Everything is in the car but springs and shocks. The driveshaft problem had a cheap and easy solution and the part is on order from Ford. The IRS is in the car, but the car is not driveable yet. At this point, just waiting on part to arrive.
The final gear is 3.27, same as my old 7.5. They didn't change to 3.55 until the '03-'04 IRS which is a different but similar design.
I learned a lot, hehe. It will all be in the write-up.
The write-up is underway. I've just finished writing page 3.
The driveshaft flange yoke that is needed to install the IRS rear in a V6 is a 1310 series 3x3" square (4-1/4" diag) large bolt pattern flange yoke with a 2" female pilot hole. The only place I was able to find one online was a place called Denny's Driveshafts. However, if you have a driveshaft shop nearby, it is a fairly common part that I am sure they can order or may even have in stock. Expect to pay around $40.
This is, of course, if you have a 1310 series u-joint. If you have upgraded to a larger 1330 or 1350, then you will need the 1330 series flange yoke. The important thing to note is that it requires the LARGE bolt pattern typically found on Cobras (surprise... ), light trucks, and large cars (i.e.; Crown Vic)
The driveshaft flange yoke that is needed to install the IRS rear in a V6 is a 1310 series 3x3" square (4-1/4" diag) large bolt pattern flange yoke with a 2" female pilot hole. The only place I was able to find one online was a place called Denny's Driveshafts. However, if you have a driveshaft shop nearby, it is a fairly common part that I am sure they can order or may even have in stock. Expect to pay around $40.
This is, of course, if you have a 1310 series u-joint. If you have upgraded to a larger 1330 or 1350, then you will need the 1330 series flange yoke. The important thing to note is that it requires the LARGE bolt pattern typically found on Cobras (surprise... ), light trucks, and large cars (i.e.; Crown Vic)
I'm still here! Still waiting for that write-up haha - no worries, I understand how long things like that can take. I'm just happy you are sharing your experience on this rather difficult task!
__________________
YELLOW JACKET = 1998 Chrome Yellow V6
POWER: BBK CAI, TB, UDPs; Bosch Platinum +4 plugs
BEAUTY: black projector headlights, taillights, and mesh grille; 5% tint; shorty antenna; interior billet
ROLLERS: XXR 006 black spoke with blue lip; 18x8.5 & 9.5; BFG KDW/2 245/40R18 & 275/35R18
DRIVER: Jonathan, 6'2, 190 lbs
RIDER: my wife, 5'4 brunette hottie and my 1st baby on the way...
In 03 they changed the diff to a shorter casing. In fact, they made numerous changes in the geometry of the rear so much so that it might as well be a different rear altogether. To be honest, I don't know what they used in 03. But I have a feeling it is the same 4" x 4" square bolt pattern. You would have to measure it to be sure. Ford made two...one was 2.5" x 2.5" (came on the v6) the other was 3" x 3" and came on the GT and Cobra. Both have 2in pilot holes and are made by Spicer but only available through Ford. I don't think you will need new u-joints, they should be 1330 series on your car. You will need Cobra brake lines and a custom brake hose with a 4.7mm bubble thread metric TEE on the passenger side that goes between the calipers. V6's did not come with traction control, Cobras did...meaning 2 individual brake lines going to the back of the car Vs. our one.
I am nearly done with my swap and now just need wheels.
Soon as I am done...write up.
Also, I will gladly help you in any way I can.
-Zach
Last edited by Zach'sV6; 10-09-2009 at 03:54 AM.
Reason: Typo - spelling error
First off what year mustang do you have?? That IRS will only fit 99-04 models.
Hmm with a bit of Fab they will fit into just about any "fox-esk" chassis, saw a great install into a 88 TurboCoupe that make me second guess the 8.8 install into my 86 TC
In 03 they changed the diff to a shorter casing. In fact, they made numerous changes in the geometry of the rear so much so that it might as well be a different rear altogether. To be honest, I don't know what they used in 03. But I have a feeling it is the same 4" x 4" square bolt pattern. You would have to measure it to be sure. Ford made two...one was 2.5" x 2.5" (came on the v6) the other was 3" x 3" and came on the GT and Cobra. Both have 2in pilot holes and are made by Spicer but only available through Ford. I don't think you will need new u-joints, they should be 1330 series on your car. You will need Cobra brake lines and a custom brake hose with a 4.7mm bubble thread metric TEE on the passenger side that goes between the calipers. V6's did not come with traction control, Cobras did...meaning 2 individual brake lines going to the back of the car Vs. our one.
I am nearly done with my swap and now just need wheels.
Soon as I am done...write up.
Also, I will gladly help you in any way I can.
-Zach
Ok, thanks for the clarification. I'll have to check and make sure it is the 4x4 bolt pattern. I'm pretty sure my car has individual brake lines going to the rear. My car has ABS and traction control. I remember reading somewhere that I should be able to re-use my stock brake lines.
No, you won't be able to use the stock brake lines. You can use the stock calipers but not the brake lines. Look at the pictures. In the first picture, you can see Cobra brake line (upper) and V6 line (lower). The cobra line is almost all hose and has a mounting bracket halfway down it's length to attach to the upper control arm. The V6 line is shorter and half steel and has no such bracket. The stock lines V6 lines do not connect to the upper control arm and therefore do not follow the arm as it moves up and down which can lead to interference with the CV joint and overextension at full travel. The cobra lines are $14.99 each at most part stores. $30 ain't too much to ensure properly functional brakes.
However, you can use your original e-brake cables. They fit just fine.
Oh, and it's a 3" x 3" bolt pattern that should be on Cobras...
not 4" x 4"...that's only on LARGE trucks. The 4" x 4" description was a typo...sorry.
Sort of. You need to use the cobra ABS sensors, which are mounted near the diff. But you can cut the wires that lead from your V6 ABS sensors and splice together the wires to the Cobra ABS sensors. Brown wire to Brown wire, black to black...and you'll be fine.
The sensors themselves are not interchangeable, different mounting points. So leave the Cobra ones where they are, cut your old ones off, and connect your wires to the Cobra wires.
man this is awsome but what if you dont have abs just dont plug into anything willl it still work or will you have to find a corba that didnt have abs ... is that possible ??
If you don't have ABS, then it just makes the swap that much easier, fewer wires to run. You don't have to have ABS to use an ABS rear end. You would just have two rings on your rear near the diff that aren't hooked up to anything.
It took a while, obviously. Longer than I expected but that was a all due to a health dose of my personal ability to procrastinate mixed with a lack of time and topped off with parts delays. Yay...
But...it IS done and DRIVING!
This is how the car is set up now:
V6: Bone stock
Tranny: Bone stock
Exhaust: 1/2 of stock Cobra (see pic, yeah...it's temp, but I am doing something different)
Front/Rear rims and tires: Cobra 17x9's with GY Eagle GS F1's
Front Struts/Springs: Gabriel Ultras (no shooting at me please, they are temps)/Stock v6 Springs
Rear Shocks/Springs: Bilstein for Cobra IRS/Stock 99 Cobra springs
Rear end: 3.27:1 8.8" IRS (99 Cobra donor)
First impressions:
What a humongous difference in practically everything about the car. It handles better, rides better, looks better. Really, it doesn't even feel like a mustang anymore. It is glued to the road. I cannot make this thing break loose in turns, it just kind of drifts out a little bit if I REALLY push it hard.
Launches: I have posi now so it hooks up better, way better. People say there is wheel hop inherent to the IRS but I haven't noticed. I don't know that a stock V6 can really flog the rear enough to bring wheel hop about. And really, this whole project was more about improving the handling of the car on a road course anyway.
I'm still getting the feel of my new and improved car so my impressions may change over time, but so far....I love it. Worth every long hour, knuckle I busted, mosquito swarm I encountered, and penny spent.
YES, the write up is happening. I was spending more time trying to finish the car than writing, but now the car is done and my work, my real work, can finally be completed. For all of you waiting, I have imposed a deadline on myself of later this week.
and my 1st baby on the way... 
), light trucks, and large cars (i.e.; Crown Vic)
Still waiting for that write-up 
8.8 IRS(for teh winz)
