Full Race's "Gen 2.5" Raptor build

[Zeusmotorworks]

No, the xfer case and front diff castings are supplied by borgwarner. I have a number of contacts there, will inquire if there’s any way to get a cast iron front member

So, even if I don’t get in on it (yet extremely interested), I’m sure there are plenty of people who run this platform hard enough, modified enough, to need an iron housing. Although it may be a niche market, there’s at least some money to be made there, and or at least bragging rights for a manufacturer.

 

[Zeusmotorworks]

I’ve made this happen in the automotive world, and black rifle market in the past. It’s very doable if you can find somebody with the say so to be interested.

 

[full-race geoff]

Got off a call with my friends at BW engineering, there's no available cast iron housing for the ford IFS 8.8. The only commercially available production cast iron IFS axle housing he's aware of Hummer H3 and older toyotas. The excessive option: $6000+ for a dynatrac IFS; https://dynatracdefense.com/drivetrain-solutions/prorock-60-ifs-irs/

plating that front mount + a beefy axle-girdle cover is where I will start

 

[letsgetthisdone]

Will that girdled cover fit? The stock cover is already fairly close to the steering rack.

 

[91Eunos]

Will that girdled cover fit? The stock cover is already fairly close to the steering rack.

Depends… How badly do you want it to “fit” in that space?

 

[Zeusmotorworks]

Will that girdled cover fit? The stock cover is already fairly close to the steering rack.

Good question and an interesting cover. Since this is my only Ford, didn't know FP had their version of it. Suspect if it does fit it may have to be installed and fitted off the truck for clearance to set the torque on the tensioners. I can't remember where they would land.

 

[full-race geoff]

I’m focused on building the most reliable 3.5L ecoboost engine. All these posts about spun bearings, oil pressure warning lights, cranks and oil pumps are motivating. So I bought a couple engines to disassemble and find wear patterns



First I took my gen 1 workhorse (110k miles with twin EFR6258s for 12 years!). picked up a high mileage gen 2 donor engine in poor condition. I will tear it down to inspect the internals for wear and degradation



Second, I bought a high mileage gen 3 engine. (Transporters sent me a Nissan rogue motor . Waiting on the gen3 )

Rear axle is setup with 4.88 gears. Front axle will go under the knife Friday. Will figure out diff cover clearance in a week or so

 

[mashtastic]

Got off a call with my friends at BW engineering, there's no available cast iron housing for the ford IFS 8.8. The only commercially available production cast iron IFS axle housing he's aware of Hummer H3 and older toyotas. The excessive option: $6000+ for a dynatrac IFS; https://dynatracdefense.com/drivetrain-solutions/prorock-60-ifs-irs/

plating that front mount + a beefy axle-girdle cover is where I will start

View attachment 469199
View attachment 469198

What did you do to your Raptor today? (Gen2)

Yesterday - got it back from the shop. New SVC Baja frame cut bumper, SVC FMIC, and 4 LP6s. Also got a 454 Motorsports chase rack installed. Never say never but I think the build is nearly done. Gonna figure out what other lights I want to do but other than that, it's how I always wanted it...

www.fordraptorforum.com

It can be done with the right cover.

 

[full-race geoff]

Small midweek update:

Gen2 engine torn down and documented today. Oil light was flickering when it was pulled out so I was expecting the worst. But the bottom end was in remarkably clean condition. And the oil pressure sender tested fine. I Will create a short video showing the key takeaways. Overall the Crank pulley was bad and oil pump exhibited heavy wear. I will take some close up photos Friday afternoon


It’s interesting how these oil pumps are more like power steering pumps than traditional Gerotor oil pumps. Also interesting ford did not change the design for the gen3.


Gen3 engine finally arrived at Full Race late afternoon. After getting incorrectly shipped a Nissan rogue engine, this was a relief.



junkyard front diff will get dropped off tomorrow for a new torsen and yukon 4.88s. These aluminum front axles are so lightweight and puny compared to the rear axle. It’s no surprise they break, eventually would like a beefier case


Still undecided on whether the aftermarket diff cover / girdle bolts actually do anything?

Im inclined to go with the spicer cast iron diff cover for rigidity. although I’m pretty sure the thick aluminum ford or b&m is not easy to deflect. Don’t have much time to spend on this at the moment so will keep it simple and keep moving

 

[downforce137]

junkyard front diff will get dropped off tomorrow for a new torsen and yukon 4.88s. These aluminum front axles are so lightweight and puny compared to the rear axle. It’s no surprise they break, eventually would like a beefier case

View attachment 469891
Still undecided on whether the aftermarket diff cover / girdle bolts actually do anything?

Im inclined to go with the spicer cast iron diff cover for rigidity. although I’m pretty sure the thick aluminum ford or b&m is not easy to deflect. Don’t have much time to spend on this at the moment so will keep it simple and keep moving

you'll have to take quite a bit off the ford racing cover to clear the steering rack.

if i did it over again, Id do the spicer or ARB cover, both of which confirmed to fit on this forum..