96 gear swap
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Freshman User
Joined: Jul 2008
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From: Tuscaloosa,Al
96 gear swap
Hello to all! I'm new to the site, so bare with me. I have been searching for a couple hours. Found lots of good info, but still confused. I have a 96 f-150, 5.0,auto. I think this truck came with either 3.08 or 3.55 geared rear end. Judging by the way it drives I assume mine has the 3.08's. I have a complete 4.10 geared rear end (and many more parts) from a 93 Lightning. If I swap to the 4.10 rear, what issues might I have. Will the speedometer read correctly and or will the trans shift properly? I read that since the speed sensor reads axl rotation, that gear swap won't change speedo, but tire size will. Is that correct? Will the PSOM need to be changed or calibrated? At one time I swapped in the entire guage cluster from the Lightning. Tach,speedo, all guages appeared to work properly. After a couple days the battery went dead. Swapped back to 96 cluster, charged battery and never had any more trouble. Any feedback will be much appreciated.
Senior User
Joined: Sep 2007
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From: Iowa
There are alot of more knowledgeable folks here to confirm or correct me, but from what I understand, swapping that rear axle should not affect anything. Only thing I am not sure of is when Ford started using the PSOM (I thought it was in 92 so think you are OK)..only concern there is that they get their signal from the rear axle, not the trans. Assuming that is the case, as I understand it you are correct in that the signal comes from the axle speed so gearing has no effect, but tire diameter definitely does and you may need to reset your speedo to adjust that (it's easy...takes only a minute or two). This does affect how the trans behaves so it does need to be done if tire diameter is way different. All this is said assuming you have a 2WD truck...otherwise, obviously, you will need to swap the front gear set to match. As for your cluster swap, I swapped in a factory tach on mine but made sure was from same year truck so no issues at all and for some reason I believe it is even more critical on 96 (maybe cause first yr for OBDII?) than on 92-95 (mine's a 95).
Fleet Mechanic
Joined: Nov 2004
Posts: 1,324
Likes: 4
From: Michigan
That rear end swap is fine. The only change you get is the awsome accelleration from those 4.10 gears. You may even get better gas mileage as long as you can keep your foot out of it. I assume you're not changing wheels and tires.
The 96 cluster is pinned differently and others on this forum have had the same battery draining problem. You may be able to swap all the gauges except the PSOM. But then again, you probably want the 140 speedo.
The 96 cluster is pinned differently and others on this forum have had the same battery draining problem. You may be able to swap all the gauges except the PSOM. But then again, you probably want the 140 speedo.
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Freshman User
Joined: Jul 2008
Posts: 29
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From: Tuscaloosa,Al
There are alot of more knowledgeable folks here to confirm or correct me, but from what I understand, swapping that rear axle should not affect anything. Only thing I am not sure of is when Ford started using the PSOM (I thought it was in 92 so think you are OK)..only concern there is that they get their signal from the rear axle, not the trans. Assuming that is the case, as I understand it you are correct in that the signal comes from the axle speed so gearing has no effect, but tire diameter definitely does and you may need to reset your speedo to adjust that (it's easy...takes only a minute or two). This does affect how the trans behaves so it does need to be done if tire diameter is way different. All this is said assuming you have a 2WD truck...otherwise, obviously, you will need to swap the front gear set to match. As for your cluster swap, I swapped in a factory tach on mine but made sure was from same year truck so no issues at all and for some reason I believe it is even more critical on 96 (maybe cause first yr for OBDII?) than on 92-95 (mine's a 95).
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Freshman User
Joined: Jul 2008
Posts: 29
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From: Tuscaloosa,Al
That rear end swap is fine. The only change you get is the awsome accelleration from those 4.10 gears. You may even get better gas mileage as long as you can keep your foot out of it. I assume you're not changing wheels and tires.
The 96 cluster is pinned differently and others on this forum have had the same battery draining problem. You may be able to swap all the gauges except the PSOM. But then again, you probably want the 140 speedo.
The 96 cluster is pinned differently and others on this forum have had the same battery draining problem. You may be able to swap all the gauges except the PSOM. But then again, you probably want the 140 speedo.
As far as the cluster goes, I really just wanted it for the tach. I don't need to go 140mph, even if the truck could do it. Thanks for the info.
Fleet Mechanic
Joined: Nov 2004
Posts: 1,324
Likes: 4
From: Michigan
You should be able to swap in just the tach. The clusters are three seperate parts.
Check this out.
Installing An OEM Tachometer In A 1992-1996 F-150 Or Bronco .: Articles
And this too.
HOW TO RECALIBRATE THE SPEEDOMETER ON 92-96 FORD F-SERIES AND BRONCO .: Articles
Check this out.
Installing An OEM Tachometer In A 1992-1996 F-150 Or Bronco .: Articles
And this too.
HOW TO RECALIBRATE THE SPEEDOMETER ON 92-96 FORD F-SERIES AND BRONCO .: Articles
Hotshot
Joined: Sep 2001
Posts: 11,958
Likes: 228
The rear axle should bolt right in and just plug in the RABS/VSS sensor. A short time ago, I almost bought a complete low mileage L rear end on ebay. I wish I would have. You can look on your rear axle tag to see what ratio it is. My truck came with 3.08 gears. Man did they suck! I swapped in an axle with 3.55 T-lok about 7 years ago. The L rear end will also give you T-Lok or LS. I always wanted to put 1st gen L wheels on my truck. They are only slightly larger in diameter with the 275 60 17 tires, but the 4.10 gears will more than make up for that. A friend of mine has them on his truck. There are a few others on here that have them as well. The cluster is a plug in play swap. I put a low mileage 10K mint condition L cluster that I got on Ebay in my truck last Christmas.
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Hotshot
Joined: Sep 2001
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I just realized that since your truck is a 96, it is OBD II, so the instrument cluster swap may not work. Trucks from 92-95 are OBD I. The clusters only interchange with the following 92 and 93 since they don't have an air bag, 94 and 95, and then 96 is by itself. If you want a tach cluster get a 96 cluster on ebay. It won't have the cool speedometer, but it will have a tach.
Since Lightnings were made from 93-95 there are not any OBD II Lightnings.
Since Lightnings were made from 93-95 there are not any OBD II Lightnings.
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Senior User
Joined: Mar 2005
Posts: 341
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From: Newark
Yes, a 96 cluster is the only direct fit unit. A 94-95 cluster will work but the ABS becomes disabled and abs bulb comes on. Get yourself the right year cluster and swap in your speedo section. I believe your speedo is black so it should match for you fine.
Fleet Mechanic
Joined: Nov 2004
Posts: 1,324
Likes: 4
From: Michigan
If all he wants is the tach, is the 96 tach any different than the 95 tach? As long as he keeps his 96 cluster and installs the tach and guages along with his original 96 PSOM, it should be fine, right?
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Freshman User
Joined: Jul 2008
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From: Tuscaloosa,Al
No way to swap just the tach, its all or nothing. I swapped the whole cluster once and was amazed when it actually worked. Two days later my battery went dead in the middle of a busy intersection. Alt wasn't charging. I bought this 96 when my 93 lightning got wrecked, so I got lots of parts laying around. I put the motor in my mustang, kind of wish I had just put it in the truck though. Can't wait to get that rear under the 96, now that I know it can be done!
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Freshman User
Joined: Jul 2008
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From: Tuscaloosa,Al
Hey 12secondstang! You race at Leicester? I used to live in Canandaigua, got a buddy that races there. He used to be a MOMs member, not sure if he still is. He has a Fiesta with a 351w in it.
Hotshot
Joined: Sep 2001
Posts: 11,958
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Hey rossijd, Why not put the L suspension under your 96? A friend of mine has a green 96 F150 that is a Lightning clone. It has the springs on it. You could even take the sway bars etc off of it and put them in your newer truck. If its a regular cab you could swap the seats too.
Senior User
Joined: Mar 2005
Posts: 341
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From: Newark
Ross, I know the car you are talking about. I have a pic of my stang in my gallery. I work for Wegmans and spent 6 of my 22 years with them in the Canandaigua store. Man, 22 years and I'm not even 40.
As far as your tach. The 92-93 cluster will not allow system to charge as you found out. It happens to a lot of people here on the forums. I the 93 cluster Black face? If so, just get a 96 Cluster and put in the center speedo section into the 96 cluster. It will the look and work fine for you.
It is possible to make the 93 cluster work but that requires soldering and/or re-pinning the board and harness. I have never gotten that ambitious but some folks on the forum have done it.
As far as your tach. The 92-93 cluster will not allow system to charge as you found out. It happens to a lot of people here on the forums. I the 93 cluster Black face? If so, just get a 96 Cluster and put in the center speedo section into the 96 cluster. It will the look and work fine for you.
It is possible to make the 93 cluster work but that requires soldering and/or re-pinning the board and harness. I have never gotten that ambitious but some folks on the forum have done it.