IRS Axel Build

[Jetheft]

Getting ready to put my IRS axels together....any advice?

Do I need new snap rings or are the doner one's alright?

Thanks
Joel

[Bill Hughes]

When I built my car, FFR packed new boots and snap rings with the kit. The inner cv joints I recall came apart easily.

clean and inspect everything well for the inners. Put everything back where you fornd it including the phase of the tulips (inner).

The outer joints are really hard to remove. The ball peen hammer method in the manual worked for one axle but not the other.

You need a piece of iron water pipe to pass over the tbird axle and the snap ring in the outer CV jount and enough longer than the axle so that you can slide hammer the axle out by impacting the inside end into an anvil or the concrete floor of your garage.

You are banging on the outer cv, NOT THE SNAP RING.

This one is really simple if you do it that way. I have seen an old illustration of this years ago. I could not re find it.

Put it all back together the same as you found it. DO NOT change any of the inner tulip relationships.

When you put the roadster back together, use only all new clips, axle nust boots and bands and the grease FFR gives you. Besure tyhe axle end and nut are claen and grease free and use blue locktite and touque to spec. by knowing the breaker bar length and your weight. If you get ig wromg and need to back off and do over you will need new nuts from FORD.

You can buy a crimplig tool from NAPA for the bands.


Stay calm and concentrate, this one is a bear.

Good luck

[Bill Hughes]

You also will need to clean and rebulid the knuckles. Replace all six rubber bushings with polyurathane ones. You can use bolts, washers and nuts to drag the old bushings out and the new oues in.

LOOK TO FORUM VENDORS FOR THE POLY BUSHINGS. MAYBE BREEZE?

With these new bushings you will not need the hydraulic torque arms from the mustang. You will have NO WHEEL HOP.

Also, replace the wheel bearings. You will need a special snap ring tool and at least a 12 ton prenn to get the bearings out.

DO NOT APPLY FORCE TO THE THREE ARMS. DO NOT USE ANY HAMMERS. Find a socket to use as an anvil between the knuckle and the bed of the press.

I bought a 12 ton press from harbor freight. For only 20 dollars more, get the 20 ton press.

And again, good luck, and use no hammers or propane torches.

Keep all of this stuff really clean.

[Bill Hughes]

All of this was eight years ago, but I believe I have recounted this correctly.

While your at it you ought to install new clutches and plates in the limited slip rear axle, using the Gordon Levy method. Im sure he will visit the thread and elaborate.

Getting the "S" clip back in is ALSO A BEAR, but is easy if you are clever and colapse said "S" clip with a hose clamp through the rectangular holes at each end of the "S" clip.

If you dont do everything just right you can unleash big problems.

Make sure the spider gears have good preload, (as much as your fingers can supply).Dont forget when refilling the axle to add the correct amount of friftion modifier.

Its a good idea to mix the friction modifier and axle oil outside in a can and soak the clutch discs over night just prior to assembly.

[JJ'snakepit]

[Jetheft]

Bill,
Thank you so much! I am less scared now.

Joel