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D1JL's Build Thread

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D1JL

D1JL

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Thread Starter #121
Today, I installed the mounts for the diffuser.
The right side mount, installs as per the instructions provided.



Then I ran into the first problem.
Because I am trying to keep my Curt hitch, I needed to cut the left rear mount so that it would not interfere with the hitch.



After installing the front mount, I see no problem in keeping the Eibach sway bar.
I will however, need to remove the evap canaster protector.
That of course is OK as the diffuser will accomplish that task.

 
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Thread Starter #122
This morning I completed the foam core pattern.



My next step was to remove the two inboard strakes.
Try not to damage them too much as they will be re-installed later.
Don't forget to knock out or drill the strake holes in the diffuser, this will allow perfect alignment.
At least two should be done in locations that will not be cut away.



Then I transferred the pattern to the Verus diffuser.
Don't forget to add reference lines.
Locate and mark the center line.
Also mark a line through the center of the rear mounting holes.




Now the diffuser can be cut out.

 
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D1JL

D1JL

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Thread Starter #126
Installing Race Version Powreflex Urethane Engine and Trans Mounts

Today I received all the parts needed to insert the race version Powreflex urethane engine and trans mounts.
I am also replacing the OEM bolt with the ARP bolt from Whoosh.
As I do not know the condition of my existing mounts after 50K miles, I decided to purchase new mounts from Ford.
This also allows me to prepare everything prior to taking the existing mounts out of the car.



If you are replacing the OEM bolt, remove it, this is not required to just install the urethane inserts.
After installing the ARP bolt, be sure to realign the mount so it is the same as OEM.
As shown below, the other three points are setting on the workbench.



Here is the engine mount after assembly.



Here is the trans mount after assembly.
Note: the assembly is correct if the text is outboard and the line marks align.

 
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Today I received all the parts to put the Powreflex engine and trans mounts together.
Also the ARP bolt from Whoosh.



Here is the engine mount after assembly.



Here is the trans mount after assembly.

If everyone’s doing it then everyone’s doing it. 👏
 
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D1JL

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Thread Starter #128
Installing the Engine Mount (Passenger side) With the 17S09 (cooling system) Update

You must support the engine.
You do not need to lift it but just keep it from falling.

For working room, remove the headlight assembly.
If you wish to remove the coolant tank then drain it.
However, it is not necessary to remove the tank.
Remove the top/rear coolant degas hose and lift the coolant tank.



You will now be able to see that there is another hose connecting the tank to the sensor assembly.
Removing this and the other hoses is a real PITA, that is why I didn't do it.



Believe it or not, there is enough wiggle room get to all of the attaching hardware of the mount.
You can then remove the mount by weaving it around the hoses.

Replace with the updated mount and reinstall by reversing the proceedure.
 
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Thread Starter #130
Installing the Transmission Mount (Driver side)

There is no rocket science here, you just need to remove parts until you get to it.
Many have modified air intake systems.
Much of this will need to be removed.
Disconnect (neg first) the battery and remove it.
You need to remove the battery box however attached to the battery box is the car's PCM.
There are two options here.
You can disconnect the two PCM connectors and remove the PCM with the battery box, or you can unbolt the PCM from the battery box and leave the PCM in the car, as I did.
Lastly you need to remove the battery box mounting tray..
If you have an OEM style air box it will need to be loose if not removed.


If you can't see the trans mount completely, you have not removed enough parts.



Don't forget to support the transmission so it cannot fall.

Remove and replace the trans mount with the updated one, then put everything back together again, in the reverse sequence.
 
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Thread Starter #131
Save yourself the trouble and replace that rubber band with a zip tie or wire tie. The rubber band will quickly deteriorate from engine heat and wither away, allowing the insert to slip out.
Thank you.
Yes, that is my plan and you are correct, it is best to add the zip tie before installing the mount.
However, I need to go and purchase the one I wish to use.
I am also waiting for a reply from Powerflex (called today) as to what they suggest and/or why they included an inferior part along with their product.
 
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Thread Starter #132
I finished the mount project by adding the zip tie.
As you can see I used a large zip tie.
My thought is that if the urethane insert can move (as assumed) then it could also work its way under a smaller zip tie.


(OEM, unmodified mount used for photo reference)

Here is the zip tie installed.
BTW: the zip tie can be installed after the mount is installed without too much trouble.



It is not extremely tight so as to prevent any movement at all but there is no way the insert slip out.
Don't worry, I will cut off the tail.
 
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Thread Starter #133
Today I finished the modifications to my diffuser and reinstalled the two center strakes.



Next I will be making a blind nut for the three forward mounting bolts.
This will make the installation of the diffuser much easer because my Eibach sway bar takes much of the same space.
 
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Thread Starter #134
Diffuser Install Complete

I completed the install of my diffuser.
For those that are interested here is a photo showing the space the twist beam and the diffuser with the Eibach sway bar installed.




Here is the completed install.



There is more to come.
 
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Have you considered a belly pan? I thought I saw one on the forum somewhere but I cannot find it. I’ve been thinking about building one out of ABS to see if I feel a difference. I also wondered how I’d finagle a diffuser around my Curt hitch and tie it in to the pan.. Thanks for this idea.
 
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Diffuser Install Complete

I completed the install of my diffuser.
For those that are interested here is a photo showing the space the twist beam and the diffuser with the Eibach sway bar installed.




Here is the completed install.



There is more to come.
Wing wang thang? 🤫
 
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Here is the engine mount after assembly.
Note: the ridged side of the urethane insert goes up to mate with the rubber of the OEM mount.

jDBr2RI.png

According to the PowerFlex instructions, the textured surface is supposed to face down and touch the lower half of the mount. They word it very confusingly, however, and the printed instructions provided have photos with the resolution of a vaseline-smeared potato.

Here's a better image from their online install guide, where you can see the ridges on the insert facing the lower half:
Untitled.jpg

The digital instructions can be found here.

However, I'm not entirely sure what difference it will truly make.
 

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