The rear end is from a 96 Explorer. It has 3.73 gears and traction lock. I checked ring and pinion clearance, replaced the seals and lube. I installed all new (or rebuilt) brake parts. It does have about 2" pinion offset to the passenger side, but it calculates to about 2 deg. on each end with a 50" drive shaft. I'm using the two-piece drive shaft from an 06 Mustang GT, which has CV joints on the back end, so the offset should not be a problem.
I cut off the sway bar mounts to clean up the rear end. I moved the spring perches out to the correct width for the Mustang. To get the proper pinion angle I cut off the perches, mounted the rear end in the car with the u-bolts a little loose. I put the car on jack stands to level it, then raised up the rear end to load the leaf springs. I used a jack to raise the pinion to the proper angle (-3 deg) and tack welded the perches in place. I then pulled the rear end out again and welded the perches all around.
I also cut off the mount for the damper like this guy did (not my photo).
I bought new Explorer brake hoses and made the line between them. I ran new brake line down the driver's side frame rail and subframe connector. The hose from the rear brakes connects to the brake line on the driver's frame rail near the top of the arch over the rear end (clearing the shocks and exhaust).
I changed the Explorer flange to the 06 Mustang GT flange to work with the GT drive shaft (CV joint).
Leaf springs are Maier Racing 165# and don't need traction bars since they are front biased. I used poly bushings in the front and rubber in the rear (per Mike Maier's recommendation). Mike was right - no wheel hop, but the ride is pretty stiff.
I bought new emergency brake lines for the Explorer. The left side is a short line so I bought 2 of those and made brackets to connect to a floor-mounted handle from an 89 Mustang. I'm not crazy about the location and will probably use the under-dash handle when I can figure out a cable assembly for it.
I tried some 05+ Mustang Bullitt wheels but they were too close in the back and too tall in the front. I got some 03 Mustang Bullitt wheels with 245/45 17s in the back and 225/45 17s in the front. They fit just right in the back and have a 1" spacer in the front. These were taken before the car was loaded down and settled. It dropped about 1" all the way around.
