OK, here we go... After a lot of discussion, inspection, and analysis of user failures, there's a few of us who believe that the best course of action is to seek the production of some vastly superior attachment bolts in place of the "ordinary" Ford-supplied M8 bolts.
As has been discussed here before, the primary suspicion of the root cause of the bolt-loosening and shearing problem is the fore-aft rotational play between the splines of the output shaft and the hub. This continuous movement is suspected to be the "force" which causes the bolts to loosen.
Historically, popular opinion (including my own), was that the M8 attaching bolts would eventually back our far enough so that the splined shaft could be dis-engaged. This disengagement would cause the torque load of the wheels to be completely upon two minuscule M8 bolts which would mean an instant shear condition.
HOWEVER, there has been at least one owner reporting a failure of an M8 bolt (sheared head), while the second bolt is still in place and in tact. (Obviously this discovery would be found during a preventative maintenance task since the transaxle would remain fully functional with just one bolt in place.) Furthermore, for those that have had a failure, the bolts are most frequently found sheared right where the threads meet the head. This is, by far, the weakest part of a bolt and would lend credibility to the theory that the bolts are being sheared by fore-aft fatigue and not solely because of complete loosening (and ultimate shearing because of spline disengagement).
The scariest part of this later scenario is twofold;
1. Ford has made no change to the M8 attaching bolts even in the latest repair kits they are distributing.
2. Safety wiring of the weak bolts may not be sufficient to eliminate their eventual failure.
With that said, the best "fix" for the current design would be to source superior attaching bolts to be used in conjunction with Ford's hardened washer. AMB has spear-headed discussions with ARP to manufacturer M8 bolts for our application. The material of the bolts will be vastly superior to our existing bolts and the bolts will have a shoulder eliminating the weak spot where the threads meet the head. Because of the low-production run, ARP has communicated a price of $10/bolt ($40 per car) and a 10-week availability timeframe.
Both AMB and myself are "in" and will plan to use the superior bolts from ARP.
Side Note: I have GT #1208 in 2006. Upon inspection today, my driver's side halfshaft was in perfect shape other than about 1/2 teaspoon of transaxle fluid inside the coupler. The two M8 attaching bolts were torqued tight and the updated (black) washer showed no signs of warping.
This thread is intended solely to get a show of hands of other owners who are interested in the bolts. On January 28, we will compile the list of interested parties and we will place the order with ARP on January 29. So, please post in this thread if and only if you are interested to receive the upgraded bolts. If you would like to discuss or debate any of the above info, I'd kindly ask you to cut/paste the appropriate text to the merged thread discussion on the topic.
Note that neither myself or AMB have any financial interest in this bolt replacement scenario. If costs are lower than the $10 quote, it will be passed on to everyone who is "in".
As has been discussed here before, the primary suspicion of the root cause of the bolt-loosening and shearing problem is the fore-aft rotational play between the splines of the output shaft and the hub. This continuous movement is suspected to be the "force" which causes the bolts to loosen.
Historically, popular opinion (including my own), was that the M8 attaching bolts would eventually back our far enough so that the splined shaft could be dis-engaged. This disengagement would cause the torque load of the wheels to be completely upon two minuscule M8 bolts which would mean an instant shear condition.
HOWEVER, there has been at least one owner reporting a failure of an M8 bolt (sheared head), while the second bolt is still in place and in tact. (Obviously this discovery would be found during a preventative maintenance task since the transaxle would remain fully functional with just one bolt in place.) Furthermore, for those that have had a failure, the bolts are most frequently found sheared right where the threads meet the head. This is, by far, the weakest part of a bolt and would lend credibility to the theory that the bolts are being sheared by fore-aft fatigue and not solely because of complete loosening (and ultimate shearing because of spline disengagement).
The scariest part of this later scenario is twofold;
1. Ford has made no change to the M8 attaching bolts even in the latest repair kits they are distributing.
2. Safety wiring of the weak bolts may not be sufficient to eliminate their eventual failure.
With that said, the best "fix" for the current design would be to source superior attaching bolts to be used in conjunction with Ford's hardened washer. AMB has spear-headed discussions with ARP to manufacturer M8 bolts for our application. The material of the bolts will be vastly superior to our existing bolts and the bolts will have a shoulder eliminating the weak spot where the threads meet the head. Because of the low-production run, ARP has communicated a price of $10/bolt ($40 per car) and a 10-week availability timeframe.
Both AMB and myself are "in" and will plan to use the superior bolts from ARP.
Side Note: I have GT #1208 in 2006. Upon inspection today, my driver's side halfshaft was in perfect shape other than about 1/2 teaspoon of transaxle fluid inside the coupler. The two M8 attaching bolts were torqued tight and the updated (black) washer showed no signs of warping.
This thread is intended solely to get a show of hands of other owners who are interested in the bolts. On January 28, we will compile the list of interested parties and we will place the order with ARP on January 29. So, please post in this thread if and only if you are interested to receive the upgraded bolts. If you would like to discuss or debate any of the above info, I'd kindly ask you to cut/paste the appropriate text to the merged thread discussion on the topic.
Note that neither myself or AMB have any financial interest in this bolt replacement scenario. If costs are lower than the $10 quote, it will be passed on to everyone who is "in".
