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post #1 of 26 (permalink) Old 02-02-2018, 04:08 PM Thread Starter
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Rear end failure

I'm just wondering, has any one had the inner joint housing fail for any reason or had the
open differential carrier fail?

I haven't taken the rear end apart yet and am curious.

Also this is are Drive Shaft Shop axles.

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Last edited by r429460; 02-06-2018 at 12:55 PM.
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post #2 of 26 (permalink) Old 02-02-2018, 04:34 PM
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I've seen the bearings torn out; there used to be pix...

Here we go:

http://forums.tccoa.com/960-differen...t-133292.html=


Ron twisted off an axle, but that's not the same...

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post #3 of 26 (permalink) Old 02-02-2018, 04:44 PM
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Yep.


And you're running an open diff carrier? Did you weld up the spiders or something?
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post #4 of 26 (permalink) Old 02-02-2018, 04:52 PM
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The only problem I've had with a 8.8" open carrier wasn't the carrier's fault.
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post #5 of 26 (permalink) Old 02-03-2018, 03:45 AM Thread Starter
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Mini spool.

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post #6 of 26 (permalink) Old 02-05-2018, 03:48 PM Thread Starter
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The inner C/V joint that went into the mini spool broke at a 45* angle in the middle of the splines.

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post #7 of 26 (permalink) Old 02-05-2018, 05:39 PM
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I broke a New Raxle inner like that back in 03-04. Left side as I remember.Was using a 28 spline Detroit locker rear. Switched to a 31 spline locker and Drive Shaft shop Level 5 axles after that episode. Never a problem after that. Of course that was back in the IRS days.

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post #8 of 26 (permalink) Old 02-05-2018, 06:21 PM
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Chris Keggan's car experienced that at the Shootout in 2007.

IIRC, that was a Raxle halfshaft, too.
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post #9 of 26 (permalink) Old 02-05-2018, 06:48 PM
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I've never seen grain structure like that; TM is who I'd ask, iirc, he's a metals guy.

Is it just me, or does that look like only the center resisted, and most of the rest fractured?

Those are How Much?

At least Ron's stock axle twisted a half-turn or so before it gave.

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post #10 of 26 (permalink) Old 02-05-2018, 07:51 PM
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Raxle used stock Ford stubs.

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post #11 of 26 (permalink) Old 02-05-2018, 09:05 PM Thread Starter
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DSS uses stock ford inners as well.

HAs anyone switched to 31 spline inners?

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post #12 of 26 (permalink) Old 02-06-2018, 04:07 AM
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Back when I went to DSS level 5 stuff. I had to buy a set of 03-04 Cobra axles also. Had to rob the 31 spline inners to use on the Level 5's. They did not offer a complete axle at that time. Any 31 spline carrier that works in the 03-04 Cobra rear will work in your Cougar.

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post #13 of 26 (permalink) Old 02-06-2018, 12:49 PM Thread Starter
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So just go with a spool or T/L for 31 spline inners.

That is what I was thinking.

Thanks Mike.

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post #14 of 26 (permalink) Old 02-06-2018, 01:46 PM
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This thread is interesting to me so that's why I'm commenting/asking questions.

Based on where the unit broke, would 31 spline really make a difference? Is it because the 31 spline part is thicker than the 28 spline part?

"When the only tool you have is a hammer, suddenly everything looks like a nail."
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post #15 of 26 (permalink) Old 02-06-2018, 03:09 PM
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Quote:
Originally Posted by MaddMartigan View Post
This thread is interesting to me so that's why I'm commenting/asking questions.

Based on where the unit broke, would 31 spline really make a difference? Is it because the 31 spline part is thicker than the 28 spline part?
IDK about stronger, but I saw this awhile back at late model resto:



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post #16 of 26 (permalink) Old 02-06-2018, 03:15 PM
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Quote:
Originally Posted by Grog6 View Post
IDK about stronger, but I saw this awhile back at late model resto:


OK then. That answers my question perfectly.

"When the only tool you have is a hammer, suddenly everything looks like a nail."
"Nothing is foolproof because fools are so ingenious."
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post #17 of 26 (permalink) Old 02-07-2018, 10:50 AM Thread Starter
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Interesting, because rock auto advertises 2001 Mustang DOHC (cobra) half shafts for $79.79 plus shipping.

Then all I need is a 31 spline T/L or Spool?

Around $500. or go all out with laddrebars, complete axle, fuel cell, etc. for $3000 to $4000.

We will see.

Plus coil over shocks and some other stuff.

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post #18 of 26 (permalink) Old 02-07-2018, 10:57 AM
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I wouldn't trust those $79 axles. Even though they may be 31 spline, they are probably cheap metal made in china, and I doubt they will be even as strong as the stock ford parts. I believe DSS sells just the inner axle cup, still in 28 spline, but made of a much stronger material.

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post #19 of 26 (permalink) Old 02-07-2018, 11:11 AM Thread Starter
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The Level 5 axles are stock Ford 28 spline inners.

Then its off to the u pull it.

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post #20 of 26 (permalink) Old 02-07-2018, 11:42 AM
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900 HP Level 5 axle

This is the axle I used back in the day.



The Driveshaft Shop | FORD 2003-2004 Mustang Cobra 900HP Level 5 Bar/Outer and Hub Upgrade - Ford - Domestic Axles








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post #21 of 26 (permalink) Old 02-07-2018, 12:11 PM
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OK, so I realize that your axle broke at the inner but I thought that the common failure on stock half shafts was on the 28 spline outer where it went through the hub?

"When the only tool you have is a hammer, suddenly everything looks like a nail."
"Nothing is foolproof because fools are so ingenious."
1992 Ford Thunderbird SC

Coast High Peformance 347 Stroker
-Low Tension Oil Rings, Zero Gap Seconds
-10.5:1 Compression Ratio
Trick Flow Twisted Wedge heads
Trick Flow Stage 1 cam
Trick Flow Street Heat Intake
Mac 1 5/8 long tube headers
FRPP 42# injectors
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M5R2
Burned Chip for SN95 T4M0 ECM
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post #22 of 26 (permalink) Old 02-07-2018, 01:52 PM Thread Starter
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I broke three stock 28 spline outers before I went to the DSS axles.

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post #23 of 26 (permalink) Old 02-07-2018, 03:07 PM
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Quote:
Originally Posted by r429460 View Post
I broke three stock 28 spline outers before I went to the DSS axles.
OK. That makes sense. Is the breakage of the inner an indication of maybe the TL unit having an issue maybe?

"When the only tool you have is a hammer, suddenly everything looks like a nail."
"Nothing is foolproof because fools are so ingenious."
1992 Ford Thunderbird SC

Coast High Peformance 347 Stroker
-Low Tension Oil Rings, Zero Gap Seconds
-10.5:1 Compression Ratio
Trick Flow Twisted Wedge heads
Trick Flow Stage 1 cam
Trick Flow Street Heat Intake
Mac 1 5/8 long tube headers
FRPP 42# injectors
3.27 gears
Custom aluminum driveshaft
M5R2
Burned Chip for SN95 T4M0 ECM
OMGHI2U

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post #24 of 26 (permalink) Old 02-08-2018, 08:49 AM Thread Starter
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It was a open carrier with a mini spool installed.

The splines of the inner are one inch (approx.).

The pass has some wheel spin which seemed like one tire would get traction, then the other would get traction.

This was the when the shock was applied to the inner.

All before the 60' mark.

I want to say based on no knowledge of metals, the break started on the smooth part of the inner shaft.

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post #25 of 26 (permalink) Old 02-08-2018, 10:10 AM
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This powdered metal crap tends to shatter when you impact load it; I've broken transmission parts like this.

The aftermarket solution there was to use better metal; IDK what to do here.

Red '96 Cougar XR-7 240k mi. '02 4R70W, PST DS : '03 PI engine, 04 maf, 24lb injectors, 2.5" exhaust, '02 4r70w + Jmod, DirtyD0g TC + cooler + 3/8" lines, 255 walbro fp. Alpine system.
Black '96 Cougar XR-7 (Lazarus) 210k mi PI Intake, '02 4R70W, Jmod, PST DS, GrogTune, Konis, Mark LCA+Poly, racecougar Custom Engine Chain, and JL and racecougar Bracing.
Black '97 Tbird Limited Edition, '02 4R70W, 255 walbro, PST DS, PBR Brakes&SS lines, Toicko Blues & Springs, GrogTune.


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Truth Isn't Truth. - Rudy Giuliani, 2018 Award winner, “Most Outrageous Diversion” by MSNBC for this quote
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post #26 of 26 (permalink) Old 02-08-2018, 08:35 PM
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The stubs aren't made from powdered metal.

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2004 Mustang GT-The Driver-Intake/Exhaust/3.73's
1995 F150 4x4-The Mud Toy-5.0L/4R70W/33's/Warn 8274 Winch
94 LX w/Splitport 3.8L from 2000 Mustang - SOLD
2 - 90 35th Anny Ed SC's
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