okay, im about this close to throwing in the towel.....edit: found the problem

[Instigator]

FOUND THE PROBLEM: look at my post with pics

THE CAR WONT MOVE NOW!!! WTF?!?!?!:mad: :mad: :mad:

I've been fine for a 1000 miles and when i pull out of my neighborhood under normal acceleration i hear a pop and the car bucks and then i just roll to a stop idling.:disgust:

imsitting there, not one gear will make the car move. the speedo says what speed im going but the damn car wont move:cry: :cry: :cry: :cry:

if this is something major im absolutely ****ing done and im gonna cut my losses and get a kia. this is absolutely ridiculous that i have luck this bad.

in no way did i even try to give it gas when i left the neighborhood. what the hell happened? i dont have time to do it now, because im late for work.

but i can bet this is the last time ill ever be towing it.:disgust:

ill let you guys know what the problem is later tonight, if i can diagnose it.

:cry: :cry: :cry: :cry: :cry:

[jrak123]

Ummmm weill if you throw in the towel just tow the car to me. I'll take it!!!

You say the speedo moves but the car wont. I would say that there is some sort of problem with th pinion gear not meshing with the dif gear.

Did you shim the dif yourself? or did you buy a drop in unit. Or did you not work on the trans at all. I can't remember what all you did and didn't do

[BigBalledOX]

Dibs on your clutch and headers. :cover:

[Instigator]

i have the stock 4.06 in there, the car wouldnt move at all with the 3.84 final in there

so the stock 4.06 gear and the car still doesnt move. i just got home from work, im going up to the car right now and jack it up and take a look before the tow truck gets there.

ive had my quaife for 2 years, i had it in this exact tranny when it was on the 2.5 :shrug:

[Kinger]

Talk to Terry Haines he'll know exactly what is wrong, especially since your speedo is working but your not moving. Make sure the akles are seated and clipped into position.

[Instigator]

okay, this doesnt have ANYTHING to do with my problem, but.......ummmm, what tq # do you have to tighten the axle nuts to? :cover:

ok that maybe had something to do with it. if i didnt tighten the axle nut tight enough.......would this happen?

after work i went back out there and found no axle nut on the passenger side of the car.......

look alright?

http://newcougar.org/forums/attachment.php?attachmentid=24326&stc=1&d=1146384048

Maybe not....

http://newcougar.org/forums/attachment.php?attachmentid=24327&stc=1&d=1146384048

http://newcougar.org/forums/attachment.php?attachmentid=24328&stc=1&d=1146384048

http://newcougar.org/forums/attachment.php?attachmentid=24329&stc=1&d=1146384048

http://newcougar.org/forums/attachment.php?attachmentid=24330&stc=1&d=1146384048

now heres the hard part. the wheel hub, came from driveshaft shop with my stage 5 axles. i would get a stock hub, but the splines on my axles do not match the stock hub splines:disgust:

gotta give them a call on monday and see if they are covered under the warranty:(

[doublebacker4l69]

either those are red x's...or god hates me

[GrandMasterKhan]

just checking. But you do have a Ford Tech CD right?

[Instigator]

yes i hve a ford tech cd

what happened to the pics? i attached them and linked them....:shrug:

i dont really know if that nut worked its way off and caused this...? i should have look at the torque spec, i just put it on as hard as i could with a big ass bar.

[C4L3]

Good grief thats a lot of silver flakes :(

[fordrule]

u sheared the teeth off the axles , ur just lucky u did it on the hub and not the tranny. have the driveshaft shop fed ex u a new set asap. . if u didn't have them tqd down all the way or did the safety the nut might have worked its way out. do u still have the nut?

[nightracer]

That should be covered under the warranty. Since it sheared off at the splines that is probably why the nut came loose when you were watching the speedo move and you weren't going anywhere it probably backed the nut off.

[sdcougar00]

damn man I feel you I was driving home and suddenlyh my car starts vibrating so I pull over and chack the wheels and found nothing. Next morning I go more in depth found out that the cv boot was broken. All day to find a new one and finally put it on and the car won't start blew 3 20 amp fuses from the engine bay. I spent the next day trying to find the short and I come to find the sensor for the tranny has its wires crossed ? So finally finished it and test drive it. Now it vibrates at higher speeds and a little less harsh so it is the other side (right) that also needs replacing. So to day I felt like throwin' in the towel but didn't because too much of my hard earned money band time went into here, plus nI haven't paid it off

[Kinger]

Haa well that is a good thing, its a easy fix without pulling the trans. You didn't keep your stock hubs and axles did you?

[DanG]

Dude.

That's about all I can say...

Dude...

Maybe you should cut your losses... I have stock Advance Auto special halfshafts, and haven't broken a thing (knocking on wood right now!)

[Instigator]

the axle still moves in and out of the housing part that broke off of the hub. god knows how it happened. im going to call DSS tomorrow and see if i cant get another hub. i hope they have them because stock hubs dont have the same splines.

[nightracer]

Thats why I didn't get the stage 5 axles cause if you do break a hub or axle then you have to wait on them to ship one, let alone if they ever quit making them you are screwed. Where as with the other axles you can at least throw on your stock one until the new ones arrive.

[CougarGT]

Again it goes to show overkill will sometimes kill you.

first crazy sized injectors...
now some fancy "stage 5" driveshafts?

just put some stock axles in with stock hubs and get the damn car working. If you break one, its an hour job to replace it, and dirt cheap at a local auto parts store.

Unless you have drag tires, is it even possible to break a stock axle? I don't think any of the NA 3L, FI 3L or FI 2.5L have had any issues with stock axles until they went to drag tires.

[Instigator]

fyi i broke a set of stock axles before the hub with my bolted on 2.5L when i jumped the clutch pulling out into traffic

[dyed4ordblue]

I noticed something.... Did you put a new cotter pin into the axle tip? Because that is what the hole is for. It keeps the castle nut from backing off when it is installed through the teeth on top of the castle nut.

[Topik]

I don't see how some people brake **** sometimes. DanG like he said has been running stock axles on his 340 hp monster and he drives the car hard. You shouldn't have a problem unless you are misinstalling, or keep getting a bad batch of stock axles.

[CougarGT]

I don't see how some people brake **** sometimes. DanG like he said has been running stock axles on his 340 hp monster and he drives the car hard. You shouldn't have a problem unless you are misinstalling, or keep getting a bad batch of stock axles.

My point exactly.

I drove my 2.5L hard, and my 3.0L hard, both with Falken Azenis tires. I never had a single issue with drive axles.

This is a 100% installation related issue.

[Instigator]

You guys are right.

[BigBalledOX]

Just cuz I'm curious, installation issue or hardware issue or wtfe, is it necessary to kick him while he's down? I'm sure Mark feels bad enough about **** as it is, the last thing he needs is everyone basically calling him an idiot right now.

[1COUGAR99]

Well, evidence mostly points to driving habits as the cause for a lot of failures. Something that puts a lot of stress on the axle in a very short period of time can cause a failure. Stock motors can easily snap an axle. So Dans "Monster" hasn't broken them. He might beat on it but I'm willing to bet he babies the launches.

You guys shouldn't bash him because he purchased something that broke. I mean damn some of you are being harsh. Constructive criticsm is fine but you guys are taking it way to far. Reverse it, how about you buy something and then when it breaks have people start telling you that your pretty much an idiot and you should just go with what works. Well if people always followed that rule we wouldn't have forced induction motors, nor anything for that matter because OEM right out of the box would be sufficient for everyone and everything. When a part is manufactured there always is a small chance that something wasn't to the spec it should have been. I'm not a metalurgist, although to me it appears that the splines were weakened by the machining. Warmonger can chime in on this one. We need to support him, he needs it probably now more then ever since he is doubting the project.

Personally I feel that you should contact DSS and they better start bending over backwards for you. If it was a design problem then they are obligated to make it right. Hell if I invested that much money into a product and didn't even get to test anywhere near it's designed strength I'd be pretty miffed. To bad they moved down south, they used to be about 15 minutes from me. Keep us updated man, don't loose your faith yet. No matter how bad it looks just keep that idea alive in your mind of how much of a kick in the pants it's going to be once it's all together and tuned. :evil:

[GrandMasterKhan]

all the problems will make the end result that much more satisfying.

[Topik]

Basically calling him an idiot is far from what we are getting too. We simply believe it to be a installation issue and are emphasizing that we feel thats what the problem was.

Back to topic
Did you install the cotter pin as it seems you have a hole for one? Did you torque the axle nut down to spec?

[Topik]

Also how do the splines on the axle itself and the hub itself look? Are they stripped out or what?

[1COUGAR99]

I understand you guys were being constructive, but the tone that the replies had seemed a little unneccesary.

Back to Topic. From the look of his pics it appears that both the splines on the axle and the splines on the hub were damaged. Like I said I'm willing to bet the failure started with the hub splines and then the axle splines were totally stripped off.

[gyger]

You're just lucky your rim tire and hub didn't fly off the car!

[ilovemycar]

You're just lucky your rim tire and hub didn't fly off the car!

Not really possible just from an axle nut. Rim hooked to hub. Hub hooked to control arm and strut. There would have to be some MAJOR **** goin' on for the wheel to come off. I had a wheel bearing go bad on my car...but the wheel couldn't come off because of the brake rotor being held on by the caliper.

Ya...so Mark...did u keep the stock stuff? Or have you tried contacting DSS yet?

[Topik]

Wouldn't it be Rim hooked to hub, hub hooked to steering knuckle, steering knuckle hooked to Control arm and strut?

[dyed4ordblue]

Hey Instigator, trust me, I was not trying to make you feel bad or call you an idiot or call you out. Believe me, I have mad respect for you to be able to do what you have done, and get it to run!!! I just wanted to point out something that you might have missed (the cotter pin). It looked like to me you didn't put one back in because I saw no scratches from the install or removal. I could be mistaken due to the fact I am not there looking at it right there with you. There is no reason in the world that you should give up, not this late in the game. Once everything is together and reliable, you will be elated. Been there and it almost as good as sex....almost. And guys, Be easy on the dude. He has done more than I'd say about 95% of cougar owners! Good luck, Mark, and I hope to see the dyno sheets and timeslips. :evil:

[ilovemycar]

Wouldn't it be Rim hooked to hub, hub hooked to steering knuckle, steering knuckle hooked to Control arm and strut?

No. There is a rim...rotor...hub...caliper...controls arm...ball joint...tie rod.

Aw hell it don't matter. lol

[Instigator]

i called DSS and thy are making me a new hub.

the axl plines are fine. axle comes in and out and when the car is up on stands and put through the gears the axle doesnt slip on the inside and still turns the bearings. i called DSS and they are making me a new hub.

i did over look the codder (sp) pins :banghead:

i have to wait a week or so for a new hub since they do not have one in stock

ill be back soon :)

[NorCalCoug]

Ouch man, sorry to see it. :(

As a person who has screwed up putting things together many, many times, it didn't take me long to come to the realization that when putting something together:

Make a list based on what the instructions tell you in the book. Follow the instructions and check things off the list. Do this until you no longer need the list to put things together. One simple step overlooked at the very beginning can either cause a huge headache later on to take apart, or an expensive thing breaking.

[nightracer]

Hell the first time I put did wheel bearings I forgot the cotter pin and right before I put on the rims my dad walked out to see how I was doin and was like "hey you should put that in or it might get interesting for you".