8.8 Build Thread

BlueSaph95GT

Member
Sep 16, 2003
123
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16
Oak Lawn IL
So I took the plunge and began the rear end build this month. Here's what's going in:
FRPP 3.73s
FRPP 31 spline axles/lugs
FRPP 03/04 cobra differential
FRPP aluminum cover/girdle
Steeda UCA's
MM LCA's
Tokico Shocks, Ford Springs, Ford Rear Sway Bar (1/2 of the Bullitt/Mach 1 kit)
New upper/lower isolators (prothane/ford oem)
New Ford lower control arm bolts/upper bushings
Raybestos Advanced Drilled/Slotted rear rotors & pads
New Ford ABS Rings
All new bearings throughout
FRPP Speedcal module

and now for the pics so far...first up, a teardown shot in the shop:
2011-07-07162013.jpg


new shocks in, one stubborn control arm bolt that took way too long to remove. ended up cutting both ends off the bolt to get it out:
2011-07-22124013.jpg


and pics of how i left it today after pouring sweat. shocks in, uca's bolted in and hanging (no bushings in the 'ears' of the center section yet), and MM LCA's bolted up. bearings have also been removed in this pic (slide hammer worked great):
2011-08-02145022.jpg


huge thanks to my co-worker for hosting me in his shop space...i am paying 'rent' in beverages so far and he's been super helpful. we are taking our time and not rushing the project, so updates might be a while. this is my first rear end build, so i'm learning as we go.
 

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Looking good so far, nice progress. Did that pile of dirt in the second pic fall all over you during the teardown?

It's kitty litter soaking up rear gear oil. It seemed like every time we shifted the axle around during the tear down, more would leak out (from the axle tubes or the back of the pumpkin).

I got quite a bit of rust/dust in my eyes when removing the dogbone though. Lesson learned - put on shop glasses, especially when the shop fan is blowing the crap towards you!
 
Just don't get that gear oil in your hair. Your wife won't have sex with you for 3 weeks. If you've got it that far apart, you might want to just pull it and see if you can get someone to weld the tubes to the pumpkin. That makes a huge difference in strength.

Kurt
 
100% correct - the gear oil smell is pretty bad, even new. The new bearing kit and diff were leaving the Mercury smelling for a few days even after the parts were taken OUT of the trunk.

Kurt -as far as welding the tubes goes, I don't think it's in the cards at the moment. I'm also not sure it's worth it yet (?) considering the current RWHP and the fact that the car will not be on slicks any time soon - just street radials (either Kumhos or Nittos). I've heard that to do it properly requires cutting them off, resquaring the tubes to the center (I've read that from the factory they aren't typically perfectly square?), and then rewelding the axle tubes to the center. I think if it ever breaks/bends/etc, I will step up to a bolt in 9" from Strange. For now I'm living with a stock style upgrade...
 
In that case the 31 splines are totally overkill too. I forget what company specializes in the 8.8, some company in Ohio I read about in MM&FF, and even they just straight weld them just the way they are. No jig or anything like that. Anyway, that's the only thing keeping that rearend from being 1000rwhp ready to go. All a 9" does is rob horsepower. When I take my rear end apart, is' getting welded. I'm probably not going to bother with 31 splines though.

Kurt
 
I've always heard that it takes some kind of special welding to weld the tubes due to the center section being cast and the tubes being thinner walled tubing. Maybe just needing to heat the one with a torch first to get it hotter, dunno.
 
I've always heard that it takes some kind of special welding to weld the tubes due to the center section being cast and the tubes being thinner walled tubing. Maybe just needing to heat the one with a torch first to get it hotter, dunno.

I'm going to hit it with my wire feed and I'll let you know how it turns out.

Kurt