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TCI Suspension Upgrade - Get A Handle On It!, Part 2We wrap up our Falcon’s suspension upgrade project with TCI’s bolt-in four-link rear setup From the January, 2012 issue of Modified Mustangs & Fords By Mark Houlahan Photography by Ben Bryce
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Last month, we introduced you to Nick Licata and his '64 Falcon Futura that Total Cost Involved (TCI) has been using for R&D of new suspension products. We showed readers TCI's new front coil spring based double A-arm suspension system in that story. This month, in Part 2 of our look at Nick's Falcon, we'll be focusing our cameras on TCI's new Triangulated 4-Link rear suspension kit for the '60-'65 Falcon, '62-'65 Ranchero, and '62-'65 Comet. TCI's Triangulated 4-Link is designed to improve the handling of your early Falcon/Ranchero/Comet while lowering its stance via an adjustable ride height coilover shock setup. The suspension system is designed as a near bolt-in solution, requiring drilling a few holes and the welding of four housing tabs on your 8-inch axle housing (TCI offers an optional 9-inch axle housing with the tabs already located and welded in place). If you option the antisway bar, there are two additional brackets that require welding to your housing as well. The Triangulated 4-Link can easily be installed on its own, but complements the TCI front suspension already installed on Nick's Falcon very well. Remember, too, just like the front kit we installed last month, all TCI suspensions are built with U.S.-manufactured DOM steel and include a lifetime warranty as well! The Triangulated 4-Link kit, PN 527-5106-00, retails for $1,099 and includes 1-inch-diameter adjustable upper and lower links (control arms) with stainless steel adjusters, frame brackets, floor reinforcement plates, bolt-in rear crossmember, bolt-on coilover mounting brackets, and adjustable coilover shocks. TCI's option list is lengthy, including such suspension goodies as a rear antisway bar, aluminum adjustable coilover shocks, Shockwave air shocks, and a whole bevy of brake packages ranging from 11- to 13-inch rotors, all with four-piston aluminum calipers. As mentioned earlier, TCI offers a bolt-in 9-inch axle housing with drum brakes and open differential if you don't own a welder, and TCI even has optional posi units and an upgrade to a Currie-built F-9 sheetmetal housing if you want the best of the best for your build. See how it's done in the following photos and be sure to check out TCI's website for more on all the options available for their Ford suspension kits.  1 We’re starting with the...  1 We’re starting with the stock suspension already stripped from our Falcon (a good shop manual will help if you’ve never done the work before) and our 8-inch axle housing cleaned, painted, and all new seals/gaskets installed. The TCI kit will work with a 9-inch housing as well, more on that in a minute. The TCI coilover bracket is located by the axle housing’s leaf spring pad and simply bolts on with the included U-bolts. Just snug the assembly up for now.  2 Use a long piece of straight...  2 Use a long piece of straight stock, such as some square tubing, clamped to the coilover brackets to aid in aligning the brackets. With the brackets square to the housing tighten the U-bolts.  3 With the coilover brackets...  3 With the coilover brackets temporarily secured, use the bolt hole in the base of the bracket to drill a 3⁄8-inch hole through the spring pad. This will be additional mounting security to counter the forces the coilover bracket will see.  4 Unbolt the coilover brackets...  4 Unbolt the coilover brackets and rotate them 180-degrees and secure with the included Allen bolts so that you can drill the second pair of 3⁄8-inch holes in the spring perches (you won’t be able to reach the inner hole with the bracket’s design, thus the need to rotate them for access).  5 After you have drilled...  5 After you have drilled out the second pair of 3⁄8-inch bolt holes in the spring pads, rotate the coilover brackets back to their original position and reinstall the U-bolts and Allen head bolts to secure the coilover brackets for good. TCI does suggest welding these brackets to the axle housing if you can’t access the inner mounting holes on the larger diameter 8-inch axles. We’d also suggest welding on high horsepower applications as well.  6 While the majority of installs...  6 While the majority of installs will be based on the 8-inch housing we’re using in this Falcon, we did want to show readers the TCI weld-on brackets for the 9-inch application. These are primarily used with new axle housing builds and slip onto the axle tubes for welding. All dimensions are included in TCI’s well documented instructions.  7 Setting the modified axle...  7 Setting the modified axle housing aside, we can now concentrate on the rear crossmember installation. The crossmember saddle brackets slip over the rear framerails just aft of the stock axle snubber brackets. The instructions also give backup measurements to ensure the brackets are in the right location before clamping in place, drilling the 5⁄16-inch mounting holes into the floor sheetmetal, and securing with button head bolts and the included backing plates.  8 Using the included drill...  8 Using the included drill guide and a 3⁄8-inch drill bit, drill out the framerails to match the holes in the saddle brackets. You will have to drill the front hole from the inboard side of the rail and the rear hole from the outboard side for drill motor clearance. Once the holes are drilled, position the crossmember in place and slip the rear bolts through the framerail and into the crossmember on each side to hold it in place.  9 Rotate the crossmember...  9 Rotate the crossmember up to the floor of the Falcon and check for proper fit. If there are any brake line tabs that interfere with the crossmember, they will need to be removed, as the crossmember must sit flush against the floor.  10 Drill out the two center...  10 Drill out the two center bolt holes on the lower row of holes and temporarily install two 5⁄16-inch button head bolts to retain the crossmember in its proper position. Once the crossmember is secured, you can follow through with drilling out the remaining 10 bolt holes.  11 Once you’ve completed...  11 Once you’ve completed drilling out the mounting holes, the two alignment bolts can be removed and the reinforcing plates positioned over the holes in the trunk area. Secure the crossmember by installing the 12 5⁄16-inch button head bolts through the crossmember, trunk floor, and reinforcing plate to sandwich the floor sheetmetal. Secure with the included locknuts and washers.  12 Convertible owners have...  12 Convertible owners have slightly different reinforcing plates that are installed individually, as shown here.  13 At the front of the crossmember,...  13 At the front of the crossmember, there are two welded tabs that align with the OE shock mounting points in the Falcon’s floor. TCI uses the shock mounting location as additional mounting points for the crossmember by having you install these 3⁄8-inch bolts through the tab and into the shock mounting holes, which are then backed by a large washer and locknut from the other side.  14a Follow up with the two...  14a Follow up with the two final crossmember bolts at the forward ends of the framerail cradle brackets...  14b ...(installed from the...  14b ...(installed from the inboard side due to clearance issues with the snubber bracket), and the crossmember is installed.  15 At this point, all that’s...  15 At this point, all that’s left to do is install the modified axle housing and the control arms (plus the antisway bar). Begin by adjusting the lower control arms to 201⁄4 inches center-to-center length, and then install the lower arms into the original leaf spring mounts as shown with the included spacers (9⁄16-inch spacer on the inboard side).  16 Using a floor jack or...  16 Using a floor jack or other safe means, raise the axle housing up into position and install the lower control arms into the lower mounting hole on the coilover bracket and secure with the included 5⁄8-inch by 3-inch long bolts.  17 With the lower control...  17 With the lower control arms secured, the coilover shocks can be bolted up next, locking the axle housing in place to finalize the upper arm mounting points. Secure the coilovers to the crossmember and the axle housing using the included 5⁄8-inch diameter bolts, washers, and spacers.  18 The upper arms will need...  18 The upper arms will need to be adjusted to 13-7⁄16-inches center-to-center length, and then the adjuster end of the upper control arms will need to be secured to the crossmember using the 3-inch long 5⁄8-inch bolts.  19 On the solid end of the...  19 On the solid end of the upper control arms, assemble the axle housing tabs using the included mounting hardware, ensuring the longer of the two tabs is on the inboard side of the control arm (shown already welded here). The upper control arm should be parallel to the axle housing and the tabs should match the curvature of the axle housing tube. You can double check the placement by measuring from outside tab to outside tab, which should be 34 inches.  20 Before welding the tabs...  20 Before welding the tabs to the axle housing, ensure the chassis is level and affix an angle finder to the pinion yoke and use a pole jack or other suitable means to adjust the pinion angle until you have one degree upward angle. At this point, you can weld the tabs to the housing following the detailed instructions included to prevent melting the bushings.  21 Assemble the antisway...  21 Assemble the antisway bar’s mounting hardware, bushings, and lock rings per the instructions and then bolt the antisway bar to the mounting brackets provided on the TCI rear crossmember. Once the mounting brackets are tight, center the antisway bar between the rear framerails and tighten the lock rings against the flange of the urethane pivot bushings.  22 The antisway bar endlinks...  22 The antisway bar endlinks need to be assembled to a 3-7⁄8-inch center-to-center length before attaching them to the antisway bar ends. Add the stamped mounting brackets to the opposite ends of the links and position them against the axle housing as shown. Tack weld the brackets to the housing, and then remove the endlink and finish weld the brackets before reinstalling the end links and checking/tightening all suspension fasteners.  23 The finished four-link...  23 The finished four-link kit for the Falcon is ready to do battle at the next track day, and don’t think Nick isn’t going to push his Falcon hard either.
 | Total Cost Involved Inc. gives us a hand on how to change up front suspension with little worry or issue. |
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