Replacing the Rear End

[PLUMBCRAZY]

I've noticed an intermittent clicking noise coming from the passenger side rear that seems to be worsening. Searched threads and found that "soft axle shafts" and bad bearings are a common issue. Am I correct in assuming that if the issue turns out to be bad bearings it is not worth fixing, but better to replace the entire axle shaft as the original was not the best quality? And what brand is recommended for replacement? I found Dorman Axle Shaft Kits 630-214 for $88(https://www.summitracing.com/parts/rnb-630-214), is there anything better? Thanks!

[PLUMBCRAZY]

also worth mentioning im planning on 4.10 swap at same time, seems to be the time to do it.

[RubberCtyRauder]

if doing 4.10's, don't forget you;ll need a tune at time of swap and if you are going in the rear, might as well rebuild the trak-loc with new clutches, bearings and do both axles..there are better axles than dorman..depends on your budget..not sure if Ford Racing still making 28 spline stuff, Yukon, Moser all good

[PLUMBCRAZY]

Thanks man appreciate the advice. I'm not a huge car guy but I try to learn about these things as they go wrong lol. Does it make sense to upgrade to this:
https://lmr.com/item/M4204F318C/Mustang-88-31-Spline-Traction-Lok-Differential-With-Carbon-Fiber-Clutch-Disks?year=2004&gclid=Cj0KCQjwktHLBRDsARIsAFBS b6zNhS66CC7q_HWy4M69tn883rASTK VO80Bve0HzVtNa-4Kv0GnNKDMaAlILEALw_wcB
If so, my axle shafts would now need to be 31 spline, correct?
And I was holding off on getting a MartyO tune until I did the gear swap.

[RubberCtyRauder]

you'll need the tune at the same time the 4.10 are installed. you can get it early, just dont download it until swap is done. going 31 spline is a choice, youll need carrier, diff,axles, bearings. 28 spline are fine unless you plan a large hp power adder. there is a sticky post (meaning near the top of list) in here with a parts list for rear end upgrade. either in shop talk, diy, or maybe one of the specific sections.

[Svashtar]

Mine was passenger side rear as well, same noise. I referenced the soft axle TSB to the dealer, so he replaced ONLY that axle and bearing, insisted the other side was "fine." Just after warranty the drivers side failed and I paid.
Since there was 50k miles between failures the dealer insisted they weren't related. Why I hate going to Ford for anything.

Glad you're getting both replaced.


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[fastblackmerc]

In addition to getting both replaced the rear end needs to be squeaky clean, any bits of metal left will surely cause a failure in the future.

[PLUMBCRAZY]

I didn't realize there was a "soft" TSB on this. Is this worth taking to a dealership to see if its covered? I see the TSB references fleet vehicles. Coincidentally my 03A was initially sold as a corporate fleet vehicle and had 25k miles its first year, it currently has 78k.

nevermind...wishful thinking

[Svashtar]

Over 36K without an extended warranty and I think you're SOL. As I understand it Ford supplied a complete kit to dealers with new axles and bearings. My dealer chose to install half the kit, with the assumption that by some miracle only one axle was bad, and I let him get away with it.

There was also a known issue with a frequency lock problem on our radios. He replaced one, then swore to me the second one had the problem fixed; it didn't, and I've been driving without a radio.

All that to say based on those and other incidents I don't have high confidence in what (this particular) dealer tells me.


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[RubberCtyRauder]

31 spline upgrade, install and tune will cost $2k and up, just so you know.

[PLUMBCRAZY]

31 spline upgrade, install and tune will cost $2k and up, just so you know.

Sticking with 28 Spline is sounding better by the minute.
I am dropping the car off in the morning at a mechanic, I will see what they say and go from there I suppose. Thanks everyone for the advice!

[yjmud]

EVEN WITH A TRU TRAC I WAS ONLY AT ABOUT 1300 TO UPGRADE

[RubberCtyRauder]

EVEN WITH A TRU TRAC I WAS ONLY AT ABOUT 1300 TO UPGRADE


$2k ish is parts, tune, install estimate..did you install yourself? did your cost include a tune for gear change?

[Spectragod]

$2k ish is parts, tune, install estimate..did you install yourself? did your cost include a tune for gear change?

Uhhh, no.

Maybe if you don't have a tune already? And have to buy a tuner and tune?

Gears, bearings, axles, carrier......1200ish.

[WPG_Merc]

My set up was just over 2 GS USD plus $800 labor at Mo's. :bows:
& was well worth it. :2thumbs:

31 Spline Moser Axles/Trac Loc & bearings.
Already had the 410s & TA cover.

Hope all go's well for you. :beer:

[RubberCtyRauder]

Uhhh, no.

Maybe if you don't have a tune already? And have to buy a tuner and tune?

Gears, bearings, axles, carrier......1200ish.

i was going by what someone listed on parts list, their prices and added $300-400 install and $400+ for tuner with tune.

[Spectragod]

i was going by what someone listed on parts list, their prices and added $300-400 install and $400+ for tuner with tune.



Very realistic, if your not doing the work yourself, $400 for labor might be light.

It's really not a hard job, time consuming getting settings and backlash spot on.

You could save a few bucks going with Ford axle assemblies as opposed to
Moser. It would depend on where you wanted the final result for the car to be.

I ran stock 3:55's as well as axles and trac loc to 520rwhp, the car never hooked up with 295 street tires, went to a DR that was taller, I felt it needed to go to 4:10's at that point, it was a slug off the line.....slower than a DTR is normally.

Bottom line, these things are money pits, you'll spend a bunch trying to get it to where you want it, and then upgrade again, this process is rosier if you don't have a wife, just FYI.


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