
96 .250

The differences are so minimal it looks like I will be good to go using them. The only reason I am hesitant on keep them is I have 30days to exchange one and I wont be installing them right away. I would just hate to go 6 months and find (for some odd reason) one doesnt work. I know when they make them they arent going to be perfectly the same especially being years apart.

BlackGT89 · Nov 21, 2010

old_blue said:
no rubber rings on it. I thought someone on here had run into this before but I don't remember the outcome.

The yard also had bronco II's which I believe would work too.

The other thing I had a question on was the earlier aerostar did not have the little "S" clip in where the c-clips were but the 96 did. I didn't think it was a big deal as it was just an aerostar. Does this mean anything? any input would be great. I dont want to pull two more axles if I dont have to.

edit-ok the ends of the axles measure as follows-
diameter
96 1.074"
pre 1.024"
c-clip gap
96 .050
pre .045
and the area of the gap
pre .245
96 .250

The differences are so minimal it looks like I will be good to go using them. The only reason I am hesitant on keep them is I have 30days to exchange one and I wont be installing them right away. I would just hate to go 6 months and find (for some odd reason) one doesnt work. I know when they make them they arent going to be perfectly the same especially being years apart.

Here's a pic of my stock axle showing the O-Ring. I'm not sure what the purpose of it is. Probably functions fine without it...

Update: I found this discussion: http://www.stangnet.com/mustang-forums/735928-replacing-rear-axle-c-clips-cross-pin.html

old_blue · Nov 21, 2010

thanks, you were right, it was an o-ring. Hard as a rock though. Broke it taking it out. probably still going to go back to the yard to get a ranger side axle. then I will use the correct rotation. I think the 96 aerostar was an extended one and it may have had a 8.8 in it.

Mustang5L5 · Nov 21, 2010

The o ring kinda helps with the install of the c clips and keepts them from sliding or rattling around loose. Not needed really, but if you have some spare o rings you can toss one on.

New c clips here if you want

Ford Racing M-4050-B - Ford Racing 8.8 in. Axle Installation Kits - Overview - SummitRacing.com

BlackGT89 · Nov 21, 2010

That's what I was thinking, kind of a mini shock absorber of sorts.

old_blue · Nov 22, 2010

haha not sure where this derailed but I don't need c clips lol. Just wondering if this axle will work. I am still thinking I am going to take it back and get one out of a ranger or bronco II for the driver side. That way they will be on the correct side. (aerostar on passenger side of mustang and ranger on the other.

this is a new one to me, aerostar axles from 86-97 not all the same

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