Fulltext TSBs

Technical Service Bulletins

TSB
96-12-9
  • NOISE – “CHATTER” DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING – TRACTION-LOK DIFFERENTIAL – 7.5 AND 8.8 INCH RING GEAR REAR AXLES
  • AXLE – NEW SERVICE KIT AVAILABLE FOR TRACTION-LOK DIFFERENTIAL – 7.5 AND 8.8 INCH RING GEAR
  • AXLE – TRACTION-LOK DIFFERENTIAL – 7.5 AND 8.8 INCH RING GEAR – “CHATTER” NOISE DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING
Publication Date: JUNE 3, 1996

FORD:
1989-1996 CROWN VICTORIA, MUSTANG, THUNDERBIRD
LINCOLN-MERCURY:
1989-1996 COUGAR, GRAND MARQUIS, TOWN CAR
LIGHT TRUCK:
1989-1996 AEROSTAR, BRONCO, E-150, RANGER
1989-1997 F-150
1991-1996 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 NUMBERPART NAME
F5ZZ-4947-BAClutch Pack Replacement Kit – 7.5″ Ring Gear Traction-Lok Differential
F5AZ-4947-BAClutch Pack Replacement Kit – 8.8″ Ring Gear Traction-Lok Differential
EOAZ-19554-AA242 Loctite Threadlocker
F1TZ-19580-BHigh 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

OPERATIONDESCRIPTIONTIME
961209AReplace Traction-Lok Differential Clutch Packs – Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger1.4 Hrs.
961209BReplace Traction-Lok Differential Clutch Packs – Thunderbird/Cougar2.9 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
400156

OASIS CODES:

509000, 597997, 702200, 702300