My 3-Link suspension guide (definitive use of spacers)

The 3-Link information for a Mk3.1 complete kit is limited, the following information is a result of the FFR manual, build school, and cobra forum threads, it includes lessons learned as I installed a Moser 8.8 rear axle into a 3-Link suspension system. The Moser axle already has the upper arm mount pre-welded to the axle.

Note: It is OK to install the caliper brackets prior to installing the axle but DO NOT install the calipers or disk as you will not be able to pass the axle through the panhard frame mount. Don’t worry about clearance, once assembled the axle will not rest on the panhard chassis mount.

1. Install panhard bar and competition traction-lok brakets to axle (pre-paint axle prior to assembly, brackets are powder coated)

2. Place axle on jack stands or use a jack to place axle in the approximate position and install lower control arms. To keep mounting ears parallel you may need to add fender washers between LCA and mounting ears (top picture), at this stage tighten, but do not torque. User upper holes for less than 400hp

3. Assemble Koni shocks; install shocks with body at the bottom, shaft up. Use equal 1.1” spacers for the upper mount. For the lower mount use the larger 1.1” spacer at the front and the 1/8” shim at the rear (2nd picture). Install the lower shock bolt from front to back.

4. Assemble the panhard bar and install to the passenger side traction-lok bracket using the following spacers. User two 0.375” spacers and one 0.25” spacer towards the front with the 0.0625” shim to the rear. Use the 5/8” washers with the bolt and nut.(2nd picture)

5. Install the panhard bar to the frame with the remaining two 0.375” spacers to the rear and no shim at the front. Check that the rod end does not binding on the weld. (3rd picture)

6. Install upper control arm with equal 0.25” spacers, for cars with less than 400hp user upper frame mounting holes. Use 5/8” washer at axle bracket.

7. Torque all bolts, check shock does not bind.

Upper control will be used to set pinion angle, panhard bar will be used to center axle.

Final note: Be careful with shock bolts and spacers, I had very soft spacers and with a torque setting of 50 ft/lb’s the spacer compressed.

Test Fit Rear Axle – 4 Hours

For those who are not aware of the variety of rear suspension options on the Factory Five roadster, these are as follows: 3 link, 4 link, 5 link (all use a solid axle) and independent rear suspension (IRS), on the Mk3.1 you have to decide on the type of suspension when ordering your kit, after a number of months considering all options I personally decided on the 3 link setup.

Basically until the introduction of a comprehensive non-donor IRS solution, the 3-link represents an excellent suspension alternative, and remains a good choice for a lower cost build.

As I am not using a donor for this build another decision concerned the axle, Ford have basically stopped manufacturing new 79-93 Fox axles with a 59.25” hub to hub spacing (this provides the best flexibility for wheel and brake choice) . The options were to salvage and re-build an axle from a scrap yard, purchase an already re-conditioned rear end or purchase a custom axle. After some consideration, I decided on the later (although the most expensive option).

The Moser Engineering 8.8 rear axle has the following technical specifications:
• The axle housing is stock 79-93 Fox Mustang width: 59.25” hub to hub.
• The axle has the 3-Link mount welded to the axle for increased strength.
• The axle housing is all new parts. The axle tubes are 3.00” OD x ¼” wall thickness DOM tubes that are pressed and welded to the center housing this makes them resist deflection 50% more than the stock 2.75” axle tubes.
• The axle housing is assembled with a 3.31 OEM gear set and a 31-tooth OEM Traction-lok differential.
• The axles are 31-spline Moser axles rated for 7,000 ft lbs., a 40% increase over the 28-spline OEM axles.
• Fox Mustang style Pinion flange
• OEM rear axle cover
• Housing and axles only weight is 120 lbs. This is 10lbs more than stock 87-93 housing and axles.

For me the major decision factor was that the banana bracket is already welded to the Moser axel.
Installation is straight forward, the only word of warning is to remember that the DS (Drivers Side) spindle needs to pass above the ¾” frame, and as such I would strongly recommend not installing the DS disk brakes prior to axle installation.

As you can see the Moser axle is not painted, next job will be a couple of coats of POR15 black gloss, before final assembly.