Differential bolt broken

[robmustang201528]

Broke diff bolts doing a 60 roll. 3rd to 4th gear. No wheel hop. Shifted to 4th and it broke. Bk051 with the upgraded hardware bolt kit and it still broke smdh. Spoke to BMR and the recommended the BK054 with the upgraded hardware bolt kit. Has this happened to anyone else with the upgraded bolt kit. What kind of diff bolts are your guys using? What bushings kit? Thanks

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[shogun32]

I'm working on an possible solution to this problem instead of the various bandaids - no slight intended toward BMR and Steeda who came up with the best that can be done given Ford's *STUPID* design.

In simple terms it involves counter-boring the mating surfaces and using an insert to mechanically 'lock' the 2 surfaces to each other (think locating pins). While it doesn't fundamentally change the single-shear arrangement, the load it taken by both the bolt and the insert. The bolts will also be precision shoulder bolts and not this bullshit fastener slop, grade 10 or 12 notwithstanding. BMR's total bushing replacement is the best solution currently, aside from the durometer being too high. @BMR Tech how about producing a 70'ish durometer setup?

 

[esacteksab]

Drill out the housing ear and put a bolt through it with a nut on it.

 

[robmustang201528]

Drill out the housing ear and put a bolt through it with a nut on it.

So I should go with the lethal or the BmR? I think lethal is the one you have to drill out the housing ear

 

[esacteksab]

Given the pictures, I'd go Lethal. I went Fastenal for less than $20.

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