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Chris B. · 01-11-2013, 09:46 PM

Back in the end of October, one of my front wheel bearings started getting noisy. I was thinking of getting the ARP wheels studs for the car. A pair of new hubs with the bearings was $132 from Ford and the ARP wheel studs normally cost $99-$109. Then I opened up the Ford Racing Performance Parts catalog and got the part number for the FR500 Mustang's wheel hubs and found a Ford dealer selling them for $175 plus shipping. They include the ARP wheel studs. Its nice when race car parts are cheaper than street car parts. I installed them in the beginning of November.

Out with the old...

In with the new...

I also replaced the tie rod ends. I stuck with an OEM style replacement. The roll center relocation kit won't allow me to use 17" wheels or else I would have installed one.

I also wanted to replace the 4.10 rear gears with 3.55 gears so that I'd have a 1st gear that was useable for something other than 7000 RPM launches on 315 width slicks and so that the car would be more useable on road courses. I ordered all the parts:
3.55 FRPP gear set
GT500 clutch pack diff rebuild kit
All new diff bearings and axle bearings
ARP wheels studs for the rear axle
friction modifier
synthetic gear oil
and a few other miscellaneous bits

Also I had that shiny new Boss302/GT500 differential cover I ordered over the summer and never put on the car.

I dropped it off at a friend's shop in December to have the new gears put in and the diff rebuilt Originally the job was only going to take a day. Unfortunately, the shop that put in the 4.10 gears when a previous owner had the car apparently damaged a bearing when they put the new diff in and didn't replace the bearing. The bearing started wearing in an unusual way and it left metal shavings and chunks all over and it also allowed the axle to wobble as it wore. The metal bits floating around damaged the differential gears. I was lucky I decided to get it replaced when I did because it wouldn't be much longer until large chunks started coming off the bearing and might have locked up the rear as I was driving the car. The wobbling form the worn bearing also wore an axle in an unusual way and damaged the pinion gear. The pinion gear splines actually had a wavy pattern to them.

I ended up also needing a new axle. I thought about getting a set of Moser axles, but I'm not going to be doing high RPM launches with a 700 WHP car, so I decided to get a new replacement from Ford. Luckily my friend had the stock diff from his 2003 Cobra sitting around the shop, so I didn't have to order a new diff carrier.

I didn't get good pictures of all the damage, but I here are a couple that show the damage to the teeth.

The axle assembly was completely disassembled and cleaned. The only original parts in it are the housing and the passenger side axle.

Here is the car before the rebuilt axle goes back in. You can see the shiny new diff cover with cooling fins.

Now the car has a useable 1st gear and I'm getting 2-3 MPG better gas mileage on the highway.

01-11-2013, 09:46 PM	#174
Chris B. Tri-State Post Whore Join Date: Jul 2009 Location: Lehigh Valley Member #14208 My Ride: is Sonic Blue iTrader: (0)	Back in the end of October, one of my front wheel bearings started getting noisy. I was thinking of getting the ARP wheels studs for the car. A pair of new hubs with the bearings was $132 from Ford and the ARP wheel studs normally cost $99-$109. Then I opened up the Ford Racing Performance Parts catalog and got the part number for the FR500 Mustang's wheel hubs and found a Ford dealer selling them for $175 plus shipping. They include the ARP wheel studs. Its nice when race car parts are cheaper than street car parts. I installed them in the beginning of November. Out with the old... In with the new... I also replaced the tie rod ends. I stuck with an OEM style replacement. The roll center relocation kit won't allow me to use 17" wheels or else I would have installed one. I also wanted to replace the 4.10 rear gears with 3.55 gears so that I'd have a 1st gear that was useable for something other than 7000 RPM launches on 315 width slicks and so that the car would be more useable on road courses. I ordered all the parts: 3.55 FRPP gear set GT500 clutch pack diff rebuild kit All new diff bearings and axle bearings ARP wheels studs for the rear axle friction modifier synthetic gear oil and a few other miscellaneous bits Also I had that shiny new Boss302/GT500 differential cover I ordered over the summer and never put on the car. I dropped it off at a friend's shop in December to have the new gears put in and the diff rebuilt Originally the job was only going to take a day. Unfortunately, the shop that put in the 4.10 gears when a previous owner had the car apparently damaged a bearing when they put the new diff in and didn't replace the bearing. The bearing started wearing in an unusual way and it left metal shavings and chunks all over and it also allowed the axle to wobble as it wore. The metal bits floating around damaged the differential gears. I was lucky I decided to get it replaced when I did because it wouldn't be much longer until large chunks started coming off the bearing and might have locked up the rear as I was driving the car. The wobbling form the worn bearing also wore an axle in an unusual way and damaged the pinion gear. The pinion gear splines actually had a wavy pattern to them. I ended up also needing a new axle. I thought about getting a set of Moser axles, but I'm not going to be doing high RPM launches with a 700 WHP car, so I decided to get a new replacement from Ford. Luckily my friend had the stock diff from his 2003 Cobra sitting around the shop, so I didn't have to order a new diff carrier. I didn't get good pictures of all the damage, but I here are a couple that show the damage to the teeth. The axle assembly was completely disassembled and cleaned. The only original parts in it are the housing and the passenger side axle. Here is the car before the rebuilt axle goes back in. You can see the shiny new diff cover with cooling fins. Now the car has a useable 1st gear and I'm getting 2-3 MPG better gas mileage on the highway. __________________ To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures. To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures. To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures.