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HOMESERVICE MANUALSFORD1996MUSTANG COBRA, 2D CONVERTIBLE, STANDARDREPAIR AND DIAGNOSISDRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESDIFFERENTIALS & AXLE SHAFTSOVERHAULREAR AXLE ASSEMBLYREASSEMBLY
1996 Ford Mustang Cobra, 2D Convertible, Standard

Rear Axle Assembly: Reassembly

1996 Ford Mustang Cobra, 2D Convertible, StandardSECTION Reassembly
  1. If new components were installed, check gear set assembly using Pinion Depth Gauge (T79P-4020-A) to determine correct pinion shim thickness. See PINION DEPTH  under ADJUSTMENTS.
  2. Install new bearing cups in axle housing if necessary. Bearing cups must be seated in bores so a .0015" (.038 mm) feeler gauge will not fit between bearing cup and bottom of bore.
  3. Install necessary shims on pinion to obtain correct pinion depth. Press inner bearing on pinion shaft. Ensure bearing is seated against shims. Lubricate pinion bearings with gear lubricant. Install pinion in axle housing. Install new collapsible spacer and outer pinion bearing.
  4. Verify sealing surfaces are clean and free of burrs. Using Seal Installer (T79P-4676-A), install oil seal. Remove and replace oil seal if it becomes cocked during installation. Lubricate oil seal lips with multipurpose lubricant.
  5. Check pinion shaft and companion flange splines for burrs. Coat companion flange splines with small amount of gear lubricant. On used pinion, align scribed marks on companion flange and pinion shaft. Install companion flange on pinion shaft. Coat washer side of new pinion nut with gear lubricant, and install pinion nut.
    6. NOTE: If desired preload is exceeded, install NEW collapsible spacer, and retighten nut until proper preload is obtained.
  6. Using Companion Flange Holder (T78P-4851-A), hold companion flange and gradually tighten pinion nut. See TORQUE SPECIFICATIONS  table. DO NOT hammer or use power tools on companion flange. Rotate pinion and check pinion bearing preload often until correct preload is obtained. See PINION BEARING PRELOAD  under ADJUSTMENTS.
  7. Lubricate all parts with gear axle lubricant. Place side gears and thrust washers into differential case. Place pinion gears and thrust washers exactly opposite each other in differential case openings, and mesh with side gears.
  8. Install ring gear using new mounting bolts. Apply Loctite to bolt threads. Tighten bolts to specification. See TORQUE SPECIFICATIONS  table. Press new bearings onto differential cases using proper size sleeve. Ensure bearings are fully seated on differential cases.
  9. After proper shims have been chosen to obtain proper ring gear backlash and bearing preload, differential assembly may be installed. See DIFFERENTIAL BEARING PRELOAD & RING GEAR BACKLASH  under ADJUSTMENTS.
  10. Install differential assembly and bearing cups in axle housing. Install bearing caps and bolts. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS  table.
  11. Check ring gear backlash and gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Gear tooth contact pattern does not need to be checked if pinion depth gauge is used and backlash is correct. Pinion depth and ring gear backlash may be adjusted to obtain proper gear tooth contact pattern.
  12. Once all adjustments are correct, install axle shafts, housing cover, brake drums or calipers, and rotors (if equipped). Install wheels. Install drive shaft. Fill axle housing with gear lubricant. See LUBRICATION  .
RENDER: 1.0x

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