87350IROC

iTrader: (2)

I think based on the pictures on 9bolt.com that my posi cones are fully bottomed out. But my carrier looks a little different than those pictured on 9bolt.com So I'd like to confirm based on my pictures that the cones are indeed shot.

Thanks,

John

passenger side


driver side

subroc

iTrader: (2)

one side is bottomed for sure...the lower picture. The upper one looks like it has a 1/16th of an inch still or a bit less...maybe a 1/32...but its not far behind the other one. Time for a posi rebuild.

Twin_Turbo

iTrader: (25)

Looks like you found it fairly soon, doesn't look like they have been bottoming out for very long since 1 is making contact and the other is just or almost. Either way, you can simply machine the cones on the small end, mill the end off and trim down the center so they have play again. then shim it all up. The new cones need machining too since they are thicker in the splined area than the stockers (or, and that would be my choice, you'd need to machine the step in the carrier halves)

87350IROC

iTrader: (2)

Thanks for the info guys. Both sides are bottomed out. Its just hard to tell on the one side due to shadows.

I started noticing poor limited slip performance last year. Pretty bad for a car with only 70k miles and the first 50k were very easy stock miles.

I'm am looking at a lot of money now being thrown into this thing. Wish I could find a nice D44 for a fair price.

subroc

iTrader: (2)

You and me both! Ive been looking on and off for the past few years and the cheapest i have seen on go for was 700 and that was without shipping the thing. I considered it but passed just due to the logistics and money. Who would have thought three or more years later im still on the hunt.

87350IROC

iTrader: (2)

Yes I am aware of one available off a fresh rebuild for $2k. Honestly, if it had the limited slip I want, I'd probably just go for it. But another $600 for a T2R really kills the price. I would buy one for $700 in a second even if it needed some work.

midias

I was wondering are these the proper replacement cones for the 9 bolt

http://www.ebay.com.au/itm/Borgwarne...item43a2382821

Twin_Turbo

iTrader: (25)

Yes, but as you can see the outside is not stepped like the stockers, there's a ridge in the case that goes into this step. You eitehr have to machine the code or the case. I'd do the case, this elaves a lot more spline area on the cone over stock, these are much thicker.

Here's a stock cone, compare to ebay pic. Do a search on this forum, I advised another guy to do the same, he did and he posted pics of how to modify the case. He did a bang up job on it,

InfernalVortex

iTrader: (4)

Can you explain that a little better twin_turbo? Im just not smart enough to figure out what you're saying, sorry.

It just looks like they just flattened out the backside of the cone to me? Instead of it going out to a point, they just machined it down? Is that what you mean by step? It seems like other than that they're the same, but I'm confused because what I interpret to be spline area is in the center of the cone, which doesnt affect the machined down area at all?

And what spline count are our 9-bolts? NVM- counted your picture... 28.

Twin_Turbo

iTrader: (25)

I did a search for you, this is the thread

https://www.thirdgen.org/forums/tran...olt-cones.html

unfortunately the guy removed all the pics, send him a PM maybe he still has them

basically the step in the stock cone on the right in my pic is in there because of the ridge here in the case, both halves have it



cone sits in there like this


now, if you buy the ebay cones it will not fit. Take the 2 case halves to a machine shop, they are super easy to chuck up in a lathe if you pull the bearings off the ends. Then machine that ridge off the inside of the case. Later drop in the new cones, check for window clearance, maybe take some off the ends of the cones and then shim it all

Twin_Turbo

iTrader: (25)

Twin_Turbo

iTrader: (25)

Twin_Turbo

iTrader: (25)

Twin_Turbo

iTrader: (25)

subroc

iTrader: (2)

Just make sure you specify 28 spline axles.

midias

So your saying they will work?

Twin_Turbo

iTrader: (25)

Yes they work but only if you mill the case halves

InfernalVortex

iTrader: (4)

What spider gear shims are most people using? Im not sure of any Shims R Us around that I can go experiment with...

Twin_Turbo

iTrader: (25)

anything that works. I forgot the inner and otuer dims but I used stuff that I use to shim eaton diffs for corvettes and pinion shims.

J0386

So the pictures are for doing shims if the cones are bottomed out right? Anything special need done like anything need pressed in or any special tools needed? Judging from the windows on my 9 bolt looks like one side is bottomed out I have never touched a car rearend before so just want to know anything I can before I even attempt to take it apart

InfernalVortex

iTrader: (4)

Thank you for all the work you put in to help the rest of us Twin_Turbo.

87350IROC

iTrader: (2)

I agree. Thank you Twin_Turbo and others. I took my rear apart last night and will post up some pictures later.

My local Randy's Ring and Pinoin mentioned the possibility of an 04-06 GTO 9-bolt limited slip working. It has the same sized ring gear and spline count as our axles. I will be taking my case in to them within the next two weeks to see if it will work out.

Twin_Turbo

iTrader: (25)

Is that gto posi cone style or something else.

87350IROC

iTrader: (2)

No the drop in Truetrac for the the GTO Borg Warner differentials. I have heard it won't work. But I never seen evidence of anyone actually trying it.

http://www.summitracing.com/parts/DTL-912A642/

87350IROC

iTrader: (2)

Well I have my differential apart now. Took a ton of pictures but they all look like Twin_Turbo's so I wont add them here. But if anyone needs pictures of anything specific, now would be the time.

John

J0386

Are u adding shims? If so could u give me an idea on what to do and how I would go about taking apart my diff. Like any special precautions so if I do go to add shims I Dont lose anything or forget to put something back in, in a special order

SLEEPER 86

Has anyone in the US tried ordering from these guys? I checked their site out and they only list Australia in their shipping list.
I wonder what the damage would be for shipping to us? They also list new spider gear sets for $165 (I assume that is AU$).

By the way, thank you Twin_Turbo for the great pics and write up! Very timely as I am just starting a rebuild of one of these posi units.

Eric B

SLEEPER 86

87350Iroc, that's what my cones look like. No space in the window. Got mine off a board member who assured me there was 1/8" gap in the cone/case window. I don't know what he was looking at. It wouldn't have bothered me as much if I hadn't paid to have it shipped from Wisconsin to Kentucky! He offered to make good by splitting the cost of a new set of cones, that is until I told him what they cost. Never heard from him again.

subroc

iTrader: (2)

Posted this before. This is the procedure that i followed when i rebuilt mine.

http://www.geocities.ws/luckyducky.....air30Nov04.pdf

Edit..just tested and that link doesnt work...hmm not sure how to do this other than telling you do a google search for "BW 9 bolt posi cone repair". About 1/2 way down the page is a PDF that you download. Download it and it will probably answer all your questions. Its what i used for mine 2 years ago.

Twin_Turbo

iTrader: (25)

subroc

iTrader: (2)

Thats it!! Thanks. I knew it was on this board too but i looked and looked and didnt see it. Its no wonder that everyone has questions about them.

J0386

guess i should have asked this first before i get to deep into this. Do my cones look shot?

Twin_Turbo

iTrader: (25)

yes

subroc

iTrader: (2)

Cant really tell from those pictures but im going with yes as well since 95% of 9 bolts still on the road are shot. 20+ years of use and abuse is not kind to the posi cones.

J0386

I was afraid so heh guess im going to start to take it apart and shim it with all the pics and that pdf I should not have any problems....

J0386

update. seems mine already had a shim but its has been worn paper thin would i be able to add a new shim?

Twin_Turbo

iTrader: (25)

Some came stock with shims, one of mine did. They are real easy to shim, lay the cross in there w the spider gears and shim till all play is gone.

To get more life out of the cones you nee to machine them and shim what you mille off, they will sit deeper into the case that way

J0386

ok im trying to assemble it i get it all back together and both axles go right in but the gears on the inside will not turn and i dont want to tighten it and it break somthing are they not supposed to move freely? sorry for all the newb questions.. but better to be safe then sorry.

SLEEPER 86

did you did you assemble the posi on one of the axles? I believe everything has to be tightened down on an axle or the gears will never mesh.

Twin_Turbo

iTrader: (25)

the gears on the inside won't turn?? do you mean the spider gears? You have to exceed the posi break away torque to get them to turn. If it's too loose they move easily if you shim it too tight they will be very hard to move. Do realize that if axle speed difference increases gear meshing forces will force the cones tighter in the carrier in the same fashoin that a clutch posi compresses the clutch pack tighter.

Shim it until there's no play between the cross/spider gears and the case like in this pic



try to rock the cross assy in the carrier to see if all 4 sides are sitting flush

J0386

The spider gears look fine and ya I mean the spider gears so there not soposed to move freely? Only when there is torque on it? Just want to make sure Just incase

Twin_Turbo

iTrader: (25)

they only move when one axle turns faster than the other. The break away torque is the torque applied to 1 axle when the other is held stationairy that you need to overcome the cone friction. This can be set with the shimmng, more shims = tigher.

J0386

Ok so then its fine? Now im just having a hard time getting it back together again

85 ZXX

iTrader: (1)

I did a complete rebuild on 9 bolt with PBR's last year for my 85 Z and I had around 2K invested when all was said and done. I wished I could take it all back and invest in a brand new Ford 9" rear for my Z. http://www.spohn.net/shop/1982-1992-...r-Ford-9-Rear/

J0386

well my greatest fear came true a piece broke.. the top spring retainer broke almost in half am i screwed or can i get another one with out forking over an arm and a leg at 9bolt.com?

Twin_Turbo

iTrader: (25)

spring retainer???

J0386

not sure what they are really called but heres a pic.

J0386

would i be able to use a washer as long as it cleared the spider gears?

Twin_Turbo

iTrader: (25)

no, those will need to be replaced. Those cups transfer the pressure from center spring assy to the cone. Wonder how they got beat up like that

J0386

Do u know of any place I can get a new set?