FORD MUSTANG 1969 Volume One Chassis

03-13-02
Specifications

03-13-02

POWER STEERING PUMP

SERVICE
SPECIFICATIONS

Description

Pump Rotor Shaft End Play

Max. Torque Allowed
to

Rotate Rotor Shaft

Stamped Housing to Plate

Assy. Screw and Washer Assy.

Reservoir
to
Stamped Housing

Nut

Cam Ring to Pressure Plate

Screw

Housing to Cover Screw
Ford-Thompson

.017 in. Max.-.003 in. Min.

15 In-Lb.

28-32 Ft.-Lb.

43-47 Ft.-Lb.

_

-
Eaton

—

_

-

—

20 In-Lb.

15-20 Ft,-Lb.

FORD-THOMPSON POWER STEERING

PUMP
TORQUE
LIMITS (FT-LBS)

Description

Pump Rear Mounting Nut

Pressure Hose Nut

Pump Attaching Nuts

Bracket
to
Engine Attaching Nuts
6-Cyl.

302-351 CID

390,427,428,429 CID

Bracket
to
Cylinder Head

Belt Adjustment Bolt

Rear Support Bracket Attaching Nuts

Bracket
to
Engine Adapter

Engine Adapter
to
Engine

Engine Adapter
to
Pump
240 CID

170-200 CID

170-200 CID

250 CID

250 CID
Ford,
Mercury,

Meteor,

Thunderbird

14-18

20-30

25-35

1216

18-25

30-40

25-35

-

45-60

-

-

-

-
Cougar, Falcon,

Fairlane, Montego,

Mustang

20-30

20-30

30-40

7-10

18-25

30-40

25-35

25-35

-

25-35

17-25

30-40

25-35

INTEGRAL
POWER
STEERING GEAR SPECIFICATIONS

Description

Type

Ratio

Turns of Steering Wheel (Lock
to
Lock-Linkage Disconnected)

Fluid Specifications

Fluid Capacity (Included in Pump Reservoir Fill)

Phosphorescent Dye Additive (For Leak Detection)

Sector Shaft End Play -Linkage Disconnected

Sector Shaft Mesh Load. Total Over Mechanical Center

Position.
Must beCDGreater Than Worm

Bearing Preload Torque, Shown Below

Worm Bearing Preload

Clearance Between Valve Spool
&
Retaining Ring

Pressure Variation Between Right
&
Left Turn (At 250
P.S.I.)
-

Check Efforts Each Side
of
Center

Clearance Between Inner Sector Seal and Housing
Ford Design

(XR-«0)
Saginaw

Design

Recirculating Ball Torsion Bar

17:1

4
17.5:1

41/8

M-2C33-F

1.6 Pints (Approx.)

M99B103-A(4 0z. per quart)

None

14 In Lb (Max)

(Exc. Lincoln)

17
In
Lb (Max.)

(Lincoln)

2-7 la
U)

.0035-.0005"

Preferable .002"

4
In
Lb Max.

Variation

.025"
.002"
Max.

14
In
Lb (Max)

4-7 In Lb®

_

—

-

©8-9 In Lb (XR-50 Exc. Lincoln) 11-12 In Lb
for
Uncoln,
4-8 In
Lb
for
Saginaw Gear.

® 3 In Lb in Excess of Valve Assy. Drag Total Worm Bearing Preload and Seal Drag
not to
Exceed
8 In
Lb.procarmanuals.com

03-13-03

Specifications

03-13-03

MANUAL AND POWER

Vehicle

Model

Gear Type

Gear Ratio

Turns of
Strg.

Gr. (Lock to Lock)
®

Lube Type

Lube Capacity

(Lb.)

Worm Bearing

Preload (In Lb)®

Total Center

Meshload(lnLb)®

Adjustments

(All Models)
ASSIST STEERING GEAR SPECIFICATIONS

Ford,

Mercury,

Meteor

SM/VD-1

Manual

24:1

6-2/5

.97
±
.07

4-5

9-10
SMB-D

Manual

19.9:1

4-5/8

.55
±
.05

4-5

9-10

Adjusting
Mustang, Cougar

SMBK

Power Assist

and Manual®

16:1

3-3/4

ESW-M1C87-A

.55
±
.05

3-4®

8-9®

screw to bottom
of
sector

.000 -.002
SMB-F®

Manual

16:1

3-3/4

.55
±
.05

4-5

9-10

shaft T slot clearance:
Falcon,

Mont ego,

Fairlane

SMA-F

Manual

22:1

5-1/2

.87
±
.07

4-5

9-10
SMA-B

Power

Assist

16:1

4

.87
±
.07

3-4

8-9

©Production only
-
for service, use Model SMB-K.

®When used
for
improved
or
competition handling, worm bearing preload must
be
adjusted
to
4-5
In
Lb and total center meshload must
be

adjusted to 9-10 In Lb.

®Gear only
-
not attached to Pitman arm.

0Torque required
to
rotate input shaft
at
approximately 1-1/2 turns either side
of
center (gear
out of
vehicle
or
Pitman arm disconnected).

©Requiredto rotate input shaft and worm assembly past
the
center high point.

STEERING GEAR TORQUE UMITS(FT-LB)

Description

Sector Shaft Cover Bolts

Mesh Load Adjusting Screw Lock Nut

Ball Return Guide Clamp Screw

Preload Adjuster Lock Nut

Valve Housing
to
Gear Housing Screw

Race Retaining Inner Nut

Race Lock Nut

Piston End Cap

Set Screw-Rack Adjustment

Lubricant Fill Plug and Vent
Manual and Power Assist

Ford,
Mercury,

Meteor

30-40

32-40

18-42 (In-Lb)

60-80

3-9®
Fairlane, Falcon,

Montego

17-2?

32-40

18-42 (In-Lb) Pwr.

42-60 (In-Lb) Man.

60-80

3-9®
Mustang

Cougar

15-22

32-40

18-42 (In-Lb)

45-60

3-9®
Power steering

55-70

25-35

60-120 (In-Lb)

35-45

(D

®

50-75
Steering

30-35

20-30

3-6

50-110

50-100

® With tool T66P-3553-B
•
compute the torque as follows:

Length
of
Torque Wrench
X
60 Lb.
Ft.

°rque
"
Length
of
Torque Wrench
+
5.5 Inches

Example: With 13 inch torque wrench

13ln.
X
60 Lb. Ft. 13
X
60 Lb.
Ft.

13
In.
+
5.5 In.
18.5

®With tool T66P-3553-B
•
compute the torque as follows:

Length
of
torque wrench
X
25 Lb.
Ft.

Length of torque wrench
+
5.5 Inches

©Minimum
of
one thread must remain exposed when installed.
-0.703 X60- 42 (Lb.
Ft.)procarmanuals.com

03-13-04

Specifications

03-13-04

STEERING LINKAGE TORQUE LIMITS (FT-LBS)

Description

Cylinder Mounting Bracket
to
(Side Hole)

Underbodyor Frame (Bottom Hole)

Power Cylinder
to
Bracket

Power Cylinder
to
Bracket Lock
Nut

Steering
Tie Rod End to
Spindle
Arm

Idler
Arm
Mounting Bracket
to

Underbody
or
Frame

Pitman Arm
to
Control Valve (Power Steering)

Steering Gear
to
Side Rail
or
Frame

Pitman
Arm to
Sector Shaft

Idler
Arm to
Pitman Arm-to-ldler
Arm Rod

Spindle Connecting
Rod
Clamp
to
Adjusting

Sleeve

Pitman
Arm to
Steering Arm-to-ldler
Arm Rod

Steering Spindle
Arm
Connecting
Rod to

Arm-to-ldler
Arm Rod
Cougar, Fairlane,

Falcon,
Mont
ego,

Mustang

28-35

35-43

18-24

3-5

30-40
©

28-35

35-47
©

50-65

150-225

60-80®

10-14

35-47
©

30-40
©
Ford,

Mercury,

Meteor

-

-

-

-

35-47®

28-35

-

50-65

150-225

60-80
®

8-13

35-47
©

35-47
®
Continental

Mark
III

Thunder bird

-

-

-

-

35-47
©

28-35

-

50-65

150-225

60-80
©

8-13

35-47
©

35-47
©
Lincoln

Continental

-

-

-

-

40-55

20-30

-

50-65

150-200

40-55

19-26

40-55

40-55

CD
Torque
to low
limit
of
specification;
then,
tighten
the nut to the
nearest cotter
pin
slot
and
insert
the
cotter
pin.

STEERING COLUMN TORQUE LIMITS (FT-LBS)

Description

Column Lower Bracket
to
Column Upper Bracket

Intermediate Bracket
to
Brake Pedal

Support Bracket

Lower Trim Shroud
to
Upper Trim Shroud

Flex Coupling
to
Steering Gear

Flex Coupling
to
Steering Shaft Flange

Flex Coupling
to
Steering Shaft

Tee Plate
to
Instrument Panel

Steering Wheel Attaching
Nut

Brake Pedal Support Bracket
to
Brake

Pedal Support

Column Upper Bracket
to
Instrument Panel

Column Upper Bracket
to
Lower Clamp
Ford,

Mercury,

Meteor

Upper
9-20

Lower
8-12

9-20

5-10

24-37

10-18

-

8-13

30-40

_

-

-
Fairlane,

Falcon,

Mont
ego

10-20

_

-

24-37

12-18

-

3-8

30-40

28-42

10-16

-
Cougar,

Mustang

8-15

_

-

24-37

10-18

-

5-15

30-40

13-25

-

-
Lincoln

Continental

_

_

-

25-35

-

25-35

4-9

20-30

_

10-15

8-12
Continental

Mark
III

Thunder bird

_

_

-

25-35

-

25-35

4-9

30-40

28-42

7-12

7-1?procarmanuals.com

03-13-05

Specifications

03-13-05

TORQUE LIMITS-FRONT SUSPENSION

MONTEGO, FALCON,
FAIR
LANE,
MUSTANG AND COUGAR

Description

Shock Absorber Upper Attachment

Shock Absorber Upper Bracket to Body

Front Suspension Compression Bumper to Body

Brake Backing Plate to Spindle

Upper Arm and Inner Shaft to Body

Spring Seat to Upper Arm

Shock Absorber to Spring Seat

Ball Joint to Spindle (Upper and Lower)

Wheel Bearing Adjusting Nut

Strut to Lower Arm

Lower Arm to Underbody

Stabilizer Bar Mounting Bracket to Underbody

Strut to Underbody

Stabilizer Bar to Lower Arm

Caliper to Spindle (Disc Brake) • Upper

- Lower

Strut to Underbody Slotted Nut
Ft • Lbs

Montego, Falcon, Fairlane

20-28

15-25

12-17

9-14 (Disc) 25-45 (Drum)

75-100

30-40

8-12

60-90 ©

17-25 ©

75-105

75-100

17-25

60-80

5-10

110-140

55-75
Mustang and Cougar

10-15

22-34

12-17

9-14 (Disc) 28-45 (Drum)

75-100

25-40

8-12

60-90 ©

17-25 ©

70-105

75-100

17-25

60-80

8-12

110-120

55-75

50-70 | 50-70

©Torquethe adjusting nut to 17-25 ft-lb. Locate nut lock on adjusting nut so ,ctstellations are aligned with cotter pin hole in spindle. Then,

backoff adjusting nut and nut lock so the next castellation aligns with the cotter pin hole.

TORQE LIMITS-fRONT SUSPENSION

FORD,
MERCURY, METEOR

Description

Lower Arm to No. 2 Crossmember

Upper Arm to Frame

Upper Arm Bumper

Brake Backing Plate and Cylinder Assembly

to Spindle

Stabilizer Bar to Lower Arm

Ball Joint to Spindle (Upper and Lower)
Ft Lbs

55-75

100-130

15-25

80-106

5-10

60-90®
Description

Brake Backing Plate to Spindle

Strut to Lower Arm

Stabilizer Bar to Frame

Strut to Frame

Shock Absorber Upper Attachment

Shock Absorber Lower Arm

Caliper to Spindle (Disc Brake)
Ft-Lbs

25-45

70-113

18-27

60-90 ©

20-28

8 12

120-130

©Torque to specification, then tighten the nut to the nearest cotter pin slot and insert the cotter pin.

TORQUE LIMITS-FRONT SUSPENSION

THUNDERBIRD, CONTINENTAL MARK

Description

Lower Arm to #2 Crossmember

Upper Arm to Frame

Upper Arm Bumper

Stabilizer Bar to Lower Arm

Ball Joint to Spindle (Upper and Lower)

Strut to Lower Arm

Stabilizer Bar to Mounting Bracket

Strut to Frame

Shock Absorber Upper Attachment

Shock Absorber to Lower Arm

Brake Splash Shield (Disc) to Spindle

Caliper to Spindle (Disc Brake)

Upper Bolt

Lower Bolt
Torque

Ft-Lbs

60-90

100-150

15-25

5-10

©60-90

70-113

8-12

©60-90

20-23

8-12

9-14

110-140

90-120

©Torque to minimum specification;
then,
tighten the nut to the nearest cotter pin slot and insert the cotter pin.procarmanuals.com

03-13-06

Specifications

03-13-06

TORQUE LIMITS-FRONT SUSPENSION

LINCOLN CONTINENTAL

Description

Brace-Front Suspension to Sidemember (Model 74A Only)

Drag Strut
to
Strut Bracket Assembly

Lower Arm Assembly to Front Crossmember
-
(Attach Bracket)

Lower Arm Assembly to No. 2 Crossmember

Drag Strut
to
Lower Arm Assembly

Wheel Spindle to Lower Arm Ball Joint

Front Wheel Spindle to Upper Arm Ball Joint Assembly

Upper Arm Inner Shaft
to
Upper Arm

Upper Arm and Shaft Assembly to No. 2 Crossmember

Shock Absorber Bracket Assembly to No. 2 Crossmember Bracket

Shock Absorber Assembly to No. 2 Crossmember Assembly (Top End)

Shock Absorber Assembly Lower Arm Spring Seat Reinforcement Assembly

Upper Ball Joint
to
Control Arm

Stabilizer Bar Assembly
to
Underbody

Stabilizer Bar
to
Lower Arm

Jounce Bumper Assembly
to
Strut (Lower Arm)

Front Splash Shield to Spindle

Caliper to Spindle
FtLbs

90-110

70-90

55-75

110-140

70-90

70-90

55-75

25-35

100-125

40-55

20-30

20-30

21-29

20-30

5-10

22-28

9-14

100-140

TORQUE LIMITS-REAR SUSPENSION

FORD, MERCURY, METEOR

Description

Shock Absorber
to
Frame (Upper Attachment)

Upper Arm to Axle Bracket (Nut)

Track Bar to Axle Track Bar Stud

Track Bar Stud to Axle

Track Bar
to
Frame (Bolt Torque)

Track Bar Stud to Axle Bracket (Nut)

Wheel Lug Nut

Brake Backing Plate and Bearing Retainer to Axle-All Cars except those with 240
or
302 CID Engines

Brake Backing Plate and Bearing Retainer to Axle-All Cars with 240
or
302 CID Engines

Shock Absorber to Axle (Lower Attachment)

Bumper Assembly
to
Frame

Lower Arm to Axle-Bolt

Lower Arm to Axle-Nut

Upper Arm
to
Frame-BoU

Upper Arm
to
Frame-Nut

Lower Arm
to
Frame-Bolt

Lower Arm
to
Frame-Nut

Bumper Assembly to No. 4 Crossmember

Universal Joint
U-Bolt
Nut

Air Leveling Compressor
to
Apron

Height Control Valve to Bracket

Height Control Valve Bracket to No. 4 Crossmember
FtLbs

20-28

90-100

80-105

100-130

80-105

80-105

70-115

50-70

20-30

50-35

9-13

90-120

70-90

90-120

70-90

90-120

70-90

9-13

10-15

10-13

17-25

9-13procarmanuals.com

03-13-07

Specifications

03-13-07

TORQUE LIMITS-REAR SUSPENSION

MONTEGO, FALCON, FAIR LANE, MUSTANG AND COUGAR

Description

Spring Shackle Bars to Body and Spring

Shock Absorber
to
Upper Mounting Bracket

Shock Absorber to Spring Clip Plate

Spring to Axle U-Bolt Nut

Wheel Lug Nut 5-Lug Wheel

Spring to Spring Front Hanger
•
Bolt

Spring to Spring Front Hanger
•
Nut

Universal Joint U-Bolt Nut -Std. Trans.

Universal Joint U-Bolt Nut -Auto. Trans.
Mont
ego,
Falcon, Fair lane

15-22

20-28

20-28

35-50

70-115

90-120

40-60

6-11

10-15
Mustang and Cougar

15-22

20-28

20-28

35-50

70-115

60-85

40-60

6-11

10-15

TORQUE LIMITS-REAR SUSPENSION

LINCOLN CONTINENTAL

Description

Brake Backing Plate Bearing Retainer to Axle

Spring Center Bolt

Spring Front Bracket Assembly to Rear Floor Sidemember Assembly

Spring Front Eye Stud and Washer Assembly to Spring Front Hanger Bracket

Spring U-Bolt

Spring Assembly
to
Spring Shackle Assembly

Spring Shackle Assembly
to
Spring Rear Bracket Assembly

Spring Rear Bracket Assembly
to
Rear Floor Sidemember Assembly

Shock Absorber Upper Attaching Bracket
to
Body Crossmember

Shock Absorber Assembly
to
Shock Absorber Upper Attaching Bracket

Shock Absorber Assembly to Axle

Axle Bumper Bracket
to
Underbody

Pinion Bumper Assembly to Axle Carrier
Ft Lbs

30-55

15-20

70-90

76-106

45-65

34-59

34-59

40-67

20-30

20-28

30-45

10-15

18-25

TORQUE LIMITS-REAR SUSPENSION

THUNDERBIRD, CONTINENTAL.MARK
III

Description

Shock Absorber
to
Frame (Upper Attachment)

Upper Arm
to
Axle (Front)

Track Bar to Axle Track Bar Stud

Track Bar Stud to Axle

Track Bar
to
Frame (Bolt Torqe)

Wheel Lug Nut

Brake Backing Plate and Bearing Retainer
to
Axle

Shock Absorber to Axle (Lower Attachment)

Bumper Assembly to Frame

Lower Arm
to
Axle - Bolt

Lower Arm
to
Axle- Nut

Upper Arm
to
Frame -Bolt

Upper Arm
to
Frame
•
Nut

Lower Arm
to
Frame • Bolt

Lower Arm to Frame
-
Nut

Bumper Assembly to No. 4 Crossmember
Ft-Lbs

20-28

70-90

80-105

100-130

70-90

70-115

50-75

50-85

Self-Tapping

90-120

70-80

90-120

70-90

90-120

70-90

Self-Tappingprocarmanuals.com

03-13-08
Specifications
03-13-08

SPECIAL SERVICE TOOLS

Tool No.

T50T-100-A

T59L-100-B

T58L-101-A

T53L-200-A

T62L-201-A

OTC-462

T57L-500-A

T69L-1102-A

Tool 1175-AB

Tool 1175-AH

T56P-1217-A

T60K-1217-A

Tool 1217-J

Tool 1217-K

Tool
1217- L

Tool 1217-M

T65P-3000-A, D

T65P-3000-B, C, E, F

T57P-3006-A

T60K-3005-A

T62F-3006-A

Tool 3044-A

T54P-3044-A

T60K-3044-A

T65P-3044-A

Tool 3068

Tool 3069-AA

Tool
3069-
M

Tool 3290-C

T65P-3524-A

T66P-3553-A, B

T66P-3553-C

T65P-3548-A

T62F-3576-A

T64K-3576-A

T64K-3576-B

T65P-3576-A, B

T65P-3576-C

Tool 3583-J

T65P-3590-F

T67L-3600-A

T65P-3805-A

T63P-5310-A

T64K-5310-A, B

T66P-5310-A, B

T64N-5781-A

T64K-5781-B

Tool 6306-AG

T63L-8620-A

T63L-10300-B

T65P-10300-B

T56L-33610-D

T68L-33610-A

Tool 33623-D

T65P-3A537-A

T65P-3A537-B

T69P-3A674-A

T65P-3A733-A

T65T-3B177-A

T68P-3B586-A

T68P-3B592-A

T68P-3B592-B

T64B-3C716-A

T65P-3C732-A

T65P-3D517-A

T65P-3D525-A

T65P-3D525-B

T65P-3D526-A

T69P-3D608-A

T69P-3D608-B

T65P-3D642-A

T67P-3D739-A
Description

Slide Hammer-Long

Slide Hammer-Short

Puller Attachment

Handle Adapter

Input Shaft Seal Installer

Tie Rod Separator (Owatonna Tool Co.)

Bench Mounted Holding Fixture

Front Wheel Bearing Remover

Grease Seal Remover (Head Only)

Grease Seal Replacer

Front Hub Bearing Cup and Grease Seal Replacer

Front Hub Bearing Cup and Grease Seal Replacer

Front Hub Outer Bearing Cup Replacer

Front Hub Inner Bearing Cup Replacer

Front Hub Outer Bearing Cup Remover

Front Hub Inner Bearing Cup Remover

Adjusting Bars-Caster and Camber

Alignment Spacers

Spindle Ball Joint Remover Press

Spindle Ball Joint Press Adapter Screw

Spindle Ball Joint Press Adapter Screw

Front Suspension Upper Arm Bushing Remover

Front Suspension Upper and Lower Arm Overhaul Kit

Front Suspension Lower Arm Bushing Remover and Replacer

Upper Arm Bushing Overhaul Kit

Front Suspension Upper Arm Bushing Adapter

Front Suspension Lower Arm Bushing Remover

Lower Arm Bushings-Remover and Replacer Kit

Tie Rod Ball Ends and Control Valve Ball Stud Remover

Input Shaft Bearing Remover and Installer

Spanner Wrench

Spacer

Oil Line Connector Seal Installer

Sector Shaft Bushing Remover and Replacer

Sector Shaft Needle Bearings and Seal Remover and Replacer

Sector Shaft Needle Bearings and Seal Remover and Replacer Adapter

Sector Shaft Bushing Remover and Installer

Remover and Installer Adapter

Control Valve Bearing and Seal Remover and Replacer

Steering Pitman Arm Remover

Steering Wheel Remover

Ring Compressor-Rack Piston

Front Coil Spring Remover and Replacer

Adapters

Adapters

Rear Spring Front Bushing Remover and Installer

Rear Spring Bushing Adapter

Crankshaft Damper Remover and Power Steering Pump Sprocket Replacer

Bent Tension Gauge

Pulley Remover

Alternator Pulley Replacer

Pressure Testing Gauge Assembly

Bypass and Orifice Gauge

Pump Oil Seal Pilot

Bearing Preload Spanner Wrench

Adjuster Plug Seal Protector

Fixture Adapter Plate

Power Steering Pump Pulley Remover

Front Suspension Bushings Remover and Replacer

Pump Housing Hole Plugging Tool

Pump Shaft Seal Replacer

Pump Shaft Seal Protector

Insulator Remover and Replacer Socket

Lock Spring Installing Hook

Rack Piston Arbor

Adjuster Plug Bearing Remover and Installer

Thrust Bearing Retainer Installer Adapter

Adjuster Plug Seal Installer

Pin Straightness Checking Block

Pin Guide Support

Sector Shaft Seal Installer

Pivot Pin Removerprocarmanuals.com

04-01-01
General Axle Service

04-01-01

GROUP

4

PART
4-1
PAGE

General Axle Service 04-01-01

PART 4-2

Rear Axle
—
Removable Carrier Type ... 04-02-01

PART
4-3

Rear Axle
—
Integral CarrierType

(Except Ford Light Duty WER) 04-03-01
PART 4-4

Rear Axle
—
Ford

Light-Duty (WER)

PART
4-5

Soecifications
PAGE

04-04-01

04-05-01

PART
4-1
General Axle Service

COMPONENT INDEX

ADJUSTING DIFFERENTIAL BEARING

PRELOAD AND BACKLASH

Locating Pinion-Integral Carrier

Locating Pinion-Removable Carrier

ADJUSTING PINION AND RING GEAR

TOOTH CONTACT

Integral Carrier

Removable Carrier

BEARING CONE AND ROLLER

ASSEMBLIES

Cleaning
and
Inspection

BEARING CUPS

Cleaning
and
Inspection

CARRIER HOUSING

Cleaning
and
Inspection

CHECKING GEAR TOOTH PATTERNS

CHECKING LIMITED SLIP
OR
TRACTION

LOK DIFFERENTIAL OPERATION

CHECKING REAR AXLE COMPANIOM

FLANGE RUNOUT

DIFFERENTIAL BEARING ADJUSTING

NUTS

Cleaning
and
Inspection

DIFFERENTIAL CASE

Cleaning
and
Inspection

GEARS (ALL)

Cleaning
and
Inspection

IDENTIFICATION

INSPECTION BEFORE DISASSEMBLY
OF

CARRIER

LIMITED SLIP AND TRACTION-LOK

DIFFERENTIAL PARTS

Cleaning
and
Inspection
MODEL APPLICATION
All
Models

01-07

01-08

01-07

01-07

01-10

01-10

01-10

01-10

01-09

01-09

01-03

01-02

01-10

01-10

01-10

01-10

01-09

01-09

01-02

01-09

01-10

01-10
Ford
01-08

01-07

01-05
Mercury
N/A

N/A

01-05
Meteor
01-08

01-07

01-05
Cougar
01-08

01-07

01-05
Fairlane
01-08

01-07

01-05
Falcon
01-08

01-07

01-05
Montego
01-08

01-07

01-05
Mustang
01-08

01-07

01-05
Lincoln-
Continental
N/A

N/A

01-05
Thunderbird
N/A

N/A

01-06
Continental-
Mark
III
N/A

N/A

01-06

A page number indicates that the item
is for
the vehicle listed
at the
head
of
the column.

N/A indicates that the item
is not
applicable
to
the vehicle listed.
procarmanuals.com

04-01-02
General Axle Service

04-01-02

COMPONENT INDEX
MODEL APPLICATION

o

3
I

i

Ji

LUBRICANT LEVEL CHECK

01-10

PINION RETAINER

01-10

Cleaning and Inspection

01-10

SHIM AND BACKLASH CHANGES
01-03

Integral Carrier

Removable Carrier
01-04
N/A

01-04
01-04

01-04

01-04
01-04
01-04

N/A
N/A
N/A

U-JOINT FLANGE
01-10

Cleaning and Inspection
01-10

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.

1
COMMON ADJUSTMENTS
AND
REPAIRS

IDENTIFICATION

The AXLE code on the vehicle

Warranty Plate (Fig. 1) identifies the

rear axle type (conventional or

limited-slip differential) and gear

ratio.

A metal tag (Fig. 2) stamped with

the model designation and gear ratio

is secured to one of the rear cover-

to-housing bolts (integral carrier-type)

or to one of the carrier-to-housing

bolts (removable carrier-type).

The spaces on the top line provide

the axle model identification code.

This code, such as WDT-AN4,

WDC-AS4, WEG-C2, etc. indicates a

specific combination of the following

factors: conventional or limited slip

differential; diameter of ring gear;

small or large wheel bearings; and the

gear ratio. Refer to the specifications

group of this manual for the car-line

rear axle ratios, gear and code
identif-

ication.

The second line on the tag is used

for gear ratio, the production date

code and the production plant identifi-

cation code.
It is important to use the model

designation when obtaining correct re-

placement parts.

LIMITED-SUP
OR

TRACTION-LOK DIFFERENTIAL

OPERATION CHECK

A limited-slip or Traction-Loc dif-
ferential can be checked for proper

operation without removing the carrier

from the axle housing.

Jack up one rear wheel and remove

the wheel cover. Install the tool on the

axle shaft flange studs as shown in

Fig. 3.

AXLE MODEL

PLANT CODING

DATE (YEAR, MONTH, WEEK)

RATIO (CONVENTIONAL)

(LIMITED SLIP WOULD
BE
3L00)

E 1918-A

FIG.
2—Rear
Axle Model Identification
Tag

NOT
FOR
TITLE
OR
REGISTRATION

9G5IVI0000I
WARRANTY NUMBER

E1917-A
CONVENTIONAL

2

3

4
.

5

6

7

A

c
LIMITED SLIP

K

L

M

/

/

p
_ —

R
— —

c

—
u

V
RATIO

2.75:1

2.79:1

— 2.80:1

2.83:1

-
3.00:1

3.10:1

—
3.25:1

3.50:1

3.08:1

3.91:1

— 4.30:1

FIG.
1
— Rear Axle Gear Ratio
and
Type Identificationprocarmanuals.com

04-01-03
General Axle Service

04-01-03

Tool-759L 4204-A,

T65K 4204-
A,

T66L-4204-A,

OR

Tool-44211-A

E1897-A

FIG. 3—Limited-Slip Differential Check

Using
a
torque wrench
of at
least

200 ft-lbs capacity, rotate
the
axle

shaft.
Be
sure that
the
transmission
is

in neutral,
one
rear wheel
is on the

floor,
and the
other rear wheel
is

raised
off the
floor.
The
torque
re-

quired
to
continuously rotate
the
shaft

should
be at
least
75
ft-lbs
or 40
ft-lbs

(Traction-Lok).
The
initial breakaway

torque
may
be
higher than
the
contin-

uous turning torque,
but
this
is nor-

mal.
The
axle shaft should turn with

^ven pressure throughout
the
check

without slipping
or
binding.

If
the
torque reading
is
less than

specified, check
the
differential
for

improper assembly.

A vehicle equipped with
a
limited-

slip differential will always have both

wheels driving.
If,
while
the
vehicle
is

being serviced, only
one
wheel
is

raised
off the
floor
and the
rear axle

is driven
by the
engine,
the
wheel
on

the floor will drive
the
vehicle
off the

stand
or
jack.

GEAR TOOTH CONTACT

PATTERN CHECK

When rolling
a
tooth pattern,
use

the special compound (tube) packed

with each service ring gear
and
pinion

set.

Paint
all
gear teeth
and
roll
a pat-

tern
as
described
in
Section
3.
After

diagnosing
the
tooth pattern
as ex-

plained here, make
the
appropriate

adjustments
as
outlined
in
Section
2.

In making
a
final gear tooth
con-

tact pattern check,
it is
necessary
to

recognize
the
fact that there
are
three

different types
of
gear sets, hunting,

non-hunting
and
partial non-hunting.

Each type
is
determined
by the num-
ber
of
teeth
in the
gears.
The non-

hunting
and
partial non-hunting types

can
be
identified
by the
paint timing

marks
on the
pinion
and
ring gear

teeth. (Part 4-2,
Fig. 51).
See
Part
4-5

for complete identification specifica-

tions.

ACCEPTABLE TOOTH

PATTERNS (ALL AXLES)

Figure
4
shows acceptable tooth

patterns
for all
axles.
Any
combina-

tion
of
drive
and
coast patterns will
be

acceptable.

In general, desirable tooth patterns

should have
the
following character-

istics:

1.
The
drive pattern should
be
fair-

ly well centered
on the
tooth.

2.
The
coast pattern should
be
fair-

ly well centered
on the
tooth.

3.
Some clearance between
the pat-

tern
and the top of the
tooth
is
desir-

able.

4.
There should
be no
hard lines

where
the
pressure
is
high.

The individual gear
set
need
not

conform exactly
to the
ideal pattern

to
be
acceptable.

Any combination
of
drive
and
coast

patterns shown
in Fig. 4 are
accep-

table.

Hunting Gear
Set

In
a
hunting-type gear
set, any one

pinion gear tooth comes into contact

with
all
ring gear teeth.
In
this type,

several revolutions
of
the
ring gear
are

required
to
make
all
possible gear

combinations.
Any combination
of
drive
and
coast

patterns shown
in
Fig.
4
will
be
acceep-

table.

Non-Hunting Gear
Set

In
a
non-hunting type gear
set, any

one pinion gear tooth comes into
con-

tact with only
a few
ring gear teeth.

In this type, only
one
revolution
of
the

ring gear
is
required
to
make
all
poss-

ible tooth contact combinations.
Any

combination
of
drive
and
coast
pat-

terns shown
in Fig. 4
will
be
accept-

able.

Partial Non-Hunting

Gear
Set

In
a
partial non-hunting type gear

set,
any one
pinion tooth comes into

contact with only part
of
the
ring gear

teeth,
but
more than
one
revolution
of

the ring gear
is
required
to
make
all

possible gear tooth combinations.
Any

combination
of
drive
and
coast
pat-

terns shown
in Fig. 4
will
be
accept-

able.

SHIM
AND
BACKLASH

CHANGES

Since each gear
set
rolls
a
charac-

teristic pattern,
the
patterns shown
in

Fig.
4 are
considered acceptable
and

should
be
used
as a
guide.
The
drive

pattern
is
rolled
on the
convex side
of

the tooth,
and the
coast pattern
is

rolled
on the
concave side.

The movement
of
tooth contact
pat-

terns with changes
in
shimming
can
be

summarized
as
follows:

Removable Carrier Type Axle

1.
Thicker shim with
the
backlash

set
to
specifications moves
the
pinion

further from
the
ring gear:

2.
Thinner shim with
the
backlash

set
to
specifications moves
the
pinion

closer
to the
ring gear:

If
the
patterns
are not
correct,

make
the
changes
as
indicated.
The

pinion need
not be
disassembled
to

change
a
shim.
All
that
is
required
is

to remove
the
pinion, bearing,
and re-

tainer assembly
and
install
a
different

shim. When reinstalling
the
pinion

and retainer assembly
of a
non-
hunt-

ing
or
partial non-hunting gear
set, be

sure that
the
marked tooth
on the pi-

nion indexes between
the
marked teeth

on
the
ring gear
(Fig.
51,
Part
4-2).

Refer
to
Pinion
and
Ring Gear Tooth

Contact Adjustment, Section
2.procarmanuals.com