[QUOTE]Originally posted by HI SPEEDR
[B]Well, that makes sense, although CompTech developed a "reinforced billet aluminum pumpkin cover" that did the job.

 

Just to add some fuel to this fire, Here is a picture of a reinforced differential cover. I have only seen them made for domestic applications. They appear to be aluminum castings, and use set screws to preload the differential carrier bearing caps. To make one for the S, would most likely take a new casting of the differential housing.

 

Ok, would you agree that if you modified the car so that it gains more horsepower, torque and you added the 4.44 rear, that the gear and pinion should be a 'heavy duty' gear set to take on the extra power with a more secure pumpkin cover? Otherwise what good is adding this equipment if it's going to blow. What would make the gear and pinion 'heavier duty?'

 

I am no expert on what fails in a S's differential. From what I remember reading people have sheared teeth of both the ring and pinion and pushed the carrier out of the housing. The comptech housing, cyro treating the housing and gears are all methods of strengthening the differential. I don't know if anyone really knows what the power level a reinforced diff can take. Maybe if someone destroys one they can replace the whole thing with a Dana 44 or 60.

 

Interesting, never saw that Ford 8.8 inch cover before. The set screws are not used for bearing pre-load, that is done with shims when you set the rear up. They're using those bolts to try to hold/support the assembly in the axle which is the purpose for the upgraded Comptech housing pieces. A cover alone won't do anything for this problem

 

I edited my previous post. Bearing preload is most definitely different than preloading the bearing caps.

 

priceless