Drivetrain Roulette Sound when spinning tires while jacked up

[Knuckle Dragger]

Hey yall, used to come here alot many years ago for help with my fox but times changed and im currently 8 years into my 02 Gt.
Been having a rotational squeak coming from what i believed waas the rear right wheel for a long time. Recently the car began to vibrate a significant amount when driving and all saround the ride felt ..... Wrong. Totally off from norm and considering ive driven it for 8 years, i knew something was either wrong about to go real bad.. i got all settled in to swap out a suspected bearing but after removing the wheels i spun the hubs and noticed no sound on the pass right side but the driver side, when spun, would create a "clicking" type sound almost like a playing card in the spokes of a bicycle.

Currently have the driverside axle removed and after dinking with the bearing it doesnt make any significant noise and the only play i see is the teeth of the bearing slightly slide to and from the differential. i referenced this movement to the replacement and it seems they all do that. Now im concerned about the true culprit. i would rotate the assembly again but im a bit nervous considering somehow right before pulling the axle out , the spider gears plopped out into the diff pan and not being a cerified but self-proclaimed mechanic, i about sh** myself. so now im trying to:
1- put the damn gears back without destroying my car.
2- determine if the wheel bearing is whats bad
3- find the true culprit of this "price is right" roulette "click, click, click" sound from the shaft/differential area.

i have a video showing the sound but any advice on how to upload it would be amazing. thanks in advance

 

[Mustang5L5]

Youtube account. Upload there and share link.

Honestly, if you have the axle out and the bearing is right there, just go ahead and replace it. Those bearings are not that expensive. You can even look up the part number on the bearing itself and google it to buy one directly rather than source it and the seal from Mustang parts houses that mark it up.

A slide hammer with a bearing puller attached will take it out pretty easily and I think those can be rented from local auto parts store. Bearing and seal driver can also be rented.

There are quite a few youtube videos on 8.8 assembly and reassembly showing how to get the spider gears back in. However, i must ask...is the S-spring in place? Usually the spider gears don't fall out unless that is removed.

 

[Knuckle Dragger]

Youtube account. Upload there and share link.

Honestly, if you have the axle out and the bearing is right there, just go ahead and replace it. Those bearings are not that expensive. You can even look up the part number on the bearing itself and google it to buy one directly rather than source it and the seal from Mustang parts houses that mark it up.

A slide hammer with a bearing puller attached will take it out pretty easily and I think those can be rented from local auto parts store. Bearing and seal driver can also be rented.

There are quite a few youtube videos on 8.8 assembly and reassembly showing how to get the spider gears back in. However, i must ask...is the S-spring in place? Usually the spider gears don't fall out unless that is removed.

Im literally online right now feverishly hunting down any info on why , after removing the diff cover, there is absolutely no S spring in sight. Which is strange considering i had the rear end rebuilt about 30k ago. Ford performance 3.73 gears, new Trak-Loc kit, and Ford Performance Bearings and seals all installed at a reputable shop.. wtf?

just went to double check the past orders and yup. FRP bearings and seals, exedy mach 350 clutch kit, 3.73 gears w/ SCT Tuner, royal purple and friction mod kit, trac-lok rebuild kit w/ carbon discs, and a OEM Throwout bearing.

 

[Mustang5L5]

The carbon disk kit comes with an S-spring kit for 31-spline axles, since that kit was specific to the 03/04 cobra. With standard 28 spline axle/diff, you'd need to source an S-spring specific for 28 splines. That's likely why it didn't get installed. They could have reused the old one however.

You don't really need the S-spring, but it's more preferred as it preloads the clutch packs for quicker reaction of the clutch packs. Without it, you might notice a bit more one-wheel peel prior to the other side catching. I have seen folks omit it, but personally I would run it. You can find them for sale quite easily.

 

[Mustang5L5]

Not a huge fan of ChrisFix, but his video does show a good view of putting the spider gears and S-spring back in


View: https://youtu.be/vUJ9h_-t_e0?t=644

 

[Knuckle Dragger]

Finally had some time to actually get back into the repairs and upon closer inspection I've noticed the housing looks pretty... well.. pretty fu**** up. I'm not sure what to be looking for on the shafts as far as "that is damaged and indicates (insert problem here) is fubar" does anything look out of the norm? Bearings and seals were removed very tenderly with the proper gear so I'm 100000 % positive the scores and marring weren't from removal.