Ford Ranger Rear Axles
Most Rangers are equipped with the Ford 7.5-inch rear axle with several exceptions:
1) 1986-up "Incomplete vehicles" also known as "Chassis Cabs" were frequently equipped with 8.8" 28-spline axles, the '86-88 examples are distinctive as they are the only 8.8" Ranger rears that have no provisions for a RABS sensor.
2) 1990 & up 4.0-liter Rangers. These are ALWAYS equipped with the 8.8-inch 28-spline rear axle.
3) 1998-up 4x4 supercab Rangers regardless of powerplant are frequently equipped with 8.8" axles
4) FX4 Rangers 99-current come equipped with an 8.8 rear and 31-spline axles with either 4.10 or 4.56 axle ratios.
Swapping in an 8.8-inch 28-spline Ranger axle for the original 7.5-inch axle provides (according to Ford) a 35% increase in strength. But this strength increase refers to the greater strength of the gears and carrier bearings (Pinion bearings, axle bearings and axle shafts are exactly the same) there is NO increase in weight capacity If you are looking for greater strength for loads created by severe offroad driving or towing you'll want to go to the next step, the Explorer axle.
The rear axles on all Ford Explorers are also 8.8's, however there are some differences... The 8.8-inch Explorer axle use 31-spline axle shaft. Increasing from a 28-spline to a 31-spline axle allegedly increases strength of the axle shaft by 34%, however I'll go by the capacity ratings of the axle assemblies provided by the manufacturer. Ford Rates the Ranger axle at 2750lbs and the Explorer axle at 3200lbs this is a 16% increase in strength, which admittedly may be as conservative
as the estimate of axle strength. The Important thing about the Explorer axle assembly vis-a-vie it's strength is not the axles that are larger at the splines but that these axles are larger in diameter at the outer bearing journal AND the larger diameter bearings used.
What axle do you have now?
You can identify which axle you have by the tag attached to the inspection
cover.
Some feel better having disc brakes (I'll discuss this elsewhere
and if you want discs then look for a Explorer '95-01, as these are the ones with the disks brakes. '91-94 axle assemblies are just as strong, but have 10" drums (Which are more easily connected to your existing hydraulic lines and Parking brake cables)