Installation Tip #2: Step by step installation of an LPW Support Cap Cover and Axle Tube Brace for 1979-2004 Mustang.
The following illustrates just how easy it is to install an LPW Cap Support Cover and Axle-Tube Brace.
While the internals of the 8.8 are now much stronger with the addition of the Strange components, the differential is still not as strong as it could be. To solve that problem, we contacted LPW Racing Products and they recommended their Ultimate 8.8 Cover combined with their 8.8 axle brace kit. They are designed to work together to support the bearing caps and to prevent axle tube flex resulting in a much stronger rear end.
The difference between the stock cap and the LPW cap is extreme. The LPW cap is much beefier and just looks much better. It comes with a fill plug and a magnetic drain plug.
The axle brace kit is fairly simple and bolts directly to the LPW cap. Installing the brace kit requires welding to attach the tabs to the axle housing so make sure you can do it or get someone to do it before you start on the install.
To install the LPW components, you will need a variety of tools:
- jack, jack stands
- socket set
- a variety of metric and standard wrenches
- pan to catch gear oil
- hacksaw or reciprocating saw
- gear oil(I used synthetic 75W-90)
- hammer/prybar
- large flat screwdriver
- grinder
- welder
Cap Support Cover
Removal
1. Start off by jacking up the back of the car and securely place it on jack stands.
2. Remove the differential cover (½-inch bolts):
- loosen all of the bolts
- take off the bottom 5
- push a screwdriver in the bottom and pry a bit to start draining
- take out 2 more bolts and drain some more
- take off the rest of the bolts and remove the cover and set aside
3. Remove the bearing caps and inspect them for cracks or any wear (3/4-inch bolt). Replace if necessary.
4. Clean the gasket surface and the bolt holes.
5. One the new LPW cover, back out the bearing cap load bolts. Do this so the swivel heads pivot freely and do not contact the bearing cap. When the load bolts are backed out, apply some silicone under the jam nut to provide a positive seal.
6. Apply silicone to the cover instead of a gasket to limit cover deflection. Install the cover and torque the 10 supplied mounting bolts to 25 ft/lbs (1/2").
7. Torque the bearing cap load bolts (Allen head) to 10 ft/lbs. Do not over-tighten the bolts or bearing distortion will occur.
8. Tighten the jam nuts to a maximum of 10 ft/lbs, again caution should be taken so the bolts aren't over-tightened.
9. Fill the rear to the proper OEM gear oil levels.
Axle Brace Kit
1. Assemble the rod ends and the jam nuts to each brace. Each end threads in a different direction...so keep that in mind.
2. Assemble onto the LPW cover. Start with the 5/8" bolt, the washer, the aluminum strap, the spacer, the rod end, and the other spacer.
3. I determined that the shock was in the way of the mounting tabs so the braces needed to be cut. The nut welded to the brace should be nearest the cap support cover. Figure out how much you will need to cut off and take it off the outside end of the brace (opposite the end with the welded nut). I had to cut off 5/8" on the passenger side and 1" on the driver side. The threads went in far enough and rethreading the brace was not necessary.
4. I removed the shock to make it easier to locate the mounting tabs. The lower bolt/nut requires 18mm and 15mm while the top shock nut requires a 9/16" wrench. Keep the shock handy to make sure you have clearance for the tabs.
5. Determine the location of the mounting tabs (check with the shocks).
6. The tabs will be mounted near the edge of the control arm mount so I ground tabs to fit the contour of the control arm mount. You could also cut the tabs with a hacksaw to get the general shape then file them down smooth.
7. Grind down the control arm mount to get a nice clean surface then tack the tabs in the desired location (I tried to keep the braces as parallel to the ground as possible).
8. Unbolt the rod ends from the tabs and finish welding the tabs.
9. I sprayed the tabs and the weld with some rust proof paint and then re-installed the rod ends and the shocks.
10. Tighten the braces with the jam nuts (11/16") and the large nut welded to the brace (15/16").
The brace/cap kit basically finishes off the rear end of Deep Freeze. We now have enough strength to keep everything together at the projected power levels. The only thing that was difficult about installing these parts was the requirement of a welder. We used a mild 110V MIG welder and it worked fine. The install of the support cover was extremely easy and the brace kit required a bit more skill. The installation of both parts took a couple of hours. Deep Freeze was already mostly apart, so that made it a bit easier. Doug Fellenbaum at LPW recommended the brace kit for our power levels but it is not necessary at lower levels. LPW also makes a support cover which does not have provisions for the brace kit which would be an excellect upgrade for a more mild car.
All images and text provided by The Corral
www.corral.net
