1966 Ford Galaxie 500 XL Refurbishment : 098 Custom LIghted Window Switches - Design, CAD and Assembled


2023, November 14

part 1 - part 2 - part 3 - part 4 - part 5 - part 6 - part 7 - part 8

Hello,

Thought I'd like to conclude this thread in that I am almost completed with this project and others spawned from replacing the GM axle with a Ford 9".

I believe I left off on working on the upper control arms.

Next I took a spare set of 3rd gen galaxie lower control arms and cut them down to the size and temporarily welded them to approximate the final set I would need to make.

The galaxie lower arms are very similar to the GM ones, the only difference is the GM arms use a much larger and wider bushing than the Fords. This is probably because the car weighs 1000+ pounds more.

Another problem with correcting the pinion angle are the shock mounts are too tilted.

I sliced the inside section and bent them in line with the natural position of the shocks.

Next I needed a mount for the hydraulic line to the axle. I prefer to use OEM parts whenever I can. I am using the '73 GM hose and making a mount so I can use a Ford brake line bracket.

I pillaged this old hose and the propshaft end replete with a CV joint from a 1969 Lincoln in the junkyard.

Completed hose mount.

I had a wild idea whilst I stumbled over the Lincoln in the yard. My idea is I wonder if I can mate the back half of the Lincoln CV joint to my GM propshaft CV joint and put the companion flange on the 9" and I wonder if the extra length would save me from having a new propshaft made.

Just might work on the distance at least.

My old crusty GM CV joint.

Same ball and socket and same Cardan joints used. I think this will work.

Perfect fit.

I Installed a sleeve n seal on the flange first because of wear. Then temporarily installed.

Under worst case conditions the slip yoke is about 5/8" of an inch further out than normal. I can live with that for now. I realize my intention was to correct the pinion angle and rid the CV for simplification. However I plan on an over drive transmission for the car and the 4L80E will be about 2 inches shorter than the TH-400 now. So I'll need a new propshaft at that point regardless.

The 4L80E is like the 4R100 replacing a C6.

Click here to continue to part 6