Independent Rear Suspension - Factory Five Racing

1 Controlled Documentation DO NOT DUPLICATE CONFIDENTIAL INFORMATION AND PROTECTED UNDER COPYRIGHT LAWS 2012 Factory five Racing , INC. Server/company/instructions Independent Rear Suspension Installation Instructions PARTS INCLUDED IN THUNDERBIRD PARTS Parts NON-THUNDERBIRD PARTS TOOLS SUPPLIES SELECTION AND DISASSEMBLY OF THE THUNDERBIRD MASTER CYLINDER SELECTION MODIFICATION OF IRS CV Joints If complete axles are not Brake BOLT-ON IRS Center Lower Control IRS Rear Coil-Over Shock CV Upper Control Quad shock Rear Calipers and Emergency Brake Cable Fuel line Width FINAL Alignment Torque AFTERMARKET PARTS OLDER CHASSIS FFR Chassis Upper cage Lower Cage These instructions are designed to supplement the Assembly manual

2 Where the assembly process is different from the build-up using a solid axle. Sections of the manual that deal with the assembly of the rear end will Part Number: 12449 Revision: K Effective Date: 11/27/12 By: J. INGERSLEV Document Type (indicate): Bill of Materials Drawing (may be attached) Specification Assembly Instructions Operating Procedure Other 2 not apply and can be skipped. Read through these instructions before beginning assembly as some of the changes occur early in the build-up process. Using the Factory five Racing Independent Rear Suspension will require a conversion to 5 lug which, if you are not currently using 5 lug will require new wheels.

3 If you need 11 5 Lug rotors for the front then use 82- 83 Lincoln Continental or 91 Lincoln Mark VII LSC or Ford Racing Performance Parts # M-1102-C. Parts Included in Kit 14769 BOX 11 C IRS COMPONENTS EA 12446 BOX, PRE-PRINTED, ROLLBAR EA 12449 IRS INSTRUCTIONS EA 14852 REAR WHEEL STUDS EA 11138 HOSE CLAMP, 5/16" FUEL LINE EA 12452 FLEXIBLE FUEL LINE, 5/16" ID, HIGH PRESSURE, 24" FT 15508 STANDARD WIDTH CV AXLE EA 14690 EMERGENCY BRAKE CABLES EA 12409 BRAKE LINE ADAPTER EA 15388 " SPACER EA 10970 1/4" INSULATED CLIP EA 10984 #14 x 1/2" SCREW EA 12400 QUAD SHOCK BOLT EA 11027 QUAD SHOCK LOCKNUT EA 13976 1/2" WASHER EA 15383 HARDWARE BOX EA 14680 KONI STANDARD IRS SHOCK SET WITH KIT EA 14622 KONI SHOCK, (30-1720)

4 EA 25621 SPRING HAT EA 25622 SPRING COLLAR EA 25623 COIL-OVER THREADED SLEEVE EA 25961 SPRING, FRONT COIL-OVER, BLACK, " ID, 8", 750# EA 14700 IRS KONI COIL-OVER INSTRUCTIONS EA 14681 IRS SHOCK MOUNTING COMPONENTS 33238 " SPACER EA 15388 " SPACER EA 12385 1/2"-13 x " BOLT EA 10834 1/2"-13 NYLON LOCK NUT EA 13976 1/2" WASHER EA 12386 1/2"-13 x " BOLT EA 12268 IRS LOWER REAR CONTROL ARM COMPONENTS EA 13337 ROD END SPACER EA 12348 ROD END, RIGHT HAND THREAD EA 12380 JAM NUT EA 12384 5/8"-11 x " BOLT EA 15216 5/8"-11 LOCK-NUT EA 12428 DRIVER SIDE IRS LOWER CONTROL ARM EA 3 12429 PASSENGER SIDE IRS LOWER CONTROL ARM EA 12440 IRS UPPER REAR CONTROL ARM COMPONENTS EA 33239 ROD END SPACER, " EA 12348 ROD END, RIGHT HAND THREAD EA 12380 JAM NUT EA 12382 5/8"-11 x 3" BOLT EA 15216 5/8"-11 LOCK-NUT EA 12387 WASHER.

5 UPPER ARM TO CAGE EA 12367 IRS UPPER REAR CONTROL ARM EA 12438 IRS CAGE COMPONENTS EA 12386 1/2"-13 x " BOLT EA 10834 1/2"-13 NYLON LOCK NUT EA 10833 1/2"-13 x " BOLT EA 10834 1/2"-13 NYLON LOCK NUT EA 12327 CAGE EA 12439 IRS UPPER CAGE EA 12375 UPPER CAGE EA Lower arms and Cage (Cage separate from frame) Upper arms and Cage (Cage separate from frame) 4 Thunderbird Parts needed Vehicles For all applications make sure that the diameter of the axle shafts at the splined ends measure inches, the differential has cast into its top, and that rear disc brakes are present on the donor IRS. To determine the gear ratio, and whether or not the unit has posi-traction, look at the tag that is attached to one of the differential cover bolts.

6 The first 4 spaces signify the gear ratio and whether or not it has posi-traction. If the unit has posi-traction, then the second space will have an L in it representing (limited slip), the remaining spaces specify the gear ratio. For example, 2 L 7 3 means posi-traction with a :1 gear ratio. Most people pay a salvage yard between $300-$400 for the donor parts. Also, Ford Racing Performance Parts sells a 15lb. lighter aluminum carrier with gears and posi-traction for around $650. 1989-1997 Thunderbird Supercoupe (All Posi-traction) 1992-1997 Thunderbird V-8 models with rear disc brakes(some posi-traction) 1992-1997 Lincoln Mark VIII (All aluminum carrier, most non-posi-traction) 1989-1992 Mercury Cougar XR-7, supercharged V-6 (All posi-traction) 1993-1997 Mercury Cougar V-8 with rear disc brakes (some posi-traction), after 94 all Cougars were called XR-7 s Parts needed carrier, front mounting bushings, and rear mounting hardware.

7 Spindles and attaching hardware. Disc brakes with flexible brake lines and mounting brackets. 5 Donor fasteners needed: (Upper) spindle attaching bolts. (Lower left) Center Section front mounts. (Lower right) Center Section rear mount bolts. NON-Thunderbird parts needed Mustang Quad shocks Aftermarket KYB shocks usually interfere with tires. Lug nuts (T-bird lug nuts are metric) 6 Tools Needed Drill 3/16 drill Bit 3/8 , , 15/16 sockets 3/8 , , 15/16 wrenches 3/8 -7/16 Brake line box wrench Brake line double flare tool Brake line cutter Brake line bender Ruler/Tape measure Snap ring pliers Pliers Flat head Screwdriver Tin Snips/scissors/razor Marker Supplies needed pints Gear oil 4 oz.

8 Friction Modifier Brake Fluid Rear brake pads Selection and Disassembly of the Thunderbird Donor When selecting a donor vehicle, there are several important things to look for to avoid problems. Ford used the same IRS set-up for a few different cars. Thunderbirds between 1989 and 1997, Lincoln Mark VIII s between 1992 and 1999, and Mercury Cougar XR7 s between 1989 and 1992. Only some of the cars have the correct parts that are needed. The points to check are as follows: The first and most important item to check when looking at different rear ends is the diameter of the CV shafts. The V6 and some V8 cars came equipped with a smaller diameter CV shaft.

9 These CV joints will not work with the new shorter shafts provided or with the Torque that can be made from a HO engine so they should be avoided. To check for the proper shaft size, check the diameter of either side. The correct diameter is inches, next to the splines. If you are using a Super Coupe, the axles will be correct even if the passenger side is considerably thicker. Under the boots, it necks down to the correct size. Check the center section. What you need is an inch unit. It will have cast into the top of the differential and is noticeably larger than the inch center that was also used. Lincoln Mark VIII came with aluminum center sections that are 15lbs lighter than the iron one.

10 The Thunderbirds were available with and without rear disc brakes. We recommend one with the discs (free upgrade from a drum brake solid axle). When you find a rear you like just ask for the whole rear clip from the car. The whole thing unbolts with four bolts and they usually cut the driveshaft. This way you will be sure to get everything that you need. Limited slip (Posi-traction/Traction-Lok) and Open Differentials Early Mark VIII center sections do not have a limited slip differential. 7 The Thunderbird Supercoupe does have a limited slip differential. The IRS is an center section and it can use the same gears that the solid axle from the Mustang uses but, it can not use the same differentials.