Though I have started other threads I wanted to make a more complete thread. Long read. Long sad story. 
The beginning.
2007 GT
74,000 miles.
4.10s in stock 8.8.
Heads cams 380rwhp 350rwtq
BMR lowers relocation brackets
Metco Adjustable Upper
BMR panhard bar
Spydershaft
Car had 4.10s put in place of the 3.55s in october of 2007 with 32,000 miles on it. No problems. $40 install kit used.
A vibration was noticed in the car in February of 2008 after NSR cams, Long Tubes and prothane motor mounts. Highway vibration. Wah wah wah at cruising speeds. No noise.
Assuming the vibration was motor mount related it was ignored.
After getting tired of the vibration after many months the stock driveshaft was put back on. No change in the vibration. The stock pulley was put back on in replace of the steeda pulleys. No change in vibration.
In october of 2008 after the install of ported heads and cams and a discussion with the shop doing the work they thought the vibration was rear end related and disasembled the rear.
Only one small chip in a carrier bearing was found but since the rear was apart we replaced all bearings.
Vibration was still there.
Since the stock original clutch was still in the car with 74,000 miles on it I decided to replace the clutch and inspect the flywheel.
Spec stage I was ordered and appointment made for the following Thursday for the clutch to be installed. In that weeks period a leak in the pinion bearing developed. I called the shop that rebuilt the rear and that was going to install the clutch and they said it should be alright until thursday as the leak was fairly minor. A drip.
Thursday comes and the car is droped off for the clutch and pinion seal. car is picked up thursday night and taken to Summit Point raceway on friday morning.
After the third 20 session on the track I saw a lot of fluid on the right side of the axle running down the relocation brackets. I left the track early and drove home to Ellicott City MD from WV about 1.45 hours.
5 miles from home the rear snaps and starts to howl with smoke pouring out. I grind it another 1 mile to a ford dealership and leave it.
Pinoin bearing is welded to the housing everything is melted.
A new take off 8.8 is ordered from new takeoff.com with 4.10s installed. Arrives and is installed a week and a half later on a wednesday. Everything from the axle vent and spring seats have to be reused on the new housing from the old housing.
Friday I'm scheduled for summit point raceway again. I take the car to the track. As I get into sheppardstown WV and let off the gas for the first redlight since leaving home I notice some decel whine.
Run all four sessions.
1 month later the rear starts smoking driving on the highway. It had started whining more and more about 1 week before.
The rear is cleaned out with brake free and a new ring and pinion with master install kit is used to rebuild the rear.
Its fine for about two weeks and then the whine starts.
Its re set up with another ring and pinion and fine for about 1 month and the whine starts again getting to the point of constant whine.
I order a new FRPP complete 8.8 rear with 3.73s. Its noisey almost from day one but no decel or accell whine just constant whine while maintaining speed on the highway. The noise goes away when letting off the gas or accelerating.
Two days ago I notice the fluid coming from the pinion seal again.
The car is at ford now.
The alignment of the rear was already checked by ford on saturday. Its spot on so its not thrust angle or something.
Common denominators.
SPEC STAGE one clutch is installed
K member
A arms
Heads
Spr cams
Vent is reused from original burnt up rear.
These are the very last things installed on the car before the problems started.
I have 3 suspicions looking at it.
The vent on the axle that has been repateadley reused is bad and not venting the rear properly causing it to blow out the pinion seals. Only problem with this is that there is fluid on that side of the axle as if fluid is getting out of the vent. But maybe it wont vent hot air until the fluid builds up so much that it forces its way out.
Something is wrong with the upper control arm, pinion angle something.
Something is wrong in the transmission. Cuasing a vibration that while it feels slight to the driver, is vibrating through the TWO piece driveshaft and somehow ruining pinion bearings allowing/causing the pinion to move.
But; The vibration in the car to me is an engine vibration. If the car is in nuetral, and you rev it you can feel the vibration at about 2300. Which unfortunatley is right about where 3.73s keep my on the highway.
Will be edited when and if ford comes up with something.
July 24 update.
Ok picked the car up for Ford still whining still leaking. They really didnt do anything to that anyway. They offered to put a new ring and pinion in but....for what.
They also dont have a tool to check pinion angle?
Drove to JPC, they hooked me up checked my pinoin angle its a -1. So the mystery is solved.
The also pointed out that the paint is burnt on the cover. i noticed that but I though it was just pealing. but they showed me it was burnt off. Its overheating. The rear is full of fluild.
I called frpp they told me to send them a email with all the details, when i purchased it, how many miles on it etc, and they will talk to management and see what they can do for me.
They said they might need the rear back for inspection. No problem.
He said the only reason a rear overheats is lack of fluid. Its full, its been full. He said lack of fluid or serious road racing. Never been road raced.
So there it is, nothing new.
The beginning.
2007 GT
74,000 miles.
4.10s in stock 8.8.
Heads cams 380rwhp 350rwtq
BMR lowers relocation brackets
Metco Adjustable Upper
BMR panhard bar
Spydershaft
Car had 4.10s put in place of the 3.55s in october of 2007 with 32,000 miles on it. No problems. $40 install kit used.
A vibration was noticed in the car in February of 2008 after NSR cams, Long Tubes and prothane motor mounts. Highway vibration. Wah wah wah at cruising speeds. No noise.
Assuming the vibration was motor mount related it was ignored.
After getting tired of the vibration after many months the stock driveshaft was put back on. No change in the vibration. The stock pulley was put back on in replace of the steeda pulleys. No change in vibration.
In october of 2008 after the install of ported heads and cams and a discussion with the shop doing the work they thought the vibration was rear end related and disasembled the rear.
Only one small chip in a carrier bearing was found but since the rear was apart we replaced all bearings.
Vibration was still there.
Since the stock original clutch was still in the car with 74,000 miles on it I decided to replace the clutch and inspect the flywheel.
Spec stage I was ordered and appointment made for the following Thursday for the clutch to be installed. In that weeks period a leak in the pinion bearing developed. I called the shop that rebuilt the rear and that was going to install the clutch and they said it should be alright until thursday as the leak was fairly minor. A drip.
Thursday comes and the car is droped off for the clutch and pinion seal. car is picked up thursday night and taken to Summit Point raceway on friday morning.
After the third 20 session on the track I saw a lot of fluid on the right side of the axle running down the relocation brackets. I left the track early and drove home to Ellicott City MD from WV about 1.45 hours.
5 miles from home the rear snaps and starts to howl with smoke pouring out. I grind it another 1 mile to a ford dealership and leave it.
Pinoin bearing is welded to the housing everything is melted.
A new take off 8.8 is ordered from new takeoff.com with 4.10s installed. Arrives and is installed a week and a half later on a wednesday. Everything from the axle vent and spring seats have to be reused on the new housing from the old housing.
Friday I'm scheduled for summit point raceway again. I take the car to the track. As I get into sheppardstown WV and let off the gas for the first redlight since leaving home I notice some decel whine.
Run all four sessions.
1 month later the rear starts smoking driving on the highway. It had started whining more and more about 1 week before.
The rear is cleaned out with brake free and a new ring and pinion with master install kit is used to rebuild the rear.
Its fine for about two weeks and then the whine starts.
Its re set up with another ring and pinion and fine for about 1 month and the whine starts again getting to the point of constant whine.
I order a new FRPP complete 8.8 rear with 3.73s. Its noisey almost from day one but no decel or accell whine just constant whine while maintaining speed on the highway. The noise goes away when letting off the gas or accelerating.
Two days ago I notice the fluid coming from the pinion seal again.
The car is at ford now.
The alignment of the rear was already checked by ford on saturday. Its spot on so its not thrust angle or something.
Common denominators.
SPEC STAGE one clutch is installed
K member
A arms
Heads
Spr cams
Vent is reused from original burnt up rear.
These are the very last things installed on the car before the problems started.
I have 3 suspicions looking at it.
The vent on the axle that has been repateadley reused is bad and not venting the rear properly causing it to blow out the pinion seals. Only problem with this is that there is fluid on that side of the axle as if fluid is getting out of the vent. But maybe it wont vent hot air until the fluid builds up so much that it forces its way out.
Something is wrong with the upper control arm, pinion angle something.
Something is wrong in the transmission. Cuasing a vibration that while it feels slight to the driver, is vibrating through the TWO piece driveshaft and somehow ruining pinion bearings allowing/causing the pinion to move.
But; The vibration in the car to me is an engine vibration. If the car is in nuetral, and you rev it you can feel the vibration at about 2300. Which unfortunatley is right about where 3.73s keep my on the highway.
Will be edited when and if ford comes up with something.
July 24 update.
Ok picked the car up for Ford still whining still leaking. They really didnt do anything to that anyway. They offered to put a new ring and pinion in but....for what.
They also dont have a tool to check pinion angle?
Drove to JPC, they hooked me up checked my pinoin angle its a -1. So the mystery is solved.
The also pointed out that the paint is burnt on the cover. i noticed that but I though it was just pealing. but they showed me it was burnt off. Its overheating. The rear is full of fluild.
I called frpp they told me to send them a email with all the details, when i purchased it, how many miles on it etc, and they will talk to management and see what they can do for me.
They said they might need the rear back for inspection. No problem.
He said the only reason a rear overheats is lack of fluid. Its full, its been full. He said lack of fluid or serious road racing. Never been road raced.
So there it is, nothing new.
