Repair done and details
Okay folks, the red car is back. Took it in this morning and it was done by afternoon. No charge, under warranty. The red car is #1170, built May 5, 2005. It had silver washers that were deformed sort of concave shape but bolts were not broken. Replacement kit as referenced in my original thread last week contains 4 bolts and two washers that are flat and are hardened. They are black in color. The repair also requires the replacement of the six main axle bolts which are torque to yield bolts that cannot be reused. They are not in the kit but are ordered separately. There is NO TSB on this problem. The only TSB for the tranny axle area has to do with lubricant leakage and applies only to the 2005 cars. That TSB is used as a guide for the axle bolt repairs and it makes it clear as does the main service manual that the six axle bolts on each side are replace items not for reuse. As an aside, I suspect that the lubricant leakage is the genesis of the later over torqueing problems (just a hunch).
I talked to the tech a long time this afternoon and he took me through all the details. He has also talked to one of the Ford engineers about the problem and it sounds like there is a good bit of debate over exactly what is causing the problem. My Tech, who is very well trained and very sharp actually thinks the concave shape of the washer holds the bolts in more flush to the inner collar of the shaft. He also told me that the when the bolts break, the only effect is no power to the wheels. The shaft does not come out and is held in place by the outer shaft main bolt. The car he repaired just prior to ours had broken the bolts but did not lose any lubricant even. The GT has a limited slip rear end but even so, the loss of power to one side will disable the car.
If any of you are close to Orlando, I strongly recommend my dealer, Don Reid Ford. I had previously talked to one of their senior techs who was clueless about the GT. I have not seen him since. I apologize though for ever doubting them. They have proven my concerns about techs training to deal with these cars to be false.
My heritage 2006 goes in for the same repairs Friday. I will post details as to which washers he finds in that car then. Good fortune to all on this problem. I do think it helped that I had autographed pictures of GTJOEY in his suit that Piccola gave me to hand out to all the female staff at the dealership.