Early MK4 IRS question / concern

[MPTech]

I bought my kit just after the MK4 was released 2011, with the old IRS (T-Bird) configuration.
When the axles were shipped, FFR provided a spacer with the setup. This seemed like a shortcut to me at the time, but there wasn't a long-term fix. I didn't like it, but was told it would not compromise the setup. Installing the FFR supplied spacer moved the bearing shield away from the bearing and essentially useless.
Well 10 years / 30k+ miles later, unprotected, the DS bearing is shot. I replaced it. (not fun having to disassemble and drop it off to have it pressed out). Re-assembled it, but I'm concerned about the new, unprotected bearing. AND I'm probably going to remove and replace the PS for peace of mind. The way it is manufactured, the spacer cannot be installed after the bearing

My question/concern, as you can probably already tell, is this compromise solution. I remember hearing at the time that there was a mistake when FFR ordered the axles from the manufacturer and they were delivered too short.
Has anyone else had this issue? Is there a better solution?? What is the risk / danger of removing the spacer? Premature wear? I'm personally familiar with the risk of running the spacer with literally nothing to protect the bearing.

[rich grsc]

I'm going to jump in here.
Mark & I are good friends, I help him wrench on his car anytime he needs it. I help him spend $$$$$ all the time. :rolleyes: In fact I introduced him to my engine builder. :cool::D We have the same vintage of IRS, except mine is in a MKIII. This is a question because we happened to have them apart for repair at the same time. His because of the hub bearing failure, mine because of play in the Tri-lobe in the center section and the outer CV joints. I DO NOT have a spacer, he does. This spacer fits on the outer CV joint stub shaft, before the the shaft passes through the bearing in the hub. As Mark says the spacer keeps the dirt shield/oil seal a 1/4" away from the inner bearing in the hub. On my setup this seal runs right against the inner bearing, preventing dirt and water spray from contacting the bearing.
I recommenced ditching the spacer, I think Marks concern is with moving the tri-lobe bearing's out an extra 1/4" in it's housing.

[MPTech]

Yes! Thanks Rich, I couldn't think of the name: Bearing Shield.
And yes, my concern is running without the spacer causing premature wear of the tri-lobe. (I know that running without the shield will cause bearing failure).
Thanks Rich

[rich grsc]

You're welcome. Now about that CC number you promised..:rolleyes:

[kgkeys]

The reason the spacers were originally provided, was because there were a couple of instances, where the tri-lobe exited COMPLETELY from the plunge-joint, damaging all sorts of stuff. I wouldn't recommend removing it... I'll see if I can find one of the threads of the guys that had a separation.

Kyle

EDIT: Here's the thread I was looking for:
https://www.ffcars.com/threads/irs-cv-joint-popped-out.292076/

[Jacob McCrea]

^That is what I remember as well. I believe it happened to Karen S.'s Type 65. I have the spacers in my Type 65 and wanted extend the track width via the rod ends, but was afraid of nullifying what the spacers are there to do.

Maybe the track width could be adjusted inward 1/4" on each side, to accomplish what the spacers are there to do.

[rich grsc]

I forgot about that post. As was noted in it, the tri-lobe needs to be assembled on the shaft correctly.

[MPTech]

The reason the spacers were originally provided, was because there were a couple of instances, where the tri-lobe exited COMPLETELY from the plunge-joint, damaging all sorts of stuff. I wouldn't recommend removing it... I'll see if I can find one of the threads of the guys that had a separation.

Kyle

EDIT: Here's the thread I was looking for:
https://www.ffcars.com/threads/irs-cv-joint-popped-out.292076/

WOW!! I'm impressed you found that 11 year old post!
Yep, that's the one! Rich & I were both engaged in the post conversation. The issue mentioned there didn't cause a failure on the half-shaft, but I do believe it contributed and accelerated the bearing failure.

[CraigS]

Ya, I remember that too. I was a Lexus dealer tech at the time and one of the front wheel drive models had that tri=lobe joint. I remembered the lobes being about half way in the outer housing w/ the car at normal rest. But the FFR setup had the lobes maybe 1/4 way in. That did not seem right to me. OTOH, even though it is a pain right now, getting 10 years out of the bearing isn't really all that bad. I'd leave the spacer.