section 18 FORD MUSTANG 1969 Volume One Chassis

04-01-08
General Axle Service

04 01-08

Too/-T57L-4067-A

E 1595-A

FIG.
14
—Adjusting Side Bearing Preload—Typical

at this time to be sure that it is still

loose.) Tightening the left nut moves

the ring gear into the pinion to de-

crease backlash, and tightening the

right nut moves the ring gear away.

3.
Install a dial indicator as shown

in Fig. 14.

4.
Tighten the right nut until it first

contacts the bearing cup. Then pre-

load the bearings from 0.008-0.012

inch case spread. Rotate the pinion

gear several revolutions in each direc-

tion while the bearings are loaded, to

seat the bearings in their cups to be

sure no bind is evident. This step is

important.

5. Again loosen the right nut to re-

lease the pre-load. If there is any

backlash between the gears as shown

by the dial indicator,(Fig.l2 or Fig. 10

Part 4-4) tighten the left nut just en-

ough to remove this backlash. At this

time,
make sure that one of the slots

in the left nut is so located that the

lock can be installed without turning

the nut. Carefully, tighten the right

nut until it just contacts the cup.

6. Torque the differential cap bolts

to specification.

On integral carrier type axles, set a

preload of 0.008 to 0.012 inch case

spread for new bearings and 0.003 to

0.005 for the original bearings.

On removable carrier type axles,

the preload is 0.008 to 0.012 inch case

spread for new bearings and 0.005 to

0.008 for the original bearings. As

preload is applied from the right side,

the ring gear is forced away from the

pinion and usually results in the cor-

rect backlash.

7.
Measure the backlash on several

teeth around the ring gear. If the

measurements vary more than 0.003

inch (both integral and removable car-

rier) there is excessive runout in the
gears or their mountings, which must

be corrected to obtain a satisfactory

unit. If the backlash is out of specifi-

cation, loosen one adjusting nut and

tighten the oposite nut an equal a-

mount to move the ring gear away

from or toward the pinion. When

moving the adjusting nuts, the final

movement should always be made in a

tightening direction. For example, if

the left nut had to be loosened one

notch, loosen the nut two notches,

then tighten it one. This insures that

the nut is contacting the bearing cup,

and that the cup cannot shift after

being put in service. After all such ad-

justments, check to be sure that the

case spread remains as specified for

the new or original bearings used.

8. Again check the tooth contact

pattern. If the pattern is still incor-

rect, a change in pinion location (shim

thickness) is indicated.

PINION LOCATION

Removable Carrier Type Axle

1.
Remove the attaching bolts and

the pinion and bearing retainer assem-

bly from the carrier.

2.
Measure the original shim thick-

ness with a micrometer. Increase or

decrease the shim thickness as indicat-

ed by the tooth pattern check des-

cribed in Section 1.

3.
Replace the pinion retainer O-

ring (Fig. 39, Part 4-2). Coat the O-

ring with axle lubricant before install-

ing. Do not roll the O-ring into the

groove. Snap it into position.

4.
Being careful not to pinch the

O-ring, install the pinion and bearing

retainer assembly in the carrier with

the corrected shim pack.

Before installing the pinion and

bearing retainer assembly, determine

which type of gear set is being used.
The non-hunting and pantial non-

hunting types can be identified by the

paint timing marks on the gear teeth

(Fig. 51, Part 4-2). Part 4-5 can also

be referred to for identification.

If the gear set is of the non-hunting

or partial non-hunting type clean the

teeth on both the pinion and drive

gear so that the timing marks are vis-

ible.
Rotate the differential case and

ring gear assembly in the carrier until

the marked teeth on the ring gear are

opposite the pinion entry hole. Place

the assembly in the carrier so that the

marked tooth on the pinion indexes

between the marked teeth on the ring

gear (Fig. 51, Part 4-2).

In almost every case of improper

assembly (gear assembled out of time)

the noise level and probability of fai-

lure will be higher than they would be

with properly assembled gears.

When installing the hunting type

gear set (no timing marks), assemble

the pinion and retainer assembly into

the carrier without regard to the

matching on any particular gear teeth.

5.
Install the retainer-to-carrier

mounting bolts and torque to specifi-

cations.

6. Adjust the backlash between the

ring gear and pinion as outlined in the

foregoing procedures.

7.
Make a tooth pattern check. If

the pattern is still unsatisfactory, re-

peat this procedure changing the shim

thickness each time until a satisfactory

tooth pattern is obtained.

Integral Carrier Type Axle

1.
Remove the differential case and

the drive pinion from the carrier cast-

ing, and then remove the pinion bear-

ings as described under Removal of

Differential Case and Drive Pinion in

Section 4.

2.
Measure the original shim thick-

ness with a micrometer. Increase or

decrease the shim thickness as indicat-

ed by the tooth pattern check des-

cribed in the foregoing Section 1 and

shown in Fig. 4.

3.
Install the corrected shim pack

and the bearings on the pinion, and

then install the pinion and the differ-

ential case in the carrier casting as

outlined under Installation of Drive

Pinion and Differential Case in Sec-

tion 4 of Part 4-3.

4.
Adjust the backlash between the

ring gear and pinion as outlined in the

foregoing procedure.

5.
Make a tooth pattern check. If

the pattern is still unsatisfactory, re-

peat this procedure changing the shim

thickness each time until a satisfactory

tooth pattern is obtained.procarmanuals.com

04-01-09
General Axle Service

04-01-09

CLEANING AND INSPECTION

INSPECTION BEFORE

DISASSEMBLY OF CARRIER

(ALL AXLES)

The differential case or carrier

should be inspected before any parts

are removed from it. These inspec-

tions can help to find the cause of the

trouble and to determine the correc-

tions needed.

Mount the carrier in the holding

fixture shown in Fig. 15. Wipe the lu-

bricant from the internal working

parts,
and visually inspect the parts

for wear or damage.

Tool-T57L-500-A

FIG. 15
— Bench
Fixture for

Carrier Overhaul—Typical

Rotate the gears to see if there is

any roughness which would indicate

damaged bearings or chipped gears.

Check the gear teeth for scoring or

signs of abnormal wear.

Set up a dial indicator (Fig. 16) and

check the backlash at several points

around the ring gear. Backlash should

be within specifications.
If no obvious defect is noted, check

the gear tooth contact.

To check the gear tooth contact,

paint the gear teeth with the special

compound furnished with each service

ring gear and pinion. A mixture that

is too wet will run and smear. Too dry

a mixture cannot be pressed out from

between the teeth.

As shown in Fig. 17, rotate the ring

gear (use a box wrench on the ring

gear attaching bolts for a lever) five

complete revolutions in both directions

or until a clear tooth contact pattern

is obtained.
DIFFERENTIAL BEARING

CAP BOLTS

E 1776-A

FIG. 76-Backlash Check-

Typical
E
1001 - C

FIG.
7
7—Checking Gear Tooth

Contact—Typical

Certain types of gear tooth contact

patterns on the ring gear indicate in-

correct adjustment. Noise caused by

incorrect adjustment can often be cor-

rected by readjusting the gears. Ac-

ceptable patterns and the necessary

corrections are explained under Tooth

Contact Pattern Check in Section I.

Gear tooth runout can sometimes

be detected by an erratic pattern on

the teeth. However, a dial indicator

should be used to measure the runout

of the back face of the ring gear as

shown in Fig. 18. If this runout ex-

ceeds specifications, disassemble the

carrier and replace necessary parts as

indicated in Part 4-2, Section 4 and

Part 4-3, Section 4.
1699-A

FIG. 18 -Checking Ring Gear

Runout—Typical

Loosen the differential bearing cap

bolts,
and then torque them to 25 ft-

lbs.
Remove the adjusting nut locks.

Carefully loosen one of the adjusting

nuts to determine if any differential

bearing preload remains. If any pre-

load remains, the differential bearings

may be re-used, provided they are not

pitted or damaged.

INSPECTION AFTER

DISASSEMBLY OF CARRIER

(ALL AXLES)

Thoroughly clean all parts. Syn-

thetic seals must not he cleaned, soak-

ed or washed in cleaning solvents.

Always use clean solvent when clean-

ing hearings. Oil the bearings im-

mediately after cleaning to prevent rust-

ing. Inspect the parts for defects.

Clean the inside of the carrier before

rebuilding it. When a scored gear set

is replaced, the axle housing should he

washed thoroughly and steam cleaned.

This can onl\ be done effectively if the

axle shafts and shaft seals are re-

moved from the housing. Inspect indi-

vidual parts as outlined below.

GEARS

Examine the pinion and ring gear

teeth for scoring or excessive wear.

Extreme care must he taken not to

damage the pilot hearing surface of

the pinion.procarmanuals.com

04-02-11
Rear Axle — Removable Carrier Type

04-02-11

If the axle housing is new, install a

new vent. The hose attaching portion

must face toward the front of the ve-

hicle.

2.
If leather-type wheel bearing ser-

vice seals are to be installed, soak the

new rear wheel bearing oil seals in

SAE 10 oil for 1/2 hour before instal-

lation. Wipe a small amount of an oil

resistant sealer on the outer edge of

each seal before it is installed. Do not

put any of the sealer on the sealing

lip.
Install the oil seals in the ends of

the axle housing with one of the tools

shown in Fig. 10 and 12.

3.
Position the replacement axle

housing under the vehicle, and raise

the axle with a hoist or floor jack.

Connect the suspension lower arms to

their mounting brackets on the axle

housing with pivot bolts and nuts. Do

not tighten the bolts and nuts at this

point.

4.
Position the suspension upper

arm in its mounting bracket on the

axle housing, and install the adjusting

bolt, eccentric washers, lock washer

and nut. Leave the bolt and nut loose

at this point.

5.
Position the brake lines to the

axle housing, and secure with the re-

taining clips.

6. Install the brake backing plates

on the axle housing flanges.

7.
Connect the track bar to the

mounting stud, install the washer and

attaching nut, and torque to specifica-

tions.

8. Position the rear coil springs and

insulators in the pockets provided.

9. Connect the lower studs of the

two rear shock absorbers to the

mounting brackets on the axle hous-

ing. Install the attaching nuts, and

torque to specifications.

10.
Connect the vent tube to the

vent on the housing. If axle housing is

new, install a new vent.

11.
Clean the mating surfaces of

the axle housing and differential car-

rier. Position the carrier on the

mounting studs on the housing using a

new gasket between carrier and hous-

ing. Install the copper washers and the

carrier-to-housing attaching nuts, and

torque to specifications.

12.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, and

then raise the axle assembly to con-

trolled curb height (Fig. 15). Hold the

axle at controlled curb height by plac-

ing blocks or pieces of steel pipe be-

tween the axle housing and the bumper

rear screw on the side rail. (See speci-

fications for dimensions.)
FRAME

TIGHTEN ARM

ATTACHING BOLTS

AT 5-45/64 INCH

HEIGHT POSITION
5-45/64 INCH

HEIGHT FOR

INSTALLATION

OF ARMS

E 1600-B

FIG. 75 -Axle Normal Curb

Height and Controlled Height

for Arm Installation

13.
With the axle at controlled curb

height, torque the suspension upper

and lower arm front pivot bolts and

nuts to specifications. Torque the

lower arm-to-axle housing pivot bolts

and nuts to specifications.

14.
Remove the oil seal replacer

tool from the transmission extension

housing. Position the drive shaft so

that the front U-joint slip yoke splines

to the transmission output shaft.

15.
Connect the drive shaft to the

U-joint flange, aligning the scribe

marks made on the drive shaft end

yoke and the axle U-joint flange dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

16.
Carefully slide the two axle

shaft assemblies in the axle housing.

The shorter shaft goes into the left

side of the housing. Use care in slid-

ing the axle shafts into the housing so

that the rough forging of the shaft will

not damage the oil seal. Start the axle

splines into the differential side gear,

and push the shaft in until the rear

wheel bearing bottoms in the housing.

17.
Install the rear wheel bearing

retainers on the attaching bolts on the

axle housing flanges. Install the nuts

on the bolts and torque to specifica-

tions.

18.
If the rear brake shoes were

backed off, adjust the brakes as out-

lined in Part 2-1, and install rubber

plugs in the adjuster slots.

19.
Install the two rear brake

drums and the drum attaching (Tin-

nerman) nuts.

20.
Install the rear wheels and tires.

21.
Fill the rear axle to the bottom

of the filler plug hole located in either

the carrier casting or housing cover

with specified lubricant. Be sure that

the axle is in operating position.

22.
Road test the vehicle to be sure

that pinion and driveshaft angles are
correct. Any shudder during heavy ac-

celeration, or deceleration may require

a pinion and driveshaft angle re-

adjustment as detailed in Driveshaft

and Pinion Angle Adjustment, Group

3,
Part 3-2.

AXLE HOUSING (LEAF

SPRING SUSPENSION)

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly. Disconnect

the drive shaft at the drive pinion

flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in

Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-

fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tool shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with

mechanic's wire. The hydraulic brake

lines and the parking brake cables are

still attached to the brake backing

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 16).

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operation*.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install theprocarmanuals.com

04-02-16

Rear Axle — Removable Carrier Type
04-02-16

Tool~T53L-200-A

Tool-T57L-4625-A

or 4625-K

E 1725-A

FIG. 29—Removing Pilot Bearing

to adjust for individual variations in

both the carrier housing dimension

and in the original gear set dimension.

Therefore, to select the correct shim

thickness for the new gear set to be

installed, follow these steps:

1.
Use a micrometer to measure

the thickness of the original shim re-

moved from the axle and use the same

thickness upon installation of the re-

placement carrier assembly or drive

pinion. If further shim change is ne-

cessary, it will be indicated in the

tooth pattern check.

2.
If the original shim is lost, sub-

stitute a nominal shim for the original

and use the tooth pattern check to

determine if further shim changes are

required. Nominal shim thicknesses is

E 1734-A
PINION BEARING

RETAINER

E 1482-B

FIG. 31—Removing Pinion Front

Bearing Cup

indicated in Part 4-3, Specifications.

A new ring gear and pinion should

always be installed in an axle as a

matched set (never separately). Be

sure the same identifying (matching)

number, appears on the bolt hole face

of the ring gear and on the head of

the drive pinion (Fig. 35).

3.
After determining the correct

shim thickness as explained in the

ss
Rom

Too/-T58L-70?-A

or4675-J

FIG. 30—Removing Pinion Front

Bearing Cup
FIG. 32—Removing Pinion Rear

Bearing Cup

foregoing steps, install the new pinion

and ring gear as outlined under As-

sembly.

DIFFERENTIAL
CASE

BEARINGS
AND
RING

GEAR
TEST

If the ring gear runout check (be-

fore disassembly) exceeded specifica-

tions,
the condition may be caused by

a warped gear, a defective case, or ex-

cessively worn differential bearings.

To determine the cause of excessive

runout proceed as follows:

1.
Assemble the two halves of the

differential case together without the

ring gear, and press the two differen-

tial side bearings on the hubs.
Press Ram

Tool -

T57L - 4614-A
Tool -

T57L - 4676-A2

1736-/

FIG. 33—Installing Pinion Front

Bearing Cup

too;-
IB .

T55P-46U
A2V •H"^^

\
Press Ram

Tool-

T57L-46U-A

FIG. 34—Installing Pinion Rear

Bearing Cup

2.
Place the cups on the bearings

and set the differential case in the car-

rier.

3.
Install the bearing caps and ad-

justing nuts as outlined in Steps 11

thru 14 under Assembly and Installa-

tion of Conventional Differential Case

which follows in this section.

4.
Tighten the right nut two notches

beyond the position where it first con-

tacts the bearing cup. Rotate the dif-

ferential case several revolutions in

each direction while the bearings are

MATCHED

GEAR SET

IDENTIFICATION

E 1628-A

FIG. 35— Pinion and Ring Gear

Markingsprocarmanuals.com

04-02-20
Rear Axle — Removable Carrier Type

0402-20

THRUST WASHER

E1175-B

FIG. 48—Assembling Differential Case

13.
Install the bearing cap bolts

and alternately torque them. The 9

3/8 inch ring gear size axle requires

60-70 ft-lbs. The 8 3/4 inch and 9

inch ring gear size axles require 70-85

ft-lbs.

14.
If the adjusting nuts do not turn

freely as the cap bolts are tightened,

remove the bearing caps and again in-

spect for damaged threads of incor-

rectly positioned caps. Tightening the

bolts to the specified torque is done to
be sure that the cups and adjusting

nuts are seated. Loosen the cap bolts,

and torque them to only 25 ft. lbs be-

fore making adjustments.

15.
Adjust the backlash between the

DIFFERENTIAL

BEARING

CONE AND

ROLLER

E 1700-A

FIG. 49—
Installing
Differential

Bearing
1376-A

FIG. 50—Installing Differential

bearing
ring gear and pinion as outlined in

Part 4-1, Section 2.

16.
Be sure to make a final tooth

pattern check before installing the

carrier assembly in the axle housing.

Limited-Slip

Differential Case

1.
Place the inner side gear and

thrust washer in the differential case

(Fig. 52). Lubricate all parts liberally

with limited-slip axle lubricant during

assembly.

2.
With a soft-faced hammer, drive

the pinion shaft into the case only far

enough to retain a pinion thrust wash-

er and pinion gear.

3.
Place the second pinion and

thrust washer in position and drive

the pinion shaft into place. Carefully

line up the pinion shaft lock in holes.

4.
Install the pinion shaft lock pin.

The lock pin must not extend beyond

the surface of the case.

5. Insert two 2-inch 7/16 (NF)

bolts through the differential case

flange, and thread them three or four

turns into the ring gear as a guide in

aligning the ring gear bolt holes. Press

or tap the ring gear into position.

6. Clamp the differential case in a

soft-jawed vise. Install the differential

outer side gear on the differential pin-

ion gears. Place the clutch hub on

the side gear. Place the thrusi: washer

on the huh

Limited-Slip dutch

Plate Installation

Prior to clutch plate installation,

the friction bonded plates must be

soaked in C6AZ-19570-C (ESW-

M2C-104-A) differential lubricant for

approximately 1/2 hour. In addition,

the differential lubricant must be lib-

erally applied to all components to

be assembled.

1.
Place the clutch hub into posi-

tion in a soft-jawed vise.

2.
First, install a steel clutch plate

in the cavity of the differential case

opposite the ring gear and then a

bonded friction plate (Fig. 53). Any

tab on the steel plates can be inserted

into any cavity in the differential case,

however when the first steel plate is

inserted the others must be placed in

the same manner (Fig. 54) so the tabs

with slots line up. Install the remain-

ing plates: a steel plate, bonded fric-

tion plate, a steel plate, bonded fric-

tion plate and lastly a steel plate.

Make sure the bonded friction plate

inner-spline teeth properly engage the

hub spline.procarmanuals.com

04-03-06

Rear Axles — Integral Carrier Type

04-03-06

9. Install a new integral nut and

ivasher on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 9 while the nut is being

tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, (Fig. 6)

and take frequent preload readings

until the preload is at the original rec-

orded reading established in step 3.

12.
After original preload has been

reached, tighten the pinion nut slowly,
until an additional preload of 6 to 12

in-lbs has been added.

The preload should not exceed the

amount shown above, or bearing fail-

ure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. (In

addition, the U-joint flange must

never be hammered on, or pneumatic-

-tools used.)

13.
Remove the oil seal replacer

tool from the transmission extension
housing. Install the front end of the

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

15.
Check the lubricant level. Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole, located in

the carrier casting or housing cover.

REMOVAL AND INSTALLATION

REAR AXLE HOUSING

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly (Fig. 14). Dis-

connect the drive shaft at the drive

pinion flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in the

foregoing Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-
fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tools shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with me-

chanic's wire. The hydraulic brake

SCRIBE MARKS

5/16-24

4 REQ'D.

12-15
LB.
FT.

U-BOLT - 4529 2 REQ'D.

E 1783-A

FIG. 14—Drive Shaft-to-Axle

U-Joint
Connection

El231-A

FIG. 73—Rear Axle Installation—Typical
lines and the parking brake cables are

still attached to the brake carrier

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 13)

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operations.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install the

lower insulators. Torque the spring

clip nuts to specification.

2.
Place the brake backing plates in

their normal position on the axle

housing. Use new gaskets on each side

of the brake backing plates.

3.
Install new axle shaft oil seals

with the tool shown in Fig. 8. Soak

the new seals in light weight engine oil

(SAE 10) for 1/2 hour before install-

ing them. Installation without use of

the proper tool will distort the seal

and cause leakage. Coat the outside

edges of the new oil seal with a non-

hardening type of sealer such as Per-

matex No. 2 or its equivalent.

4.
Install the axle shafts, brake

drums and wheels as outlined in Sec-

tion 2.

5.
Attach the hydraulic brake line

T fitting to the axle housing, and se-

cure the hydraulic brake line in its re-

tainer on the axle housing.

6. Install vent tube to brake tubeprocarmanuals.com

04-03-07
Rear Axles — Integral Carrier Type

04-03-07

junction and install vent hose to vent

tube.

7.
Raise the axle housing and con-

nect the shock absorbers.
8. Connect the rear end of the drive

shaft to the axle U-joint flange, align-

ing the scribe marks made on the

drive shaft end yoke and the axle U-
joint flange (Fig. 14).

9. Fill the axle with the proper

grade and amount of lubricant.

10.
Road test the vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

All service operations on the differ-

ential case assembly and the drive pin-

ion assembly can be performed with

the housing in the vehicle.

REMOVAL OF

DIFFERENTIAL

CASE AND DRIVE PINION

1.
Raise the vehicle and support it

on the underbody, so that the rear

axle drops down as far as the springs

and shock absorbers permit.

2.
Remove the cover from the car-

rier casting rear face, and drain the

lubricant.

3.
Perform the Inspection Before

Disassembly of Carrier in Part 4-1,

Section 3.

4.
Remove both rear wheels.

5.
Remove the brake drums.
6. Working through the hole pro-

vided in the axle shaft flange, remove

the nuts that attach the wheel bearing

retainers to the axle housing.

7.
Pull the axle shafts with the tool

shown in Fig. 2. Care must be exer-

cised to prevent damage to the oil

seals.
Install a nut on one of the brake

backing plate attaching bolts to hold

the plate to the axle housing after the

shaft has been removed. Remove both

seals with the tool shown in Fig. 8.

8. Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly (Fig. 14). Dis-

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when
they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

9. Remove the differential bearing

adjusting nut locks (Fig. 15).

10.
Mark one differential bearing

cap and the case (Fig. 16) to help po-

sition the parts properly during as-

sembly.

11.
Remove the differential bearing

cap bolts and bearing caps. Hold the

differential case assembly in the hous-

ing after the caps are removed.

12.
Remove the differential case

and bearing cups (Fig. 17).

13.
Hold the drive pinion flange

and remove the pinion nut (Fig. 9).

14.
Remove the pinion flange (Fig.

10).

DIFFERENTIAL PINION GEAR

AND THRUST WASHER

COVER AND GASKET
DIFFERENTIAL SIDE GEAR

AND THRUST WASHER

SHAFT RETAINER DIFFERENTIAL

PINION SHAFT DIFFERENT|AL

DIFFERENTIAL CASE CASE COVER
BEARING ADJUSTING NUT

PINION AND RING GEAR

AXLE SHAFT
BEARING

DRIVE GEAR ATTACHING BOLT

ADJUSTING NUT LOCK

BEARING CAP

PINION LOCATING SHIMS

BEARING AND CUP

WHEEL BEARING RETAINER

GASKET
BEARING AND CUP

SEAL

AXLE SHAFT SEAL

BEARING PRELOAD SPACER/
AXLE HOUSING

FILLER PLUG

'WHEEL BEARING

WHEEL BEARING RETAINER

DEFLECTOR FLANGE

E1908A

FIG. 75—Disassembled Rear Axleprocarmanuals.com

04-03-08
Rear Axles — Integral Carrier Type

04-03-08

15.
With
a
soft-faced hammer,

drive
the
pinion
out of the
front bear-

ing cone
and
remove
it
through
the

rear
of the
carrier casting.

16.
Drive against
the
pinion front

bearing cone
and
drive
the
pinion

flange seal
and the
bearing cone
out

of
the
front
of the
carrier casting.

17.
To
remove
and
install
the pin-

ion rear bearing cone
use the
tools
in

Fig.
18 and 19.

18.
Measure
the
shim which
is

found under
the
bearing cone with
a

MARKINGS

E1909A

FIG. 16—Typical Differential

Bearing Cap Marking

E1910A

FIG. 77—Differential Case

Removal or Installation

1368-A
micrometer. Record
the
thickness
of

the shim.

DISASSEMBLY
OF

DIFFERENTIAL CASE

1.
If the
differential bearings
are to

be removed,
use the
tools shown
in

Fig.
20.

Press
Ram

REAR BEARING

CONE
AND

ROLLER
Fiber

Block

E1911A

FIG. 79—Installing Pinion Rear

Bearing Cone

Tool-

4221-AL

FIG. 18—Removing Pinion Rear

Bearing Cone
DIFFERENTIAL

BEARING

E1912A

FIG. 20—Differential Bearing

Removal
2.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the ring gear from
the
case
or tap it

off with
a
soft-faced hammer.

3.
With
a
drift, drive
out the
differ-

ential pinion shaft lock
pin (Fig. 21).

4.
Drive
out the
pinion shaft with
a

brass drift. Remove
the
gears
and

thrust washers.

PARTS REPAIR
OR

REPLACEMENT

Clean
and
inspect
all the
parts
as

outlined
in
Part 4-1, Section
3.
Before

assembling
the
carrier, repair
or re-

place
all
parts
as
indicated
by the in-

spection.

The principal replacement opera-

tions
are
covered
in the
following
pro-

cedures.
All
other repair
or
replace-

ment operations
are
performed during

Cleaning
and
Inspection Part
4-1,

Section
3, or
during
the
Assembly
in

this section.

PINION BEARING CUPS

Do
not
remove
the
pinion bearing

cups from
the
carrier casting unless

the cups
are
worn
or
damaged.

If
the
pinion bearing cups
are to be

replaced, drive them
out of the
carrier

E1913A

FIG. 21—Differential Pinion

Shaft Lock Pin Removalprocarmanuals.com

04-03-09
Rear Axles — Integral Carrier Type

04-03-09

E1914A

FIG. 22—Pinion Bearing Cup Removal or Installation

\

MATCHED

GEAR SET

IDENTIFICATION

E 1628-A

FIG. 23—Pinion and Ring

Gear Marking

casting with a drift. Install the new

cups with the tool shown in Fig. 22.

Make sure the cups are properly seat-

ed in their bores. If a 0.0015-inch feel-

er gauge can be inserted between a

cup and the bottom of its bore at any

point around the cup the cup is not

properly seated.

Whenever the cups are replaced, the

cone and roller assemblies should also

be replaced.

DRIVE PINION AND GEAR

SET

Individual differences in machining

the carrier casting and the gear set re-

quire a shim between the pinion rear

bearing cone and the pinion gear to

locate the pinion for correct tooth

contact with the ring gear.

When replacing a ring gear and pin-

ion it should be noted that the original

factory installed shim is of the correct

thickness to adjust for individual vari-

ations in both the carrier casting di-

mension and in the original gear set

dimension; therefore, to select the cor-

rect shim thickness for the new gear
set to be installed, follow these steps:

1.
With a micrometer, measure the

thickness of the original shim removed

from the axle and use the same thick-

ness upon installation of the replace-

ment carrier assembly or drive pinion.

2.
If further shim change is neces-

sary, it will be indicated in the tooth

pattern check.

3.
If the original shim is lost, sub-

stitute a nominal shim for the original

and use the tooth pattern check to de-

termine if further shim changes are re-

quired. Nominal shim thickness is in-

dicated in Part 4-5, Specifications.

A new ring gear and pinion should

always be installed in an axle as a

matched set (never separately). Be

sure the same identifying (matching)

number, painted in white, appears on

the bolt hole face of the ring gear and

on the head of the drive pinion

(Fig. 23).

4.
After determining the correct

shim thickness as explained in the

foregoing steps, install the new pinion

and ring gear as outlined under As-

sembly.

DIFFERENTIAL CASE,

BEARINGS, AND RING

GEAR

If the ring gear runout checK (be-

fore disassembly) exceeded specifica-

tions,
the condition may be caused by

a warped gear, a defective case, or ex-

cessively worn differential bearings.

To determine the cause of excessive

runout proceed as follows:

1.
Assemble the two halves of the

differential case together without the

ring gear, and press the two differen-

tial side bearings on the case hubs.

2.
Place the cups on the bearings

and set the differential case in the car-

rier.
3.
Install the bearing caps and ad-

justing nuts as outlined in steps 11

thru 14 under Installation of Drive

Pinion and Differential Case in this

section.

4.
Tighten the right nut two notches

beyond the position where it first con-

tacts the bearing cup. Rotate the dif-

ferential case several revolutions in

each direction while the bearings are

loaded to seat the bearings in their

cups.
This step is important.,

5.
Again loosen the right nut to re-

lease the preload. Check to see that

the left nut contacts the bearing cup.

Using the dial indicator set-up shown

in Fig. 10, Part 4-1, adjust the preload

to 0.008 to 0.012 case spread for new

bearings or 0.005 to 0.008 for the

original bearings, if reused.

6. Check the runout of the differen-

tial case flange with a dial indicator.

If the runout does not now exceed

specifications, install a new ring gear.

If the runout still exceeds specifica-

tions,
the ring gear is true and the

trouble is due to either a defective

case or worn bearings.

7.
Remove the differential case

from the carrier and remove the side

bearings from the case.

8. Install new bearings on the case

hubs,
and again install the differential

assembly in the carrier without the

ring gear.

9. Check the case runout again with

the new bearings. If the runout is now

within limits, the old bearings were

excessively worn. Use the new bear-

ings for assembly. If the runout is still

excessive, the case is defective and

should be replaced.

ASSEMBLY

Refer to Part 4-1 for Cleaning and

Inspection before starting assembly

operations.

ASSEMBLY OF

DIFFERENTIAL CASE

1.
Lubricate all the differential

parts with axle lubricant, before they

are installed in the case.

2.
Place the side gears and thrust

washers in the case.

3.
Place the two pinion gears and

thrust washers exactly opposite each

other in the case openings and in

mesh with the side gears.

4.
Turn the pinions and thrust

washers until the holes in the pinion

gears align with the pinion shaft holes

in the case.

5.
Start the pinion shaft into the

differential case. Carefully align the

shaft lock pin hole with the pin holeprocarmanuals.com

04-04-04
Rear Axle — Ford Light-Duty (WER)

04-04-04

REMOVAL AND INSTALLATION

AXLE HOUSING

Refer to Fig. 7.

REMOVAL

1.
Raise the vehicle on a hoist.

2.
Remove the wheels and tires

from the brake drums.

3.
Position a drain pan and loosen

the rear axle cover to housing attach-

ing bolts. Drain the housing.

4.
Remove the attaching (Tinner-

man) nuts that secure the brake drums

to the axle shaft flanges, and then re-

move the drums (Fig. 7).

5.
Remove the axle housing cover

bolts,
cover and gasket. Discard the

gasket. Remove the drain pan.

6. Disconnect the drive shaft at the

drive pinion companion flange. Re-

move the drive shaft from the trans-

mission extension housing. Install an

oil seal replacer tool in the transmis-

sion housing to prevent leakage. Refer

to the transmission group for the ap-

propriate tool.

7.
Disconnect the lower end of the

shock absorbers at the mounting

brackets.

8. Disconnect the track bar from

the axle housing stud. If the axle

housing is to be replaced, transfer the

stud to the new housing.

9. Position safety stands under the

rear frame members. Lower the vehi-

cle with the hoist and allow the axle

to lower far enough to relieve rear

spring tension.

10.
Remove the pinion shaft lock

bolt and pinion shaft (Fig. 2), differ-

ential pinion gears and thrust washers.

11.
Push the axle shaft(s) inward

toward the center of the axle housing.

Remove the C-locks from the inner

ends of the axles (Fig. 3). Remove the

axle shafts from the housing. Extreme

care must be used to avoid contacting

the axle shaft seal lip with any portion

of the axle shaft other than the seal

journal.

12.
Disconnect the vent hose from

the rear vent tube and remove all

brake lines from the axle housing re-

taining clips.

13.
Remove the brake backing

plate attaching nuts and the plates

from the axle housing. Suspend the

plates above the axle housing with

mechanics wire. The hydraulic brake

lines and the parking brake cables will

remain attached to the brake backing

plates.
14.
Support the rear axle housine

on a jack.

15.
Remove the right and left rear

springs and insulators.

16.
Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

17.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and two eccentric washers.

18.
Lower the rear axle to the floor

with the jack and remove the axle

from under the vehicle.

19.
Remove the wheel bearings and

oil seals with the tool shown in Fig. 4.

20.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. Refer

to Section 4, Major Repair Operation

for the procedure.

INSTALLATION

1.
Lightly coat the wheel bearing

rollers with axle lubricant. Install

wheel bearings in the axle housing

with the tool shown in Fig. 5. The

bearings should seat firmly against the

shoulder.

2.
Wipe all lubricant from the oil

seal bore before installing the seal. If

axle housing is being replaced, new

seals must be installed.

3.
Inspect the original seal for

nicks,
scuffs or abnormal wear, and

replace if necessary. New seals are

pre-packed with lubricant and do not

require an oil soak.

4.
Install the seal with the tool

shown in Fig. 6. Installation without

the use of the proper tool will distort

the seal and cause leakage.

5. Raise the rear axle into position

under the vehicle with a hoist or floor

jack. Connect the suspension lower

arms to their mounting brackets on

the axle housing with pivot bolts and

nuts.
Do not tighten the mounting

bolts at this point.

6. Position the suspension upper

arm in its mounting bracket on the

axle housing and install the adjusting

bolt, eccentric washers, lock washer

and nut. Do not tighten the mounting

bolt at this point.

7.
Place the rear coil springs and

insulators into position in the pockets

provided.
8. Place the brake backing plates

on the axle housing flanges, install 4

attaching bolts and nuts and torque

them to specifications.

9. Position the brake lines to the

axle housing and secure them with the

retaining clips. If the axle housing is

new, install a new vent. When install-

ing the new axle vent apply a small

amount of Locktite (C5AZ-19554-B)

to prevent oil leakage between vent

and axle housing. Connect the vent

tube to the vent.

10.
Install the pinion side gears and

thrust washer.

11.
Slide the axle shafts into place

in the axle housing. Exercise care that

splines or any portion of the axle

shafts do not damage the oil seals and

that they engage with the splines of

the differential side gears.

12.
Install the axle shaft C-lock O-

ring and C-lock on the inner end of

the shaft and push the shaft outward

so that the shaft lock seats in the

counterbore of the differential side

gear.

13.
Position the pinion differential

gears and thrust washers 180 degrees

apart to the differential side gears.

Revolve the gear assembly until the

holes in the differential case are al-

igned with the pinion gears.

14.
Position the differential pinion

shaft through the case and pinions, al-

igning the hole in the shaft with the

lock bolt hole. Install the lock bolt

and tighten it to specification.

15.
Clean the gasket mounting sur-

face of the rear axle housing and the

cover. Install a new cover gasket,

cover and the attaching bolts. Torque

the bolts to specification.

16.
Raise the rear axle on a hoist

and remove the safety stands.

17.
Connect the track bar to the

mounting stud. Install the washer and

nut. Torque the nut to specification.

18.
Connect the two rear shock ab-

sorbers to the mounting brackets on

the axle housing and torque the at-

taching nuts to specification.

19.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, then

raise the axle assembly to the con-

trolled height (Fig. 8). Hold the axle

at the controlled height by placing

blocks or pieces of steel pipe between

the axle housing and the bumper rear

screw on the side rail.procarmanuals.com