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I have the clearance spec for the air gap between the VSS sensor and the exciter ring; but, how do I measure the clearance. I'm guess I could use a depth gauge to measure the distance between the exciter and the VSS mounting surface; then, mic the length of the vVSS referencing the same mounting surface; and, shim for air gap? The new VSS measures at least 40 thousandths longer than the old one, and the old one shows evidence of having made contact w/exciter. Both test within proper resistance range, I may just put the old one back in.
 

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yo,

PSOM Pointer Waiver TSB 96-21-11 by Ford for 92-96
Programmable Speedometer/Odometer Module Pointer Waiver Article No. 96-21-11
ISSUE: The speedometer needle may waver and/or a light surge may occur on some vehicles when speed control is used
at highway speeds between 80-113 km/h (50-70 mph). This may be due to slight dents/chips in either the exciter ring
or the Vehicle Speed Sensor (VSS) and air gaps between the VSS and the exciter ring.
ACTION: Replace the Programmable Speedometer/Odometer Module (PSOM) if required. New PSOM's come with increased immunity to system
variability. Refer to the following Diagnostic Procedure for details.
DIAGNOSTIC PROCEDURE
BRONCO/F-SERIES - Perform normal PSOM diagnostics per Pinpoint Tests "H" and "J" of the 1996 F-Series/Bronco
Body/Chassis Service Manual, Pages 13-01-30 through 13-01-32 and Pinpoint "B" of the 1996 Powertrain/Drivetrain Service Manual,
Page 10-03-11.
1. Any slight dents, chips, etc., in either the exciter ring or VSS will create needle waver. Measure air gap between
the VSS and exciter ring. It should be 0.38-0.51 mm (0.015-0.020").
2. Check exciter ring runout per the same ring gear backface runout procedure of the appropriate model 1996
Powertrain/Drivetrain Service Manual, Section 05-00. Make sure the exciter ring is mounted correctly to the
ring gear. If runout is more than 0.1 mm (0.004"), perform the differential runout check per the procedure in the
appropriate model 1996 Powertrain/Drivetrain Service Manual, Section 05-02A or 05-02D, to find cause and repair as needed.
3. If all items listed above check good, replace the Instrument Cluster Assembly. Obtain the correct service part number from the Parts Catalogue
and then contact the Electronic Odometer Exchange Center at (800) 259-9700 for U.S. Dealers and (800) 663-9974 for Canadian Dealers.
NOTE: DEALERSHIP MUST TELL THE ODOMETER EXCHANGE CENTER THAT YOU NEED A PSOM3 LEVEL CLUSTER FOR A SPEEDOMETER NEEDLE WAVER CONCERN.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
Bronco 962111B Replace Programmable 0.7 Hr.
BASIC PART NO. CODE 10849 06
OASIS CODES: 204000, 204100, 204200, 205000
by Ford via ME @ http://home.comcast.net/~miesk5/technical_service_bulletins.htm#technical_service_bulletins.htm

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1996 Bronco/F-Series Table of Contents
Group 05: DRIVELINE
Section 05-02G: Axle, Integral Carrier, 8.8-Inch Ring Gear
DESCRIPTION AND OPERATION

Brake System, Anti-Lock
F-150 vehicles use the rear anti-lock brake system. Bronco vehicles use the 4-wheel anti-lock brake system. Both systems feature an anti-lock speed sensor ring that is pressed on the differential case (4204) behind the ring gear. If the anti-lock speed sensor ring is removed, it must be discarded and replaced with a new one. The anti-lock speed sensor ring works in conjunction with an electronic rear brake anti-lock sensor. This sensor is retained in a bore at the top of the carrier housing and fastened by one bolt. There is a space provided between the ring gear and anti-lock speed sensor ring for measuring the ring gear backface runout.

Section 06-09A: Brake System, Anti-Lock, Rear 1996 F-150, F-250, F-350 Workshop Manual
REMOVAL AND INSTALLATION
RABS Sensor
Removal
Pull the wiring harness connector off.
Remove the RABS sensor hold-down bolt and remove the RABS sensor from the rear axle housing (4010).
Installation
Clean the axle mounting surface. Use care to prevent dirt from entering the rear axle housing.
Inspect and clean the magnetized RABS sensor pole piece to make sure that it is free from loose metal particles which could cause erratic system operation. Inspect the RABS sensor O-ring for damage and replace if necessary.
NOTE: Do not apply force to the plastic RABS sensor connector. The RABS sensor flange should slide to the mounting surface. The air gap setting is between 0.127-1.14mm (0.005-0.045 inch).
Lightly lubricate the RABS sensor O-ring with motor oil, align the RABS sensor bolt hole, and install.
Install the RABS sensor hold-down bolt and tighten to 34-41 Nm (25-30 lb-ft).
Inspect the blue RABS sensor connector seal and replace if missing or damaged. Push the connector on the RABS sensor.
 

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