DEFYING NATURE
August 14, 2024
THE AUTO BUILDER
Featured
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Spotlighter
Narrowed Rear
Measuring and Assembling a Pro Street-style Differential
Author
Jeff Tann
Story & Photography
The Build Begins: A Fast and Nasty ʼ54 Chevy Truck
When this ʼ54 Chevy truckʼs owner started building it, he wanted it to be fast and to have a nasty appearance. He always liked the Pro Street style, so that is the direction he decided to follow. He started by ordering a custom back half that was narrowed and set up with a narrowed rear differential with coilover shocks, a Panhard bar, and ladder bars. In order to complete the back half, the car was delivered to Dream Cars, where the suspension was installed.
Strange Engineering Ford 9-Inch Center Section
The truck was outfitted with a Strange Engineering-prepared Ford 9-inch center section that features 3.73:1 gears and a Traction-Lok unit. Strange also built the strong axles that should be able to hold up to the torque produced by the big-block Chevy engine.
Assembling the Differential for a Big-Block Engine
The back half came in kit form with a narrowed Ford 9-inch differential housing. It was Dream Carsʼ job to get the parts that were needed to finish the differential. Since this car is going to be powered by a 547ci big-block Chevy engine, the differential had to be equipped with racecar-strong parts. First, a Strange Engineering-prepared Ford 9-inch center section was ordered with Traction-Lok (limited slip) and 3.73:1 gears. Before the axles could be ordered, the differential center section had to be installed so the axle length could be measured. Ford differentials have an offset pinion, and that means one axle will be longer than the other.
Measuring and Installing the Axles
Dream Cars began by installing the Ford centersection and then measured from the splines in the differential to the outside of the housing to get the correct axle length. After the measurements were made, a heavy-duty differential was ordered from Strange Engineering, along with the corresponding axles. The axles are super-strong racecar units that should be able to hold up to the torque and horsepower produced by the big engine.
Adding Stopping Power: Wilwood Disc Brakes
This truck will have plenty of “go” power with its healthy Chevy engine, and that means it should also have ample “whoa” power. Dream Cars suggested using a new Wilwood disc brake system with internal emergency brakes. This will be used in conjunction with large Wilwood disc brakes on the front suspension. We will show you how Dream Cars assembled this rearend from start to finish, and in the process, we will also show you how the brakes were installed.
1. The truck was outfitted with a Strange Engineering-prepared Ford 9-inch centersection that features 3.73:1 gears and a Traction-Lok unit. Strange also built the strong axles that should be able to hold up to the torque produced by the big-block Chevy engine.
2. The axle housing was set up in the chassis and was ready to accept the centersection. Before it was installed, the mating face was coated with high-temperature silicone.
3. Then the differential gasket was installed. The other side was also coated with silicone to improve the sealing properties.
4. The super-strong Strange Engineering differential was lifted and installed on the studs in the differential. It is important to do this carefully so the studs do not get damaged in the process.
5. It is important for the differential to seat properly on the studs, so a little persuasion was used. The case was tapped lightly to make sure it was evenly set all the way around.
6. Nuts and washers were installed fingertight on the studs to make sure that the studs were not damaged. In this case they were all fine, but a thread tap was on hand just in case.
7. The differential nuts were tightened with a 9/16-inch socket wrench. It is a good idea to tighten them from the center outward, similar to torquing a head or installing an oil pan.
8. The axles were measured to find the correct length for each side. This is the same way the differential was measured to determine the axle length before it was ordered from Strange Engineering. This side measures 18 inches.
9. Since Ford pinions are offset, one axle will always be slightly longer than the other one. The axle on this side measures 20-1/2 inches.
10. The axles were measured to make sure they were the correct size. This one was perfect. Note that the splines are 2-1/2 inches long, so if the axle was a little longer than necessary it could be altered to fit.
11. The axle seal was installed next. Before it was installed, the seal was coated with white grease.
12. The bearing that was supplied with the axles was installed next. Remember that there are different bearing sizes, so bearings must be ordered to match the housing’s axle diameter.
13. Finally the bearing collar had to be installed. The collar has a press fit and keeps the bearing in place.
14. The collar and bearing were pressed onto the axle prior to installation in the axle housing.
15. After the parts were in place the lug nuts were installed in the axle. We recommend doing the installation with an impact gun.
16. Deceleration is as important as acceleration, so the truck was outfitted with Wilwood disc brakes that have an internal parking brake system. This kit is designed to fit the Ford 9-inch rearend.
17. The small brake assembly was installed on the axle tube. It will be held in place with the U-style keeper ring after the axle is installed.
18. Before the axles were installed, the bearing was coated with high-temperature silicone.
19. The axle was installed, and care was taken to seat the bearing and grease the seal. Note that the flange is drilled for Ford’s 5-on-4-1/2 and GM’s 5-on-4-3/4 lug-bolt spacing.
20. The U-style keeper was installed and the bolts were tightened one by one. There is a hole in the axle flange that makes the installation of the bolts much easier.
21. The unidirectional and cross-drilled rotor was installed next. It is held in place with three flathead screws.
22. A close look from the inside of the unit reveals the special caliper mounting bracket and the bracket for the emergency brake cable.
23. Using the high-strength bolts supplied in the kit, the caliper was secured to the bracket. It would be a good idea to use Loctite for this application.
24. The brake pads were installed in the calipers. They simply slip in from the top of the caliper.
25. After the pads were installed, they were held in place by a large cotter key.
26. Here is the finished brake assembly. It will provide excellent stopping power, plus it looks nice and adds to the truck’s high-performance styling.
27. Here is the rearend assembly that is set up racecar-style, with adjustable ladder bars, two coilover shocks and plenty of bracing on the axle housing.
ARTICLE SOURCES
Dream Cars – CLOSED
8300 Austin Ave
Morton Grove, IL 60053
847/663-1701
Wilwood Engineering
4700 Calle Bolero
Camarillo, CA 93012
805/388-1188
Dream Cars – CLOSED
4265 Apricot Rd
Simi Valley, CA 93063
