Ford Thunderbird, Mercury Cougar 1996 Factory Service & Shop Manual
Complete workshop & service manual with electrical wiring diagrams for Ford Thunderbird, Mercury Cougar 1996. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Ford Thunderbird, Mercury Cougar 1996 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
A B C D E F
G H I J K L
M N O P Q R
S T U V W
00: GENERAL SERVICE INFORMATION
02: FRAME AND MOUNTING
06: BRAKE SYSTEM
09: EXHAUST SYSTEM
10: FUEL SYSTEM
11: STEERING SYSTEM
12: CLIMATE CONTROL SYSTEM
13: INSTRUMENTATION AND WARNING SYSTEMS
14: BATTERY AND CHARGING SYSTEM
15: AUDIO SYSTEMS
18: ELECTRICAL DISTRIBUTION
Group 03: ENGINE
Section 03-00: Engine Service
Section 03-01A: Engine, 3.8L
Section 03-01B: Engine, 4.6L (2V)
Section 03-03: Engine Cooling
Section 03-04A: Fuel Charging and Controls 3.8L
Section 03-04B: Fuel Charging and Controls 4.6L (2V)
Section 03-05: Drive Belts, Accessory
Section 03-06: Starting System
Section 03-07A: Ignition, Electronic 3.8L
Section 03-07B: Ignition, Electronic 4.6L (2V)
Section 03-08: Engine Emission Control
Section 03-12: Intake Air System
Section 03-13: Evaporative Emissions
Section 03-14: Engine Controls, Electronic
Pinion Bearing Preload Bench Check
The absence of differential bearing preload causes noise as driving loads tend to move the gear pattern to the outside (heel) of the ring gear. If the preload is not set right, it can move out to the edge and score the gears.
Both the differential pinion bearing and differential bearing preload must be checked so the pattern will stay in place under load.
NOTE: Lower front of axle to perform this check. Refer to Section 05-02A (7.5 inch ring gear) or Section 05-02B (8.8 inch ring gear).
Check the pinion bearing preload by putting a Nm (lb-in) torque wrench on the pinion nut and measuring the torque effort it takes to turn the pinion. Compare the reading with the preload specification for used bearings.
NOTE: The rear axle drive pinion seal (4676) will offer a resistance equivalent to 0.056-0.451 Nm (0.5-4.0 lb-in). If the bearings are preloaded, a reading higher than 0.056-0.451 Nm (0.5-4.0 lb-in) on the torque wrench scale must be obtained. If not, there is no preload.
Another indication is some threads protruding from in front of the nut. Normally about 2.29-2.54 mm (0.090-0.100 inch) of threads protrude if the preload is set properly. If the nut is flush with the end of the stem, chances are the preload was not set. Refer to Drive Pinion Shim Selection procedure in Section 05-02A (7.5 inch ring gear) or Section 05-02B (8.8 inch ring gear) for resetting the proper preload.
NOTE: The absence of preload here may indicate that the differential drive pinion collapsible spacer (4662) must be replaced if sufficient pinion nut torque is not achieved when tightening new pinion nut to desired rotational torque.
Tighten the pinion nut, rotating the pinion occasionally to ensure proper bearing seating. Take frequent drive pinion bearing torque preload readings until the original recorded preload reading is obtained.
If the original recorded preload is lower than specification, tighten to specification. If the preload is higher than specification, tighten to original reading as recorded.