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New Edge Cobras
Project: Designated Driver
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<blockquote data-quote="pdm" data-source="post: 10677336" data-attributes="member: 78261"><p><strong>Fixed the clunk!</strong></p><p></p><p>THE CLUNK IS GONE!!! :burn:</p><p></p><p>Well, my assumption was correct. The excessive gear lash in the original Trac-Lok diff was causing my clunk, and here’s how I fixed it.</p><p></p><p>With a fresh, complete Trac-Lok diff from Tousley Ford and the carbon clutch pack and side gear shims from the initial install, I went to work on the new setup. First I noticed that the new diff had more lash in the gears than I would like (a likely culprit to the presence of the clunk in some brand new cobras). I tore it down and made a few comparisons. The old spider gear shims were quite a bit thinner than the new ones (I did not mic them, just a physical observation). I started off with stacking the clutches in alternating order with 4 frictions on each side. I tried different side gear shims until a 0.025” one on each side allowed me to rotate the spider gears into place by lightly tapping them with a dead blow hammer. The Trac-Lok carrier is a perfect gauge for finding the right shim. If it doesn’t fit, the shim is too heavy, and when they just barely fit, you’ve got it right. I installed the “S” spring and checked the lash in the gears. It was minimal, but they were not bound together. Just the way I wanted it.</p><p></p><p>Fast forward and everything is buttoned back up. Time to fill ‘er up with a bottle of Motorcraft friction modifier and 2 1/3 qt. of Mobil 1 75W-90. Next to a pump, the best tool for filling the diff or transmission is an enema bag. It’s a heavy 2qt rubber bag that comes with a fitting, hose, clamp, and a plug to seal it up and store for later use. I keep several of these on hand with various gear and transmission fluids in them. Bring on the jokes, but it’s fast, easy, and there’s no cleanup.</p><p></p><p>Test drive: Fire it up, slam it into first, and… nothing… no sound. I head down the street and downshift as I come to a stop. Jam first again, and… nothing… THE EVIL CLUNK IS DEAD! If I get in and out of the throttle hard, I can hear a slight clunk, but that is the only time… not while shifting N-1, N-R, or any other time shifting. It was so nice driving to work this morning. There’s a long hill with a stop light at the bottom. After coasting down this hill, it always clunked when I hit first to take off again, but not today. As far as the Trac-Lok setup, I love it. The friction is perfect. Good traction, but no binding in a sharp turn. I am a happy Cobra owner once again!:banana::burnout:</p></blockquote><p></p>
[QUOTE="pdm, post: 10677336, member: 78261"] [b]Fixed the clunk![/b] THE CLUNK IS GONE!!! :burn: Well, my assumption was correct. The excessive gear lash in the original Trac-Lok diff was causing my clunk, and here’s how I fixed it. With a fresh, complete Trac-Lok diff from Tousley Ford and the carbon clutch pack and side gear shims from the initial install, I went to work on the new setup. First I noticed that the new diff had more lash in the gears than I would like (a likely culprit to the presence of the clunk in some brand new cobras). I tore it down and made a few comparisons. The old spider gear shims were quite a bit thinner than the new ones (I did not mic them, just a physical observation). I started off with stacking the clutches in alternating order with 4 frictions on each side. I tried different side gear shims until a 0.025” one on each side allowed me to rotate the spider gears into place by lightly tapping them with a dead blow hammer. The Trac-Lok carrier is a perfect gauge for finding the right shim. If it doesn’t fit, the shim is too heavy, and when they just barely fit, you’ve got it right. I installed the “S” spring and checked the lash in the gears. It was minimal, but they were not bound together. Just the way I wanted it. Fast forward and everything is buttoned back up. Time to fill ‘er up with a bottle of Motorcraft friction modifier and 2 1/3 qt. of Mobil 1 75W-90. Next to a pump, the best tool for filling the diff or transmission is an enema bag. It’s a heavy 2qt rubber bag that comes with a fitting, hose, clamp, and a plug to seal it up and store for later use. I keep several of these on hand with various gear and transmission fluids in them. Bring on the jokes, but it’s fast, easy, and there’s no cleanup. Test drive: Fire it up, slam it into first, and… nothing… no sound. I head down the street and downshift as I come to a stop. Jam first again, and… nothing… THE EVIL CLUNK IS DEAD! If I get in and out of the throttle hard, I can hear a slight clunk, but that is the only time… not while shifting N-1, N-R, or any other time shifting. It was so nice driving to work this morning. There’s a long hill with a stop light at the bottom. After coasting down this hill, it always clunked when I hit first to take off again, but not today. As far as the Trac-Lok setup, I love it. The friction is perfect. Good traction, but no binding in a sharp turn. I am a happy Cobra owner once again!:banana::burnout: [/QUOTE]
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