Question - Axle Girdle / Emergency Brake Cable Bracket

[gdmjoe]

For those that have installed the axle girdle ( replaces the differential cover ) .....

What fabrication worked for you in re-mounting the emergency brake cable bracket that used the top three differential cover bolts ?


While all suggestions will be considered, some will be discarded :D



Yeppers ... Upgraded the Goth Vic's rear ...

Rear Axle Housing

- Traction Lok differential. *Out of a 2003 Cobra ( with 1300 miles on the clock ); meaning - fairly new carbon fiber clutches.
- 3.55 ring and pinion gears. *Was 3.27
- Ford Racing Performance Parts axle girdle.
- Synthetic 75W-140 rear axle lubricant ( with FEHP friction modifier ).

Suspension

- Lincoln limo' upper/lower control arms ( polished and then clear coated ).

Pic's

http://bellsouthpwp.net/g/d/gdmjoe/REcrew.jpg
*The Haywood Custom Speed (http://www.haywoodcustomspeed.com/pages/1/index.htm) crew that did the install - Tony (left) and Ray (right).

http://bellsouthpwp.net/g/d/gdmjoe/REgirdle.jpg
*All buttoned-up. If ya look close you'll notice the polished AMMC driveshaft installed previously ( the METCO driveshaft safety loop doesn't show-up ). *Reference thread (http://www.crownvic.net/ubbthreads/showflat.php?Cat=&Board=UBB2&Number=852336) <<<<< -click-. And Yes the mufflers are Flowmaster stainless steel 50 SERIES™ Delta Flow®

http://bellsouthpwp.net/g/d/gdmjoe/REca01.jpg
http://bellsouthpwp.net/g/d/gdmjoe/REca02.jpg
*Lincoln limo' control arms. Oooooh ... shiney.

Fall-out / Downside

When the axles were removed it was apparent that my vehicle is one of the 2003s that is affected by the defective axle TSB; there was a run of axles that didn't get properly treated. Ray tried to use his influence / contacts with the Ford dealership, however, it was a no-go; having everything torn-down and out would have saved FoMoCo some $$$$$, however, they wouldn't allow a swap-new-for-defective. *The TSB kit includes new axles and bearings.

Oh wahell ... Looks like FoMoCo will be into the rearend (again) soon as part of the ESP. *The trouble is, I had taken the vehicle in before the 3year/36000mile warranty expired noting a slight rearend growl; they sluffed it off as tire noise and wouldn't do a tear-down inspection. We shall see who eats the deductible. *SIGH*

[ctrcbob]

What is the TSB Number?

Any other TSB's out there for 03's?

[fastblackmerc]

For those that have installed the axle girdle ( replaces the differential cover ) .....

What fabrication worked for you in re-mounting the emergency brake cable bracket that used the top three differential cover bolts ?


While all suggestions will be considered, some will be discarded :D



Yeppers ... Upgraded the Goth Vic's rear ...

Rear Axle Housing

- Traction Lok differential. *Out of a 2003 Cobra ( with 1300 miles on the clock ); meaning - fairly new carbon fiber clutches.
- 3.55 ring and pinion gears. *Was 3.27
- Ford Racing Performance Parts axle girdle.
- Synthetic 75W-140 rear axle lubricant ( with FEHP friction modifier ).

Suspension

- Lincoln limo' upper/lower control arms ( polished and then clear coated ).

Pic's

http://bellsouthpwp.net/g/d/gdmjoe/REcrew.jpg
*The Haywood Custom Speed (http://www.haywoodcustomspeed.com/pages/1/index.htm) crew that did the install - Tony (left) and Ray (right).

http://bellsouthpwp.net/g/d/gdmjoe/REgirdle.jpg
*All buttoned-up. If ya look close you'll notice the polished AMMC driveshaft installed previously ( the METCO driveshaft safety loop doesn't show-up ). *Reference thread (http://www.crownvic.net/ubbthreads/showflat.php?Cat=&Board=UBB2&Number=852336) <<<<< -click-. And Yes the mufflers are Flowmaster stainless steel 50 SERIES™ Delta Flow®

http://bellsouthpwp.net/g/d/gdmjoe/REca01.jpg
http://bellsouthpwp.net/g/d/gdmjoe/REca02.jpg
*Lincoln limo' control arms. Oooooh ... shiney.

Fall-out / Downside

When the axles were removed it was apparent that my vehicle is one of the 2003s that is affected by the defective axle TSB; there was a run of axles that didn't get properly treated. Ray tried to use his influence / contacts with the Ford dealership, however, it was a no-go; having everything torn-down and out would have saved FoMoCo some $$$$$, however, they wouldn't allow a swap-new-for-defective. *The TSB kit includes new axles and bearings.

Oh wahell ... Looks like FoMoCo will be into the rearend (again) soon as part of the ESP. *The trouble is, I had taken the vehicle in before the 3year/36000mile warranty expired noting a slight rearend growl; they sluffed it off as tire noise and wouldn't do a tear-down inspection. We shall see who eats the deductible. *SIGH*
I should be getting my stud girdle shortly... will let you know how I mount the e-brake cable.... lookin good!!

[gdmjoe]

ctrcbob - What is the TSB Number?
2003 Crown Victoria, Grand Marquis, Town Cars Have Defective Axles
30 August 2003
Robert Lane

Ford Motor Company told dealers to be on the lookout for comsumers that complain about rear axle noise in their 2003 model year Ford Crown Victoria, Mercury Grand Marquis or Lincoln Town Car. According to Ford, the vehicles may have a defective rear axle.

The bulletin applies to models produced before 1-1-2003 and includes all models except those using a Limo and Hearse chassis.

According to Ford, the rear axles "may exhibit rear axle shaft and/or axle bearing permature wear. This is caused by excessive load, temperature, and inadequate lubrication."

Ford will replace the axle bearings under dealer operation code "030505A" under the provisions of the bumper to bumper warranty.


Any other TSB's out there for 03's?
Crown Victoria, Grand Marquis May Have Defective Front Coil Springs
07 August 2003
Robert Lane

Some 2003 Ford Crown Victoria and Mercury Grand Marquis models may have defective front coil springs. The springs may cause the vehicle to have a harsh ride or the suspension may sit low in the front.

If such conditions apply, owners may be entitled to have their dealer replace the existing springs with revised Ford springs. According to a Ford memo, the revised springs provide a higher ride height at curb and reduce the possibility of the front being too low.

The new front coil springs are listed as part numbers: 3W1Z-5310-EA and 3W1Z-5310-HA.

Panthers Built, Serviced With Wrong Exhaust/Emissions Parts
28 July 03
Robert Lane

Ford Motor Company built certain vehicles based on the "Panther" platform with incorrect emission/exhaust parts. The vehicles were built at the St. Thomas Assembly plant from 08 August 2000 through 04 April 2003. Vehicles based on the Panther platform include the Crown Victoria, Grand Marquis and Lincoln Town Car.

Further, dealerships servicing the vehicles may have replaced components with incorrect ones due to a Ford Customer Service parts book catalog error.

In some states, the vehicle must be repaired with the correct parts or the vehicle registration may not be renewed.

There are others, however, they only apply to the 4.6L 2V ( not the 4.6L 4V ).

[gdmjoe]

fastblackmerc - I should be getting my stud girdle shortly... will let you know how I mount the e-brake cable.... lookin good!!
Thanks for the compliment.

As a BTW ... IIRC I read here that the axle girdle drain plug is prone to leak; as a safeguard I wrapped mine with a section of teflon pipe tape.

Tip - Get the Ford Racing Performance Parts 8.8" Reusable Case Gasket; part# M-4211-A (http://www.fordracingparts.com/parts/part_details.asp?PartKeyField= 5958) <<<<< -click-

[metroplex]

- Traction Lok differential. *Out of a 2003 Cobra ( with 1300 miles on the clock ); meaning - fairly new carbon fiber clutches.
- 3.55 ring and pinion gears. *Was 3.27
- Ford Racing Performance Parts axle girdle.
- Synthetic 75W-140 rear axle lubricant ( with FEHP friction modifier ).

I could not find replacement carbon fiber clutches as a separate part... according to the Ford parts guy, those clutches are serviced WITH the differential as an entire assembly. Good luck rebuilding it...

How did the S-spring fit with the 3.55s? I have stock 3.55s and I'm in the process of installing a T-lok to replace my grenaded TrueTrac. Does the S-Spring look like it would come out/install with the ring gear in place? I know with 3.73s it's almost impossible.

What's with the axle girdle? The fill plug isn't particularly useful, but I wouldn't find the drain plug. Not for $150 though... :D Are you pushing that much torque that your case is twisting?

Are any of you guys taking a hit in gas mileage using 75W-140 instead of 75W-90 synthetic?
I did the math and if the 75W-90 saves you 1-2 mpg a year, I can buy a new rear-end in 5 years worth of savings, and the rear won't weld itself shut using quality synth 75W-90 for 5 years.

[gdmjoe]

metroplex - I could not find replacement carbon fiber clutches as a separate part... according to the Ford parts guy, those clutches are serviced WITH the differential as an entire assembly. Good luck rebuilding it...
I'll bridge that pass when (if) I come to it. *Who knows, maybe by then they'll be available.


How did the S-spring fit with the 3.55s? I have stock 3.55s and I'm in the process of installing a T-lok to replace my grenaded TrueTrac. Does the S-Spring look like it would come out/install with the ring gear in place? I know with 3.73s it's almost impossible.
It's tight, but should be (?) doable.


What's with the axle girdle? The fill plug isn't particularly useful, but I wouldn't find the drain plug. Not for $150 though... :D Are you pushing that much torque that your case is twisting?
I'm one of those guys that do menial ( often not necessary ) upgrades when opportunities present themselves. In this case ( pun intended ), the differential cover had to come-off so why not improve ( another option was a shiney chrome one, but HEY ... it's the Goth Vic ).

Besides it ...
- Provides additional support for differential bearings.
- Increases ring and pinion gear life.
*Or so says the Ford Racing Performance Parts catalog. :D

[metroplex]

Did you get the stud kit to go with the girdle? Otherwise you're not extending the life of the $15 bearings :D I think it adds slightly more fluid capacity too.

I've taken off my alum cover at least 3-4 times already. I'm sure my Addco rear bar would prevent the large girdle cover to be installed :(

[gdmjoe]

metroplex - Did you get the stud kit to go with the girdle?
Yes ( got the stud kit ).


I think it adds slightly more fluid capacity too.
Yep ... ~ 1/2 quart.

[Haggis]

I'm sure my Addco rear bar would prevent the large girdle cover to be installed :(

No the girdle will fit with the Addco rear bar. I have them both on my car. :up:

[gdmjoe]

Haggis
OK, since you're the 1st to respond that has it installed .....

What fabrication did you do to (re)mount the emergency brake cable bracket ?

[metroplex]

So what is the total fluid capacity with that SVO/FRPP cover?

I'm usually using 2.25 qt of gear oil in my stock 8.8

[gdmjoe]

metroplex - So what is the total fluid capacity with that SVO/FRPP cover?

I'm usually using 2.25 qt of gear oil in my stock 8.8
Buy 3 quarts you'll have just a little bit left. As mentioned previously ... ~ 1/2 quart more ( than stock ).

[metroplex]

Hmmm they're selling the Summit and TFS covers for a $140 ea. Is there any reason I must go with the Ford cover?

[SergntMac]

OK, since you're the 1st to respond that has it installed...
What fabrication did you do to (re)mount the emergency brake cable bracket ?
I have the Ford Racing cover installed too, Joe, can I help?

When I read your question the first time, I drew a blank. I'll tell you now that I am not a wrench. I don't do my own work, but I do watch the pros with great interest and I learn all I can about what's going on.

I drew a blank because we (wrench and me) didn't have an emergency brake cable to deal with on this mod. Now it's been a few days since I've been under my MM, so, this is by memory, but I believe the emergency brake cable on the Marauder isn't routed to the rear end in the manner you question us with. I see two cables (1L & 1R) that run along the inside of the frame and drop down to the axle between the upper and lower control arms, where they clip to the axle and twist out towards the rear brake assembly. I have a detailed pic of this, but it's too large to post here. I made a thumbnail I can post, e-mail me at SergntMac@aol.com if you need me to FWD the better pic.

Hmmm they're selling the Summit and TFS covers for a $140 ea. Is there any reason I must go with the Ford cover?
No. The 8.8 covers are all the same, just different engraving. You get a choice in showing off your favorite brand (if that floats your boat), but the performance specs are identical across the selection. Hell, you can even polish off the engraved name, and add any logo you wish in it's place. The pad is that thick at this point.

Considering that "Ford Racing Products" is really a clearing house for certified performance parts, and not a manufacturer themselves, I presume that their 8.8 cover is outsourced for production under their license. I happen to like Ford Racing stuff, so, it's okay with me, but like all other FRP offerings, "Ford Racing" is more management and certification of authorized racing parts. You pay a little extra, but that's insurance that the product is high quality, and sure to fit and function correctly. Get the Summit cover, Jegs, whatever, they are all the same. Ditto deep tranny pans, and lot's of other stuff in the FRP catalogue.

Happy motoring, y'all.

[Haggis]

OK, since you're the 1st to respond that has it installed .....

What fabrication did you do to (re)mount the emergency brake cable bracket ?
I didn't do it my self. My service dealer did the girdle cover and Reinhart did the Addco sway bar. I don't remember anyone mentioning a remount or fabrication. Contact Mac above^^^, I believe he will/can help you.

[metroplex]

I think the Marauders might be different from the Panthers.

I have the bracket that uses the 3 top bolts to hold down some type of cable (no idea what cable, I forgot and I probably knew at one point and wrote it in the TT install page on my site)

[fastblackmerc]

Hmmm they're selling the Summit and TFS covers for a $140 ea. Is there any reason I must go with the Ford cover?
$140.00 for a cover!! I just got mine from somewhere on the internet (PM me for the website). It's aluminum, comes with a gasket and allen-head bolts and washers. Even has teflon tape on the fill & drain plugs. The down side is that it's not shiney which is alright with me as I'm going to get it powdercoated. The price including shipping (to N.C.) was $20.00 less than either the Summit or TFS covers. :beatnik:

[metroplex]

I ordered the T&A Performance cover from Wes (Innovative Interceptors) for $160 shipped. That cover is very stout and is the same as the SVO cover sold by FRPP.

I bet that you bought a Granatelli Motorsports cover. I've seen those for sale at $110-$120.

[fastblackmerc]

I ordered the T&A Performance cover from Wes (Innovative Interceptors) for $160 shipped. That cover is very stout and is the same as the SVO cover sold by FRPP.

I bet that you bought a Granatelli Motorsports cover. I've seen those for sale at $110-$120.
That could be... :dunno: there are absolutely no identifying marks on the cover, it weighs 3-5lbs and is 7/8'" thick at the flange.

[metroplex]

It's not very shiny right? I saw the GMS cover and its about the same price you paid. I have no idea if it's better or the same as the TA/FRPP cover. I decided to pass on the TFS/Summit cover (the same thing) because I noticed 1/4 of those covers were flat so you lose some capacity.

Plus with the FRPP cover you can squeeze in a tad more gear oil :evil:
The instructions say to open the rear stock fill plug and fill it through the cover plug until it drains out the stock fill plug location. According to gdmjoe, that would happen at about 2.75 qt or so. Close up the factory fill port and jam in that extra 1/2 qt to get a full 3 qt in the rear end :evil: by using the elevated cover fill port.

Joe: Is the teflon tape really necessary for the drain plug? I'll do it just in case. Is it a tapered pipe plug?

[gdmjoe]

metroplex ... The instructions say to open the rear stock fill plug and fill it through the cover plug until it drains out the stock fill plug location. According to gdmjoe, that would happen at about 2.75 qt or so. Close up the factory fill port and jam in that extra 1/2 qt to get a full 3 qt in the rear end :evil: by using the elevated cover fill port.
Wouldn't recommend cramming in the extra 1/2 quart; the 2 3/4 quart fill is possible by using the fill to the stock plug method.


Joe: Is the teflon tape really necessary for the drain plug? I'll do it just in case. Is it a tapered pipe plug?
May or may-not be necessary; was taken as a precautionary measure. Others have noted using a dab of silicone on the threads.

[metroplex]

It's just an extra 1/4 of a qt! I wonder what would happen? I hate leaving half-empty bottles of gear oil around. It just goes stale when you find it in 5 years to change the gear oil again...

[gdmjoe]

It's just an extra 1/4 of a qt! I wonder what would happen?
Misread your post ( missed the top it off at 3 quarts; saw 2 3/4 and adding 1/2 ).

Probably (?) it wouldn't hurt since the fill isn't really exact.


I hate leaving half-empty bottles of gear oil around. It just goes stale when you find it in 5 years to change the gear oil again...
What half-empty bottles ? *I put residue into an oiler ( for lack of a better term ) and use it to lube/oil stuff. :D

[ahess77]

Question:
"For those that have installed the axle girdle ( replaces the differential cover ) .....

What fabrication worked for you in re-mounting the emergency brake cable bracket that used the top three differential cover bolts ?"

Answer:
** Left it hanging, figure I don't need no stinking emergency brakes. **
(Seriously, I did. It just kind of hangs on the top, but there's no bolt holding it to the differential cover anymore.)

[metroplex]

I got my cover from Wes! I took lots of pics w/ the digicam to show how beefy it looks.

I have a question tho:

The FRPP SVO instructions say to torque the load bolts to 5-10 ft-lb, and the jam nuts to 25-30 ft-lb.

The TA Performance instructions say to torque the load bolts to 5 ft-lb MAX, and the jam nuts to 5 ft-lb to snug it down.

Which values did you use?

And are you sure no one has had clearance issues with the Addco rear anti-sway bars? This girdle cover is HUGE.

[SergntMac]

Are you sure no one has had clearance issues with the Addco rear anti-sway bars? This girdle cover is HUGE.Installed mine two years ago, Addco bar in use. It looks tight, but it all fits.

[metroplex]

Sgt Mac: Thanks for posting the link in the other thread.

Joe: http://www.mercurymarauder.net/forums/showthread.php?p=255403#post25 5403

Check out the pics I uploaded near the end of the thread.