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Installation Instructions S197 Mustang Watts Link System Bolt-In Type

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Installation Instructions S197 Mustang Watts Link System Bolt-In Type Sonoma, CA • Boise, ID • 83704 • p: 415.489.0866 Installation Instructions S197 Mustang Watts Link System Bolt-In Type 2005-2014 Mustang Shelby/Boss/GT (8.8 inch Rear End) Including Convertible* Congratulations on your purchase of a CorteX Xtreme-Grip Suspension System. Through professional engineering and extensive testing both on the street and race tracks such as Sonoma, Thunder Hill, and Laguna Seca with record setting cars, we’ve created a system that delivers unsurpassed handling with minimal modification to your Mustang. We wish you much success! While the Xtreme-Grip Watts link system is designed to be minimally invasive, due to the technical nature and specialized equipment required, professional installation is recommended. Go to www.CorteXracing.com for a list of approved installers. CorteX engineers suspension systems designed for ease of installation, however we do not guarantee proper installation by shops other than our own. If you choose to attempt installation of the system yourself, please carefully review these instructions to determine whether you have the tools and experience necessary before beginning disassembly. A factory Ford service manual should also be consulted for disassembly/reassembly details and Original Equipment Manufacturer (OEM) bolt torque specifications. For technical assistance or questions please call CorteX Precision Technology at 415.489.0866 * Convertibles can utilize the watts link although it may not Be possible to use all the watts link adjustment positions and still clear the OEM trunk Bracing. Clearance will depend on which rear shocks are used and how much droop travel the shocks allow. © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 1 of 14 Contents Getting Started ............................................................................................................................................ 3 Xtreme-Grip Watts Link Installation Instructions ........................................................................................ 4 APPENDICES - Xtreme-Grip Watts Link Exploded View ......................................................................... 14 © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 2 of 14 CAUTION: Installation of the Xtreme-Grip Watts Link systems requires working under your Mustang. It is the responsibility of the installer to ensure a safe working environment. The use of an automotive lift is recommended, though installation is possible with use of floor jacks. In either case, always ensure that the vehicle is safely supported with multiple jack stands, and always wear appropriate safety gear and safety glasses. Getting Started TECHNICAL NOTE: When installing full suspension kit, installation should always be performed beginning with the rear suspension followed by the front suspension. 1. Disconnect the negative cable from the battery. If welding is to be performed also disconnect the PCM connections. 2. Place vehicle on chassis lift. If a lift is unavailable then raise vehicle with floor jacks and support unibody at lifting points specified in the Ford service manual. 3. Remove the rear wheels. 4. With the rear suspension in full droop, position two jack stands under the rear axle with one at each axle tube just inboard of the cast iron center section. Figure 1: Supporting the Rear End Housing. © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 3 of 14 Xtreme-Grip Watts Link Installation Instructions 1. Read the “Getting Started” Instruction Section and complete tasks 1-4. 2. Have the following on hand before you begin: a. 4 quarts of appropriate gear oil b. Friction modifier if you have the OEM clutch type differential c. Permatex ® Ultra Grey High Temperature RTV Silicone Gasket Maker Can (85084) d. Permatex® High Temperature Thread Sealant (59214) for NPT threads 3. Familiarize yourself with the diagram in Appendix A. 4. Remove OEM rear anti-roll bar. Figure 2: Anti Roll Bar Being Removed. 5. Remove Panhard bar from vehicle. If you are using lower control arm relocation brackets that rely on the panhard bar axle bolt for mounting you must install a shorter bolt to re-attach the upper axle mounting point. This bolt is included with our Lower Control Arm System, CLCA-40-1000/S, however if you are not installing this system you must source your own hardware. 6. Remove body diagonal brace (above axle). © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 4 of 14 Figure 3: Panhard Bar Diagonal Brace Removal. 7. Using the OEM diagonal brace bolts, install the watts tower bracket and the support bracket (Item 20, APPENDIX A) to the driver side frame rail in the location of the original brace bolt holes. The M10 OEM bolts pass through both the watts tower and support bracket (Item 20, 30). Also insert the M12 stabilizer bar bolt through the frame mounting bracket and support bracket to ensure later alignment. Figure 4: Initial Fitment of Drive Side Watts Tower. 8. With the driver side bracket is installed, move to the passenger side. Install the passenger side bracket (Item 8) into the OEM panhard bar frame mount shown in Figure 5. The bracket attaches to the panhard bar and brace mounting holes. The bottom bolt (originally the panhard bolt hole) also attaches the diagonal brace so be sure to slide the bolt through the brace first. With the bolt started, but not tightened, the brace can hang in the vertical position until it is time to attach the opposite end to the watts tower. Leave all bolts loose until all hardware is in place. Torqueing all fasteners will be done at the very end. © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 5 of 14 Figure 5: Passenger-side Watts Bracket. 9. Adjust the depth of the rod end on the driver side of the diagonal brace so that the ½-20 bolt slides through the brace and the watts tower with minimal resistance. Snug, but do not torque both diagonal brace bolts. Once all these items fit correctly, go back and tighten the two OEM watts tower bolts to the specified torque of 46 ft-lb. Figure 6: Watts Tower Installed. © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 6 of 14 10. As an optional step, the watts tower can be welded to the frame driver frame rail. Welding is recommended but not necessary since it creates a more rigid, maintenance-free connection. Competition vehicles that do not plan to switch back to the OEM panhard bar should consider this option. If welding will be performed ensure the PCM connections are unplugged before beginning to protect the vehicle electronics from possible damage. Figure 7: Creating a Welding Ground Connection (Optional). 11. If performed, the welds should be 3/16-inch lap welds at least 1 inch long positioned on three sides of the bracket frame plate ideally at the plate edges across from the two M10 bolts. Figure 8 shows an example of the procedure. Figure 8: Welding of Watts Tower (Optional). 12. Place an oil catch pan underneath the differential, remove the OEM differential cover from the rear end housing. Drain all of the oil and extract any leftover oil from the bottom of the housing so that it stops oozing and the sealing surface can be cleaned complete. Clean the rear end sealing surface thoroughly so it is free of © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 7 of 14 any debris or grease. We suggest the sealing surface be prepped with brake cleaner as a final step before applying sealant. Figure 9: Cleaned and Prepped Sealing Rear End Surface. 13. Remove the CorteX rear end girdle cover from the box and find the supplementary instructions included. Familiarize yourself with these instructions. Except for the drain plug, which has an o-ring, remove all thread-in plugs from the cover and apply a high quality, thread sealant to each and re-install back into the cover. 14. Ensure the inside of the girdle cover is clean of all debris. We suggest using an aerosol solvent such as brake cleaner followed by blowing out the inside of the girdle cover with a high-pressure air nozzle. Always use safety glasses and point the nozzle away from you. 15. Carefully apply a thin layer of high temperature RTV sealant to the sealing surface of the cover. Note: A rear end cover gasket will not be used. (See Figure 10). Figure 10: Applying Sealant to Differential Cover. © CorteX Precision Technology 2009-2016 All Rights Reserved v5 Page 8 of 14 16. Place the girdle cover on the rear end housing following the instructions included in girdle cover box. Ensure all the bolts are torqued to 25 ft-lb (Figure 11). Figure 11: Torque Rear End Girdle Cover Bolts to 25 ft-lb. 17. Vehicles with differential coolers can now be plumbed appropriately using the pickup and return ports available in the differential cover. 18. The rear axle requires ventilation. We recommend the breather line be plumbed to the available tapped hole in the top of the axle tube. Remove the OEM plug and install a -4 AN O-ring fitting and plumb the fitting to a catch tank located as high above the axle as possible. This is critical if no differential cooler is used. 19. Wait the suggested cure time (per sealant manufacturer’s directions before adding any gear lube to ensure consistent sealing. After fully cured, fill the differential with high quality gear oil that meets the manufacturer’s requirements. To determine the amount of gear oil to add remove the factory fill plug located near the pinion shown in Figure 12, on the forward facing portion of the cast iron differential housing. Vehicles equipped with a clutch-style locking differential will require a gear oil friction modifier available at Ford dealerships for proper limited slip function. Make sure to add this first in the filling process to ensure enough is added. The watts differential has a larger capacity than the factory cover and holds approximately 3.25 quarts of fluid.
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