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Old 11-13-2005, 11:31 PM   #426
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any updates?
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Old 11-14-2005, 05:29 PM   #427
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I took it to the Caribou Hills last weekend for a winter run, and it worked well for the most part. I had two yellow top optimas take a dump, and the fan solenoid quit on me once, while blasting down the trail at full throttle. I caught it at about 250* Somethings gotta change on that this winter. I dont know if its the solenoid itself or the fact its exposed to the weather and mud/water, or if its because it just isnt up to the duty of running a taurus fan on high 24/7.

I still need to add some damping to the rear suspension, and maybe some stiffer springs, but the bumpstops are working really well (Timbren overloads)

I also want to turn the antisquat down on the rear suspension. Fortunately this will be very easy since I took the time to build adjustable upper link mounts.

Overall, everything is working well.... Oh, I would like to lock the front... the powerlock works good in the snow, but crawling through washes this summer it let me down quite often. Its just not enough for that big of tire and so much traction.
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Old 11-14-2005, 06:51 PM   #428
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Are you running a Ford starter relay for the fan?
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Old 11-14-2005, 07:02 PM   #429
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No, its an aftermarket piece I found at a parts store.
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Old 12-25-2005, 08:43 PM   #430
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Default Re: Should have never used pipe.... My cage fell off!

Here is the thread about the plow mounting I just finished.
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Old 12-25-2005, 08:56 PM   #431
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Default Re: Should have never used pipe.... My cage fell off!

These are the limit straps I made this summer. I used strapping that I cut off my 2" trailer tie downs. The tabs were cut from 3/16 A36 plate. I had the local upholstery shop sew them after dinking around for a couple hours with a sewing awl, and not even getting one side, of one strap sewn. lol. 25 bucks to have them all sewn, and that included a good sized tip for doing it while I waited. :smokin:

I made them to bolt on at the shock mounts, and had them sewn so they would stop the shock at about 1" short of full extension with no load. Total cost for 4 custom length limit straps... $40.
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Last edited by bgreen776; 12-25-2005 at 09:17 PM.
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Old 12-25-2005, 11:49 PM   #432
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Default Re: Should have never used pipe.... My cage fell off!

Why the tape on the bottom of the coilover?
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Old 12-26-2005, 07:59 AM   #433
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Default Re: Should have never used pipe.... My cage fell off!

its to keep the spring seat from falling out. The spring combination I have is a bit too stiff to allow me to adjust the upper seat down (and still maintain the desired ride height) far enough to prevent the springs from going slack. Pretty Ghetto, but it works. The other option is to buy a $200 tender coil setup. Na. for now I'll stick to .20 worth of duct tape.
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Old 12-26-2005, 12:32 PM   #434
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Default Re: Should have never used pipe.... My cage fell off!

Brook - how much were those coilovers?

Cheers

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Old 12-27-2005, 09:34 AM   #435
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Default Re: Should have never used pipe.... My cage fell off!

I think they were around 1100.
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Old 01-02-2006, 07:15 PM   #436
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Default Re: Should have never used pipe.... My cage fell off!

Several months ago, on a run to the caribou hills, I hit a mud hole too fast, with too much throttle. When I hit the other side I heard a loud bang, but could find nothing wrong so I just forgot about it. Toward the end of the run I noticed I had developed a squeeky wheel bearing from what was most likely water contamination from the summers water crossings.

Well, one full run later, some snow plowing, and a bit of yard wheeling I ended up with this....

The loud bang was the spider gears breaking, the squeeling was the bolts machining their way into the side of the differential housing. When the Spider Gears broke, it forced the two case halves apart, breaking about half the bolts. This caused the case to flex and the rest of the bolts to start backing out. Once the bolts backed out far enough, they started wearing on the housing.

Finally, while doing some yard wheeling I lost drive to the front axle. This was caused by pieces of the spider gears getting wedged between the ring and pinion, causing several teeth to break off.

Junk =
  • Ring and Pinion
  • Powerloc
  • Differential Housing
  • Drivers inner C (a seperate event)
At some point the passenger side outer bearing race broke in half.


So, it looks like I'll be building up a new axle. I'd like to do 5.13 gears and detroits front and back, but its just not in the cards at this point. So Im going to install a different axle, with 4.10s and a welded diff for now. Not really looking forward to cutting off all the old brackets, and welding them to a new axle, so I might, (heavy on the might) build a different suspension while Im at it.

BTW, the welded u-joints and bushings are still holding up well.

On to the pics...
  1. Notice the case halves spread apart.
  2. Notice the one short bolt and the one with the bent shank.
  3. Notice the spiders
  4. Notice the broken outer race
  5. Notice the bolts have cut clear into the threads that hold the caps on
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Last edited by bgreen776; 01-02-2006 at 07:21 PM.
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Old 01-02-2006, 07:50 PM   #437
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Default Re: Should have never used pipe.... My cage fell off!

any way you might be able to write some of it off under waranty from powerloc. or has it been to long? what caused the failure was it just stress?
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Old 01-02-2006, 08:57 PM   #438
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Default Re: Should have never used pipe.... My cage fell off!

Mine was similiar. All the bolts came loose. The side of my housing didn't get near that bad though. Blamed it on taking it apart and putting it together several times to tune the clutch packs. Replaced the bolts, cleaned and air dried the threaded holes, installed red locktite and never had another problem. Looks like a good canidate for safety wire. I look at all the bolts through the fill hole in the front of the van periodically. They are all still good.


Just fill weld the areas around the bolt holes and re-tap it. Then run it. Will be a good chance to see how it works. I think it will work just fine.
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Old 01-02-2006, 09:04 PM   #439
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Default Re: Should have never used pipe.... My cage fell off!

There is no way I'm going to keep running this housing. Its shot, and I have 3 others that will fit the bill. I would have to repair/replace the drivers side inner C too. I should be able to piece one back together in a few weeks. I think brazing is actually a viable option, but welding... wouldnt tap very well. You would have to build a fixture, or do the drilling in a mill to prevent the drill from walking off and taking out the opposite side of the threads.

Anyone wanna plow my driveway in the mean time?

I hear you on the safety wire, thats the first thing that went through my mind. Then I started thinking back and remembered the deal on our hills run. It was a Very loud bang, and I'm 100% sure this is where the failure happened. Tack welding the bolts is another option, and IMO, MUCH better than safety wire.
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Last edited by bgreen776; 01-02-2006 at 09:14 PM.
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Old 01-02-2006, 09:07 PM   #440
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Default Re: Should have never used pipe.... My cage fell off!

Quote:
Originally Posted by murphyslaw
any way you might be able to write some of it off under waranty from powerloc. or has it been to long? what caused the failure was it just stress?

This powerloc is prolly 10 years old or more, so no dice on the warranty. The failure was caused by stress.

Quote:
Several months ago, on a run to the caribou hills, I hit a mud hole too fast, with too much throttle. When I hit the other side I heard a loud bang, but could find nothing wrong so I just forgot about it. Toward the end of the run I noticed I had developed a squeeky wheel bearing from what was most likely water contamination from the summers water crossings.

Well, one full run later, some snow plowing, and a bit of yard wheeling I ended up with this....

The loud bang was the spider gears breaking, the squeeling was the bolts machining their way into the side of the differential housing. When the Spider Gears broke, it forced the two case halves apart, breaking about half the bolts. This caused the case to flex and the rest of the bolts to start backing out. Once the bolts backed out far enough, they started wearing on the housing.

Finally, while doing some yard wheeling I lost drive to the front axle. This was caused by pieces of the spider gears getting wedged between the ring and pinion, causing several teeth to break off.
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907Diesel

Last edited by bgreen776; 01-02-2006 at 09:09 PM.
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Old 01-03-2006, 09:14 AM   #441
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Default Re: Should have never used pipe.... My cage fell off!

Quote:
Originally Posted by bgreen
Several months ago, on a run to the caribou hills, I hit a mud hole too fast, with too much throttle.
You to much throttle? No never.

To bad that **** broke, i had a feeling there was going to be some good action.

so what are the plans for a new front suspension?
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Old 01-03-2006, 12:18 PM   #442
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Default Re: Should have never used pipe.... My cage fell off!

Too soon to have any real plans yet.
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Old 01-03-2006, 01:45 PM   #443
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Default Re: Should have never used pipe.... My cage fell off!

Brook, do you have link to your current fron link setup? I read about it a few years ago, but would like a link with the specifics again if you still have it somewhere. Thanks.

Are you planning to stay with a 60 in the front? Or are you now considering alternative options; 14 bolt hybrid front, new 2.5s or 5-ton etc???
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Old 01-03-2006, 04:31 PM   #444
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Default Re: Should have never used pipe.... My cage fell off!

Im going to stick with regular old 35 spline dana 60 stuff. I dont want to this repair to take any longer than necessary so Im going to keep things simple.

Front suspension threads:
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Old 01-03-2006, 04:44 PM   #445
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Default Re: Should have never used pipe.... My cage fell off!

thanks!
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Old 01-03-2006, 06:30 PM   #446
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Default Re: Should have never used pipe.... My cage fell off!

I had a Truetrac in the front end of my Dodge do the same thing. I was lucky and caught it early.
I hope this makes for some good reading on the board with a new front suspension and a fancy front axle build eventually.
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Old 01-08-2006, 06:54 PM   #447
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Default Re: Should have never used pipe.... My cage fell off!

I dont think im going to do the suspension, too much work for something that really doesnt need to be done.


I cut apart one of my old crew cabs this fall, so I saved the fenders thinking I might use them to make the buggy look a bit more like a chevy truck again. I got held up on the axle project for a bit, so I decided to see if I could make these fenders fit. Obviously they need a bunch more fitting, but you get the idea.

Whatcha think?
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Old 01-08-2006, 09:17 PM   #448
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Default Re: Should have never used pipe.... My cage fell off!

"freaky"
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Old 01-08-2006, 09:30 PM   #449
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Default Re: Should have never used pipe.... My cage fell off!

that would be SWEET. make it work brook.
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Old 01-09-2006, 08:25 PM   #450
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Default Re: Should have never used pipe.... My cage fell off!

Worked on the piece that goes between the fender and door. What a PITA. Ended up just trimming the difficult part off No dime width body gaps here! The door and cab are so thrashed that I just gave up on the usual bgreen anal fitup.

A couple more hours of tabing and fitting the fender and I'll be done with this side.

Did you notice how the body lines dont line up. I never realized that I mounted the hood that far above stock. Good thing its shorter than stock or I would have been loosing quite a bit of view.
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