TSB 96-12-09 Traction-Lok Differential - 7.5" and 8.8"…

TSB 96-12-09 Traction-Lok Differential - 7.5" and 8.8" Chatter During Tight Turns, or Turns After Extended Highway Driving
Publication Date: JUNE 3, 1996

FORD: 1989-96 CROWN VICTORIA, MUSTANG, THUNDERBIRD
LINCOLN-MERCURY: 1989-96 COUGAR, GRAND MARQUIS, TOWN CAR
LIGHT TRUCK: 1989-96 AEROSTAR, BRONCO, E-150, RANGER
1989-97 F-150
1991-96 EXPLORER

ISSUE: A "chatter" noise can be felt and/or heard during tight turns or turns after an extended period of highway driving. This is due to insufficient specified friction modifier, or over-shimming of the clutch packs within Traction-Lok differentials.

ACTION: Install revised Clutch Pack Replacement Kit (F5ZZ-4947-BA for 7.5" ring gear and F5AZ-4947-BA for 8.8" ring gear), with improved friction material, in the differential after confirming the "chatter" concern with a road test of the vehicle. Refer to the Instruction Sheet within the kit for details.

NOTE: THE CLUTCH PACK REPLACEMENT KIT INCLUDES SELECTED SHIMS. IT WILL NOT REQUIRE THE ORDERING OF INDIVIDUAL SHIMS BASED UPON TEARDOWN MEASUREMENTS.

REAR AXLE ASSEMBLY IDENTIFICATION
See metal Service Identification tag for rear axle ring gear size and differential type. The identification tag is attached to the rear axle cover by means of a cover bolt.

The Clutch Pack Replacement Kit (F5ZZ-4947-BA) for the 7.5" ring gear traction-lok rear axle contains the following:
Two (2) Clutch Packs
One (1) Pinion Shaft Lockbolt
One (1) 4 oz. bottle of Friction Modifier
Two (2) Shims - 0.025" thick
Two (2) Shims - 0.030" thick
Two (2) Shims - 0.035" thick
Two (2) Shims - 0.040" thick
Two (2) Shims - 0.045" thick
One (1) Instruction Sheet (I.S. #7145)

The Clutch Pack Replacement Kit (F5AZ-4947-BA) for the 8.8" ring gear traction-lok rear axle contains the following:
Two (2) Clutch Packs
One (1) Pinion Shaft Lockbolt
One (1) 4 oz. bottle of Friction Modifier
Two (2) Shims - 0.025" thick
Two (2) Shims - 0.030" thick
Two (2) Shims - 0.035" thick
Two (2) Shims - 0.040" thick
Two (2) Shims - 0.045" thick
One (1) Instruction Sheet (I.S. #7146)

PART NUMBER PART NAME
F5ZZ-4947-BA Clutch Pack Replacement Kit - 7.5" Ring Gear Traction-Lok Differential
F5AZ-4947-BA Clutch Pack Replacement Kit - 8.8" Ring Gear Traction-Lok Differential
EOAZ-19554-AA 242 Loctite Threadlocker
F1TZ-19580-B High Performance Rear Axle Lubricant (For 8.8" Ring Gear Traction-Lok Differential - 1996 Explorer With 5.0L And 1993-94 Light Trucks With 4.10:1 Ratio)

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Vehicles And Basic Warranty Coverage For All Other Vehicles

OPERATION DESCRIPTION TIME
961209A Replace Traction-Lok Differential Clutch Packs - Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger 1.4 Hrs.
961209B Replace Traction-Lok Differential Clutch Packs - Thunderbird/Cougar 2.9 Hrs.

For other TSBs, check here.

Owner caption April 2009 · Photo 2379 of 6546