axle FORD MUSTANG 1969 Volume One Chassis

NUT-33847-S8
9/16-12
100-130 LB FT.

*-34785-S7

-CAM-5A637 (2 REQUIRED)
• NUT-55754-S7

9/16-12
60-85 LB. FT.

4002 (2 REQUIRED)
• BOLT-304907-S2

9/16-12
80-105 LB. FT.
NO.
4 CROSSMEMBER-5029

VENT TUBE-4A001

NUT-34664-S

3/8-24
(2 REQUIRED)

15-25 LB. FT.

WASHER-18041

(2 REQUIRED)
BOLT-559bl-S2

(2 REQUIRED)
TRACK BAR STUD-4269

•110-140 LB. FT.
VENT-4338

VENT MUST POINT

TO THE REAR
CLIP-374998-S100

BUMPER ASSEMBLY-4906
BUSHING-500939

(4 REQUIRED)

WASHER-18171

(2 REQUIRED)

BOLT-40923-S2

(2 REQUIRED)
BOLT-39883-S8

(4 REQUIRED)

9-13 LB. FT.
NUT-33847-

9/16-12*100-130
LB. FT

L
OC
KWASHE R -34
785
-S 7
BACKING PLATE

ASSEMBLY

*2290 R.H. #2210 L.H.
REAR AXLE ASSEMBLY

4001 REFERENCE
TRACK BAR AND

BUSHING ASSEMBLY-5A639

NUT-55754-S7
9/16-12
80-105 LB. FT.

TRACK BAR AND

oJSHfNG ASSEMBLY

5A639
PARKING BRAKE

CABLE »2A635 R.H

•2A809 L.H.

(2 REQUIRED)
SHOCK ABSORBER-18080'

REFERENCE (2 REQUIRED)

•BOLT-2248

(8 REQUIRED)

• SEAL-2256

(2 REQUIRED)

PRONGS MUST BE SECURELY

LOCKED IN PLACE
WHEEL-1007

(2 REQUIRED)

INSULATOR-5536

(4 REQUIRED)
TIRE VALVE-1700

(2 REQUIRED
TIRE VALVE

XTENSION-1705©

(2 REQUIRED)

FRAME ASSEMBLY-5005

LOWER ARM-5A648

DRIVE SHAFT ASSEMBLY-4602
SPRING-5560

(2 REQUIRED)

• NUT-34447-S8
7/16-20

(8 REQUIRED)

30-45 LB. FT.

•BRAKE DRUM-1126

(2 REQUIRED)

TIRE-1508

(2 REQUIRED)

• NUT-372188-S32 (6 REQUIRED)

ASSEMBLE NUTS TO HOLD DRUM ASSEMBLY

SECURELY AGAINST FLANGE
BOLT-379334-S8

9/16-12
(2 REQUIRED)
NUT-375022-S2

70-90 LB. FT. NUT

90-120 LB. FT. BOLT
NUT-375022-S2

(2 REQUIRED)

-90 LB. FT. NUT

90-120 LB. FT. BOLT
BOLT-3 79334-S8

(2 REQUIRED)

NUT-34988-S4

(4 REQUIRED)

44-52 LB. FT.

FRAME ASSEMBLY-5005

REFERENCE
2

o

i

O

TO

<D

Q

>

X

TO

<D

O

3

n

Q

©USE 1705 VALVE EXTENSION

WITH FULL WHEEL COVERS

* TORQUE NUT OR BOLT

TORQUE NUT OR STUD

ITEMS MARKED •

PURCHASED AS PART OF

4001 REAR AXLE ASSEMBLY
NUT-375032-S36
1/2-23

(2 REQUIRED) 50-85 LB. FT.

SPRING MUST BE POSITIONED

AS SHOWN FOR R.H. SIDE
SPRING MUST BE POSITIONED

AS SHOWN FOR L.H. SiDE
NUT-375022-S2 (2 REQUIRED)

70-90 LB. FT. NUT

90-120 LB. FT. BOLTl
TIONAL

El 746-A
?

6

FIG. 14—Redr Axle Installation—Thunderbird—Typical Ford, Mercury, Meteor and Continental Markprocarmanuals.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

WASHER

18041

EXISTING
HOLE

IN
SIDE RAIL

#1
NUT 372188-

S32

4137-WEDGES

SPRING-5556

INSULATOR-5732

SHACKLE
5A630

NUT34448-S8

E
1510-B

FIG. 16—Rear Axle Installation—Lincoln Continental—-Typical of Cougar, Fairlane, Montego and Mustangprocarmanuals.com

04-02-13

Rear Axle
—
Removable Carrier Type
04-02-13

lower insulators. Torque
the
spring

clip nuts
to
specification.

2.
Place
the
brake backing plates
in

their normal position
on the
axle

housing.

3.
Install
new
axle shaft
oil
seals

with
the
tool shown
in Fig. 10.
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 tube

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.

9. Fill
the
axle with
the
proper

grade
and
amount
of
lubricant.

10.
Road test
the
vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY
OF

DIFFERENTIAL CARRIER

CONVENTIONAL

DIFFERENTIAL

A disassembled view
of the
rear

axle assembly
is
shown
in Fig. 17.

After mounting
the
carrier
in a

holding fixture, disassemble
the car-

rier
as
outlined
in the
following proce-

dures:

1.
Mark
one
differential bearing

cap
and the
mating bearing support

with punch marks
to
help position
the

parts properly during assembly
of the

carrier. Also, mark
one of the
bearing

adjusting nuts
and the
carrier with

AXLE SHAFT-4725
RETAINER RING-1100
scribe marks
for
proper location
dur-

ing assembly.

2.
Remove
the
adjusting
nut
locks,

bearing caps,
and
adjusting nuts. Then

lift
the
differential case assembly
out

of
the
carrier.

(Remove
the
bearing caps
by tap-

ping
the
caps lightly with
a
soft
mal-

let).

3.
Remove
the
differential bearings

with
the
tools shown
in Fig. 18.

4.
Mark
the
differential case, cover,

and ring gear
for
assembly
in the
orig-

inal position.

5.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the gear from
the
case
or tap it off

with
a
soft-faced hammer.

6. With
a
drift, drive
out the
differ-

AXLE HOUSING-4010

DIFFERENTIAL

PINION SHAFT-4211
ential pinion shaft lock
pin (Fig. 19),

and separate
the
2-piece differential

case.

7.
Drive
out the
pinion shaft with
a

brass drift
(Fig. 20).

8. Remove
the
gears
and
thrust

washers
(Fig. 48).

LIMITED-SLIP DIFFERENTIAL

1.
Remove
the
differential case

from
the
carrier
and
remove
the
bear-

ings from
the
differential case
in the

same manner
as the
conventional
dif-

ferential case.

2.
Place
the
differential case
in a

hydraulic press,
and
apply about
one

ton pressure across
the
case bearing

hubs while removing
the
ring gear
at-

FLAT WASHER (LIMITED SLIP ONLY)

DRIVE GEAR ATTACHING BOLT

DIFFERENTIAL CASE COVER -4206

DIFFERENTIAL PINION GEAR-4215

THRUST WASHER-4230

ADJUSTING NUT-4067

CARRIER HOUSING-4025

DRIVE PINION-4610
PINION BEARING

SPACER-4662

PINION FRONT

BEARING-4621

RING GEAR

PILOT BEARING-4A242

FIG. 17—Rear Axle Disassembled—Typical
PILOT BEARING

RETAINER-4627

PINION REAR

BEARING CUP-4616
DEFLECTOR-4859

PINION RETAINER-4668

SEAL-4676
FLANGE_4858
E1750-Aprocarmanuals.com

04-02-14

Rear Axle
—
Removable Carrier Type

04-02-14

DIFFERENTIAL

BEARING
Tool—
7
571-4220-A

T66P°4220-P

E1015-B

FIG. 18—Removing Differential

Bearing—Ford

taching bolts. Applying pressure will

contain
the
spring pressure between

the differential case
and
cover until

after
the
bolts
are
removed,
and
there-

by prevent stripping
of the
threads.

3.
Release
the
hydraulic press
ram,

and remove differential case cover.

4.
Remove
the
Belleville spring

(Fig.
54).

5.
Remove
the
steel
and the
bonded

clutch plates.

6. Remove
the
differential clutch

hub,
side gear,
and
thrust washer.

7.
Remove
the
ring gear from
the

differential case.

8. Drive
out the
differential pinion

shaft lock
pin.

9. With
a
brass drift, drive
out the

differential pinion shaft. Then remove

the pinion gears,
the
other side gear,

and thrust washers.
E 1724-A

FIG. 20—Driving
Out
Differential

Pinion Shaft

TRACTION-LOK

DIFFERENTIAL

1.
Remove
the
differential case

from
the
carrier
and
remove
the
bear-

ings from
the
differential case
in the

same manner
as the
conventional
dif-

ferential case.

2.
Remove
ten
bolts securing
the

ring gear
to the
differential case
as-

sembly.
The
ring gear must
be re-

moved
in
order
to
separate
the
case

halves.

3.
Remove
the
ring gear
by
tapping

the gear with
a
soft hammer
or
press

the gear from
the
case.

4.
Place
the
differential case
in a

press
to
load
the
bearing journals
so

that
the
pre-load
of the
springs
is ov-

ercome (approx.
1,500
lbs.).
(If a

press
is not
available,
two 7/16
inch

bolts
and
nuts
can be
used
in the
ring

gear mounting holes
(one on
each

side)
to
compress
the
case halves
to-
gether
and
overcome pre-load spring

tension.) Then, while
the
case
is
still

under pressure, loosen
the two
Allen

or Phillips head screws which hold
the

case halves together until
one or two

threads
of the
screws remain engaged.

Remove
the
case assembly from
the

press.
Tap on the
cover
to
spring
it

loose; then, remove both screws.

5.
With
the
cover facing down, lift

off
the
case. Remove
the
pre-load

spring plate
and
four pre-load springs.

6. From
the
cover remove
the
side

gear, four clutch plate
ear
guides,

clutch
hub,
friction
and
steel clutch

plates
and
shim(s).

7.
With
a
suitable drift, drive
out

the pinion shaft lock pins from
the

case.

8. With
a
brass drift, drive
out the

long pinion shaft from
the
case. Drive

from
the end
opposite
the
lock
pin

hole.

9. Remove
the two
short pinion

shafts using
a
drift, driving each shaft

from
the
center outward. Lift
out the

center block, then remove
the
pinion

gears,
thrust washers
and
side gear

and thrust washer.

10.
If the
differential bearings
are

removed,
the
bearings
can be
installed

in
one of the
following ways:

a. With
the
differential case
and

cover completely assembled.

b.
On the
case
or
cover when disas-

sembled. However, when pressing
the

bearings
on the
cover,
a
block
of

wood
or
fiber must
be
used
as
shown

in Fig.
21 in
order
to
avoid damage
to

the cover.

E 1709-A

FIG. 79—Removing Differential

Pinion Shaft Lock
Pin
DIFFERENTIAL BEARING

E1892-A

FIG. 21—Installing Differential Bearing—Traction-Lokprocarmanuals.com

04-02-15

Rear
Axle — Removable Carrier Type

04-02-15

REMOVAL AND

DISASSEMBLY OF

DRIVE PINION AND

BEARING RETAINER

I. Turn the carrier assembly

upright and remove the pinion shaft

nut (Fig. 22 and Fig. 23).

2.
Remove the U-joint flange from

the pinion shaft (Figs. 24 and 25).

3.
Remove the pinion seal (Fig. 26).

4.
Remove the pinion, bearing, and

retainer assembly from the carrier

housing (Fig. 41). Measure the shim

thickness with a micrometer. Record

this original shim thickness. If a new

gear set is installed during assembly, a

new shim will have to be installed.

The original shim thickness is one of

the factors necessary in determining

the new shim thickness. Extreme care

must be taken not to damage the

mounting surfaces of the retainer and

carrier.

5. Place a protective sleeve (hose)

on the pinion pilot bearing surface.

Press the pinion shaft out of the pin-

ion front bearing cone with the tool

shown in Fig. 27.

O/-T57L-485
7-A

E1485-A

FIG.
22—Removing Pinion Shaft

Nut

E 1486-B

FIG. 23—
U-Joint Flange Holding

Tool

6. Press the pinion shaft out of the

pinion rear bearing cone and roller

(Fig. 28).

PILOT BEARING

1.
Remove the pilot bearing as

shown in Fig. 29. Drive out the pilot

bearing and the bearing retainer to-

gether.
FIG.
24 —
Removing
U-Joint Flange

E1902A

FIG.
25 —Flange Removal Tool

Tool-
7 7
75-AB

Tool—T50T-100-A

|E
1780.
A

FIG.
26—Removing Pinion Seal

PINION BEARING CUPS

Do not remove the pinion bearing

cups from the retainer unless the cups

are worn or damaged. The flange and

pilot of the retainer are machined dur-
ing manufacture by locating on these

cups after they are installed in their

bores.
If the cups are worn or dam-

aged, they should be replaced.

Remove the bearing cups as shown

in Figs. 30, 31 and 32. Install the cups

as shown in Figs. 33 and 34.

Press
Ram

Tool
-

757L-4674-A
Fiber Block

HOSE

\

1710-A

FIG.
27

Bearing
-Removing
Pinion Front

FIG.
28 —Removing Pinion Rear

Bearing
Cone

After the new cups are installed,

make sure they are seated in the re-

tainer by trying to insert a 0.0015-inch

feeler gauge between the cup and the

bottom of the bore.

Whenever the cups are replaced, the

cone and roller assemblies should also

be replaced.

DRIVE PINION AND

RING GEAR SET

When replacing a ring gear and pin-

ion, note that the original factory in-

stalled shim is of the correct thicknessprocarmanuals.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

04-02-17
Rear Axle
—
Removable Carrier Type
04-02-17

Too/-T53L-200-A

L-462S-A

4625-K
or
4625-KA

>:
M
E 1726-A

FIG. 36—Installing Pilot Bearing

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 ori-

ginal bearings,
if
re-used.

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.
Press,
Ram

REAR BEARING

CONE
AND

ROLLER

Too/-

T57L-46U-A
Fiber B/oc.

DRIVE

PINION

Too/-

T57L-4621-B

1701-A

FIG. 37—Installing Pinion Rear

Bearing Cone

PRESS RAM

Tool - 4621
L

E1903A

FIG. 38—Installing Pinion Rear

Bearing Cone

ASSEMBLY
OF
DIFFERENTIAL

CARRIER

PILOT BEARING

INSTALLATION

1.
Drive
the new
pilot bearing
in-

ward until
it
bottoms,
as
shown
in

Fig.
36.

2.
Using
the
same tool indicated
in

Fig.
36,
install
the new
pilot bearing

retainer with
the
concave side
up.
COLLAPSIBLE PINION

BEARING SPACER

INSTALLATION

1.
Install
the
drive pinion rear bear-

ing cone and roller
on the
pinion shaft

(Figs.
37
m 38).

Place
a new
spacer
on the
pinion

shaft (Fig.
39).

2.
Place
the
bearing retainer
on the

pinion shaft,
and
install
the
front

bearing cone
and
roller. Press
the

front bearing cone and roller into posi-

tion
as
shown
in Fig. 40. Be
careful

not
to
crush
the
bearing spacer.

3.
Lubricate
the
O-ring with axle

lubricant and install
it in its
groove
in

the pinion retainer.
Be
careful
not to

twist
it.
Snap
the
O-ring into position.

4.
Place
the
proper shim
on the

carrier housing
and
install
the
pinion

and retainer assembly, being careful

not
to
pinch
the
O-ring (Fig.
41).

5. Install
the
pinion attaching bolts.

Torque
the
bolts
to
specification.

6. Place
the
slinger over
the
pinion

shaft
and
against
the
front bearing.

7.
Install
a new
seal
in the
bearing

retainer (Fig.
47).

8. Install
the
U-joint flange
(Fig.

49).

9. Start
a new
integral
nut and

washer
on the
pinion shaft.

Press
Ram

L*
Fiber Block

Tool-

T57L-4621

E 1712-A

FIG. 40—Installing Pinion Front

Bearing

FLANGE
O-RING

REAR BEARING

SPACER

SEAL
FRONT BEARING

RETAINER
SHIM
PINION

FIG. 39—Pinion
and
Bearing Retainer
PILOT

BEARING

RETAINER

PILOT

BEARING

E 1782-Aprocarmanuals.com

04-02-18
Rear Axle — Removable Carrier Type
04-02-18

E 1195-C

FIG. 41—Removing
or
Installing

Pinion
and
Retainer Assembly

10.
Hold
the
flange with
the
tool

shown
in Fig. 22
(Ford)
or Fig. 23

(Mercury),
and
torque
the
pinion shaft

nut
to 175
ft-lbs.
Do not
exceed
175

ft-Ibs
at
this time.

11.
Check
the
pinion bearing
pre-

load
as
shown
in Fig. 42.
Correct

pre-load will
be
obtained when
the

torque required
to
rotate
the
pinion
in

the retainer
is as
specified
in
Part
4-3.

If
the
torque required
to
rotate
the pin-

ion
is
less than specified, tighten
the

pinion shaft
nut a
little
at a
time until

Inch-Pound

Torque Wrench

E1899A

FIG. 42—Checking Pinion Bearing

Preload
the proper preload
is
established.
Do

not overtighten
the nut. If
excessive

preload
is
obtained
as a
result
of
over-

tightening, replace
the
collapsible

bearing spacer.

Do
not
back
off the
pinion shaft
nut

to establish pinion bearing preload.
If

the torque
on the
pinion shaft
nut is

less than
175
ft-lbs after bearing
pre-

load
is
established,
a new
collapsible

spacer must
be
used.

SOLID PINION BEARING

SPACER INSTALLATION

The spacer
is
serviced
in 20
sizes

listed
in
Part
4-5. The
manner
of sel-

ecting
the
size spacer required
for ob-

taining correct preload
is
included
in

the following assembly procedure.

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

pinion shaft
as
shown
in
Figs.
38 or

39.

2.
Select
a new
solid spacer
of a

larger size (0.485 inch thick),
and
slide

it over
the
pinion shaft against
the

rear bearing.

The pinion bearing preload
can be

accurately measured only when
the

pinion shaft
nut is
torqued
to 180-

220 ft-lbs.
If a
spacer smaller than
re-

quired
was
used,
the
specified
180-

220 ft-lbs torque would damage
the

bearings.
For
this reason,
the
largest

spacer should
be
tried first. Then,
if

the bearings
are too
loose,
the
size
of

the spacer
can be
decreased until
the

correct preload
is
obtained.

3.
Position
the
bearing retainer
and

cup assembly
on the
pinion shaft
and

install
the
front bearing cone
and rol-

ler. Press
the
front bearing cone
and

roller assembly into position,
as

shown
in Fig. 38.

4.
Mount
the
retainer
in a
holding

fixture
as
shown
in Fig. 23, and
place

the slinger over
the
pinion shaft
and

against
the
front bearing.

5.
Install
the
U-joint flange with

the tool shown
in Fig. 46.

6. Hold
the
flange with
the
tool

shown
in Fig. 23 or 24, and
install
the

old pinion shaft
nut.
Using
a
ft-lb
tor-
que wrench, torque
the nut to
180-220

ft-lbs.
While tightening
the nut,
rotate

the bearing retainer
to
determine
the

existance
of any
bearing preload

which will
be
indicated
by a
slight

drag
in the
rotation
of the
retainer.

DETERMINING SPACER

SIZE FROM

PRELOAD READING

1.
If
bearing drag indicates
a pre-

load condition exists, apply
an
in-lb

torque wrench
to the
pinion
nut as

shown
in Fig. 42 and
read
the
torque

required
to
turn
the
shaft. Effort

should
be
12-1/2
to
32-1/2 in-lbs.

2.
If
preload
is the
correct valve,

proceed with assembly procedure

given
in
Final Assembly
of
Pinion
and

Retainer, which follows.

2.
If
preload exists,
but is
below

specification, select
the
correct spacer

from
Fig. 43 and
install, completing

assembly
as
shown
in
Final Assembly

of Pinion
and
Retainer.

DETERMINING SPACER

SIZE FROM
END

PLAY READING

1.
If no
perceptible preload
is
felt

when rotating
the
pinion shaft, install

a dial indicator
as
shown
in Fig. 44,

so that
the
indicator point
is
resting

on
the end of the
pinion gear shaft

(companion flange
end).

2.
Use
both hands
to
squeeze
the

pinion shaft
and the
bearing retainer

together
(Fig. 45).
Record
the
endplay

reading shown
on the
dial indicator.

3.
Disassemble
the
pinion shaft
and

retainer
and
install
the
correct spacer

as shown
in Fig. 43.

4.
Proceed with assembly
of the pin-

ion shaft
and
retainer
as
directed
in

Final Assembly
of
Pinion
and
Retain-

er.

FINAL ASSEMBLY
OF

PINION
AND
RETAINER

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

AS
END
PLAY

READS

(10/1000 inch)

USE THIS

SPACER
0

0.481
1

0.480
2

0.479
3

0.478
4

0.476

If there
is no end
play
and
preload
on the
bearings

IF PRELOAD READS

(in-lbs.)

USE THIS SPACER
2-11

0.482
12-20

0.483
5

0.476
6

0.474
7

0.474
8

0.472
9

0.472
10

0.470
11

0.470
12

0.468
13

0.468
14

0.466
15

0.465

exists:

21-30

0.484
31-45

0.485

FIG. 43— Solid Spacer Selectionprocarmanuals.com

04-02-19
Rear Axle — Removable Carrier Type
04-02-19

POINTER RESTING ON

PINION NUT

E 1505-B

FIG.
44
— End Play Indicator

Installation

pinion shaft as shown in Figs. 37 and

38.

2.
Slide the correct spacer over the

pinion shaft against the rear bearing.

3.
Position the bearing retainer and

cup assembly on the pinion shaft and

install the front bearing cone and rol-

ler. Press the front cone and roller

into position, as shown in Fig. 46.

4.
Lubricate a new O-ring with axle

lubricant and install it in the groove

provided in the pinion retainer. Be

careful not to twist the O-ring. Install

it by snapping it into place.

5.
Place the proper shim on the

carrier housing and install the pinion

and retainer assembly, being careful

not to pinch the O-ring (Fig. 41).

6. Install the pinion retainer bolts.

Torque the bolts to specification.

7.
Place the slinger over the pinion

shaft and against the front bearing.
Tool - 4858-
E

E 1197-D

FIG. 46—Installing
U-Joint
Flange

8. Install a seal in the bearing re-

tainer, (Fig. 47).

9. Start a new integral nut and

washer on the pinion shaft.

10.
Hold the companion flange with

the tool shown in Fig. 20 or 22 and

torque the pinion nut to specifications

(200 ft-lbs).

11.
With a new seal installed pin-

ion bearing preload should now read

17 to 32 in-lbs for new pinion bearings

and new seal, or 8 to 14 in-lbs for ori-

ginal bearings and a new seal.

ASSEMBLY AND

INSTALLATION OF

DIFFERENTIAL CASE

Conventional

Differential Case

1.
Place a side gear and thrust

washer in the differential case bore

E 1506-B

E 1629-A

FIG. 45— Checking Pinion End

Play
FIG. 47—Installing Oil Seal
(Fig. 48). Lubricate all differential

parts liberally with axle lubricant dur-

ing assembly.

2.
With a soft-faced hammer, drive

the differential pinion shaft into the

case only far enough to retain a pin-

ion thrust washer 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 pin holes.

4.
Place the second side gear and

thrust washer in position (Fig. 48),

and install the cover on the differen-

tial case. Install the pinion shaft lock

pin. A pinion or axle shaft spline can

be inserted in the side gear spline to

check for free rotation of the differen-

tial gears.

5.
Insert two 7/16 (N.F.) bolts two

inches long 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. Install and tighten the ring gear

bolts and washers evenly, and torque

them alternately across the gear to

specification.

7.
If the differential bearings have

been removed, press them on as

shown in Figs. 49 and 50.

8. Wipe a thin coating of lubricant

on the bearing bores so that the dif-

ferential bearing cups will move easily.

9. Place the cups on the bearings.

If the gear set is of the non-hunting or

partial non-hunting type, assemble the

differential case and ring gear assem-

bly in the carrier so that the marked

tooth on the pinion indexes between

the marked teeth on the ring gear as

shown in Fig. 51.

In almost every case of improper

assembly (gears assembled out of

time),
the noise level and probability

of failure will be higher than they

would be with properly assembled

gears.

When installing the hunting type

gear set (no timing marks), assemble

the differential case and ring gear as-

sembly in the carrier without regard

to the matching of any particular gear

teeth.

10.
Slide the assembly along the

bores until a slight amount of back-

lash is felt between the gear teeth.

11.
Set the adjusting nuts in the

bores so that they just contact the

bearing cups. The nuts should be en-

gaged about the same number of

threads on each side.

12.
Carefully position the bearing

caps on the carrier. Match the marks

made when the caps were removed.procarmanuals.com