service FORD MUSTANG 1969 Volume One Chassis

03-10-04
Ford-Thompson Power Steering Pump

03-10-04

OUTLET FITTING

GASKET
Wood Block

0-RING SEAL

G1345-
-500-
A

G1603- A

FIG. 6—Gasket Locations
FIG.
7—Installing
Reservoir

on Pump—Typical
2.
Apply vaseline to the reservoir

O-ring seal and to the inside edge of

the new reservoir flange. Do not twist

the O-ring seal.

3.
Position the reservoir over the

pump and align the notch in the reser-

voir flange with the notch in the outer

diameter of the plate and bushing as-

sembly.

4.
Install the reservoir on the pump

and O-ring seal with a plastic or rub-

ber hammer and a block of wood as

shown in Fig. 7. Tap at the rear of the

reservoir and on the outer edges only.

5.
Inspect the assembly to be sure

the reservoir is evenly seated on the

pump housing plate.

6. Position the service identification

tag on the outlet fitting and install the

outlet fitting hex nut. Torque the nut

to specification (Part 3-13). Do not

exceed specification.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

Disassembly of the pump and its

subassemblies must be made on a

clean work bench. In repairing any

hydraulically operated unit, cleanliness

is of utmost importance. Clean the ex-

terior of the unit with a suitable sol-

vent and drain as much of the fluid as

possible.

If only the reservoir is to be re-

moved, plug the inlet and outlet open-

ings with masking tape or plugs. Do

not immerse the shaft oil seal in sol-

vent. If only the rotor shaft seal is to

be replace, see Rotor Shaft Seal Re-

placement outlined in this section.

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mount-

ed holding fixture Tool T57L-5OO-A

(Fig. 8).

2.
Position the pump assembly,

with pulley assembled, on the adapter

plate, pulley facing down.

3.
Remove the outlet fitting nut and

the service identification tag.

4.
Invert the pump assembly and,

using a block of wood and a rubber or

plastic hammer, remove the pump res-

ervoir and seal by tapping around the

flange of the reservoir and on the und-

erside of the filler neck.

5.
Again invert the pump assembly,

loosen and remove the pump housing

retention bolts and remove the pump

housing.
6. If necessary, remove the fol-

lowing components from the pump

housing: the housing cover, the O-ring

seal and the pressure springs. These

components normally will remain in

the pump housing when it is removed.

7.
Remove and discard the pump

cover gasket.

8. Remove the retainer end plate

and upper pressure plate (in some

pumps, the end plate and upper pres-

sure plate are integral).

9. Remove the loose fitting dowel

pin. Be careful not to bend the fixed

dowel pin which remains in the hous-

ing plate assembly.

10.
Remove the rotor assembly

being careful to prevent the springs

and slippers from falling out and be-

coming lost. Do not disassemble fur-

ther unless the lower pressure plate,

housing plate, rotor shaft and/or seal

is to be replaced.

11.
Invert the pump assembly and,

using Tool T63L-1O3OO-B, remove the

pulley.

12.
Clean any rust, road dirt, burrs,

scoring, etc. from the pulley end of

the rotor shaft prior to removal of the

shaft from the housing plate. The

shaft must come out without restric-

tions to prevent scoring or damage to

the bushing. Remove the pump rotor

shaft.

13.
Remove the lower pressure

plate.
PARTS REPAIR OR

REPLACEMENT

ROTOR SHAFT

SEAL REPLACEMENT

Removal

1.
Remove the pulley from the

rotor shaft as described under Power

Steering Pump Pulley Removal.

2.
Position the pump assembly in

T57L-500-A

T69P-3A674-A

•
G1604-A

FIG. 8—Adapter Plate Installationprocarmanuals.com

03-10-07
Ford-Thompson Power Steering Pump

03-10-07

15.
Place small amounts of vaseline

on the pump housing plate to hold the

cover gasket in place. Install the gas-

ket on the pump housing plate.

16.
Insert the pressure plate springs

into the pockets in the pump valve as-

sembly. Vaseline may be placed in the

spring pockets to hold the springs in

position (Fig. 17).

17.
Using Tool T69P-3B586-A,

plug the intake hole in the housing

(Fig. 17).

18.
Lubricate the inside of the

housing and the housing cover seal

with C1AZ-19582-A lubricant. Fabri-

cate two studs (3/8-16x1.55 ) to be

used as positioning guides. Install one

in the housing plate bolt hole closest

to the drain hole and one in the bolt

hole diametrically opposite.

19.
Align the small diameter lube

hole in the housing rim with the lube

hole in the housing plate.

20.
Install the housing, applying an

even, downward pressure. The pres-
sure plate springs must not be jarred

and moved out of position. Remove

the guide studs.

21.
Install the housing retaining

bolts finger tight.

22.
Remove Tool T69P-3B586-A.

23.
Torque the retaining bolts even-

ly to 28-32 ft-lbs until the housing

flange contacts the gasket.

24.
Install a 3/8x16 hex head

screw, finger tight, into the end of the

rotor shaft. Using a torque wrench,

check the input torque of the shaft

(Fig. 18). The torque should not ex-

ceed 15 in-lbs. If it does, loosen the

retaining bolts slightly, rotate the

rotor shaft, retorque the bolts evenly

and again check the shaft torque. The

pump must not be used if the shaft

torque exceeds 15 in-lbs.

25.
Release the pin in the bench

holding fixture and agitate the pump

assembly back and forth. If there is a

rattle, the pressure plate springs have
fallen out of their seats and must be

reinstalled.

26.
Install the reservoir O-ring on

the housing plate being careful not to

twist the O-ring. Apply vaseline to the

seal and to the ID of the reservoir

flange.

27.
Install the reservoir, aligning

the notch in the reservoir flange with

the notch in the OD of the pump

housing plate and bushing assembly.

Using only a plastic or rubber ham-

mer, tap at the rear on the outer cor-

ners of the reservoir to avoid damage.

28.
Inspect the assembly to deter-

mine if the reservoir is seated on the

housing plate.

29.
Install the service identification

tag on the outlet valve fitting.

30.
Install the outlet valve fitting

nut and torque to 43-47 ft-lbs.

31.
Invert the pump assembly.

32.
If the pulley was removed, in-

stall the correct pulley using Tool

T65P-3A733-A.procarmanuals.com

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

03-13-08
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

04-01-04

General Axle Service

04-01-04

ACCEPTABLE TOOTH PATTERN LIMITS

ANY COMBINATION
OF
DRIVE AND COAST PATTERNS SHOWN PERMISSIBLE

Toe

Toe

Toe

Toe

Heel

Heel

LOW HEEL COAST

MM

DRIVE

COAST

FIG. 4—Acceptable Tooth Pattern Limits
(All
Axles)
E 1680-Aprocarmanuals.com

04-01-05

General Axle Service

04-01-05

Integral Carrier Type Axle

1.
Thinner shim with
the
backlash

set
to
specifications moves
the
pinion

farther from
the
ring gear.

2.
Thicker 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

differential case
and
drive pinion will

have
to be
removed from
the
carrier

casting
to
change
a
shim. When
re-

installing
the
pinion
and
ring gear
of a

non-hunting
or
partial non-hunting

gear
set, be
sure that
the
marked

tooth
on the
pinion indexes between

the marked teeth
on the
ring gear

(Fig.
51,
Part
4-2).
Refer
to
Pinion

and Ring Gear Tooth Contact Adjust-

ment, Section
2.

REAR AXLE COMPANION

FLANGE RUNOUT CHECK

ALL AXLES EXCEPT

THUNDERBIRD
AND

CONTINENTAL MARK
III

1.
Raise
the
vehicle
on a
hoist that

supports
the
rear axle (twin-post

hoist).

2.
Remove
the
driveshaft assembly

(Group
5).

3.
Check
the
companion flange

damage
to the
universal joint bearing

locating lugs.
If the
universal joint

bearing locating lugs
on the
compan-

ion flange
are
shaved (worn)
or dam-

aged, replace
the
companion flange

(Fig.
5).

PROPERLY SEATED
CUP SHAVES LUG

E 1621-A

FIG. 5—Checking Companion

Flange

4.
The
rear axle companion flange

runout
is
checked with
a
modified uni-

versal joint (checking tool)
a
dial indi-

cator with
1.000
inch minimum travel,
and
a
cup-shaped dial indicator adapt-

er tool
(Fig. 6). To
fabricate
the

checking tool, modify
a
universal joint

assembly
by
removing
two
bearing

cups that are opposite each other, and

cuttting
or
grinding
off
one
of
the uni-

versal joint bearing flanges (Fig. 6).

5.
Install
the
cup-shaped adapter
on

the dial indicator stem. Install
the
dial

indicator
on the
pinion retainer
or pi-

nion nose bumper bracket. Position

the indicator
to
allow
an
indication
at

the ends
of the
universal joint bearing

cups
and the
remaining exposed jour-

nal
of the
cross-shaft.

6. Turn
the
companion flange
so

that
the
dial indicator cup-type adapt-

er rests
on the
machined surface
of

the bearing
cup (Fig. 6).
Rotate
the

companion flange side-to-side slightly

to obtain
a
reading indicating that
the

bearing
cup
surface
is
perpendicular
to

the indicator cup-type adapter. This

will
be the
point
at
which
the
dial
in-

dicator
cup is
closest
to the
center
of

companion flange rotation.
It is
also

the point
at
which
the
dial indicator

hand will reverse direction
as
the com-

panion flange
is
turning.
Set the
dial

indicator
to
zero.

oo/-6565,
Used

'With Bracket From

Too!-4201-C

MOUNT HERE

Tool-4201-C

E
1622-
A

FIG. 6—Flange Bearing
Cup

Run-out Check—Typical
7.
Carefully retract
the
dial indica-

tor stem
and
rotate
the
companion

flange 180 degrees
to
position
the ma-

chined surface
of the
opposite univer-

sal bearing under
the
dial indicator

adapter tool. Again, slightly rotate
the

flange side-to-side
to
position
the

bearing perpendicular
to the
dial indi-

cator adapter. Again, this
is the
point

at which
the
indicator hand will
rev-

erse direction
as the
flange
is
rotated.

Record
the
flange bearing
cup
runout

reading obtained from
the
indicator

(Fig.
7).

Rotate
the
companion flange
90

degrees
and
position
the
dial indicator

adapter
on the
machined
end of the

exposed journal
(Fig. 8). Be
sure
the

end surface
of the
exposed journal
is

perpendicular
to the
indicator
cup-

type adapter. This requires that
the

cross-shaft
be
moved fore
and aft on

the flange bearing cups. Note
the

point
at
which
the
indicator hand rev-

erses direction. Rotate
the
flange
as-

sembly side-to-side until
the
cross-

shaft
is
perpendicular
to the
pinion

shaft axis,
and the
indicator hand
re-

verses direction. Zero the dial indicator

and check the zero point again by

Tool-6565, Used

With Bracket
Fro

Tool-4201 -C
MOUNT HERE —

Too/-4207-C

E 1624-A

FIG. 8—Cross Shaft Runout

Check—Typical

INDICATOR

READING

1

2

3

Average
FLANGE

BEARING CUP

RUNOUT—INCH

0.C04

0.002

0.003

0.003
DRIVESHAFT UNIVERSAL

CROSS-SHAFT

RUNOUT—INCH

0.005

0.004

0.003

0.004

FIG. 7—Flange Bearing
Cup and
Cross Shaft Runout Averaging

Chart—Typical Readingsprocarmanuals.com