differential FORD MUSTANG 1969 Volume One Chassis

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

04-03-10
Rear Axles
—
Integral Carrier Type

04-03-10

in
the
case. Drive
the
shaft into place

and install
the
lock
pin
(Fig.
21).

6. Place
the
ring gear
on the
differ-

ential case
and
install
the
bolts.
Tor-

que
the
bolts
to
specification.

7.
If the
differential bearings have

been removed, press them
on as

shown (Fig.
24).

INSTALLATION
OF
DRIVE

PINION
AND
DIFFERENTIAL

CASE

1.
Place
the
shim
and
pinion rear

bearing cone
on the
pinion shaft.

Press
the
bearing
and
shim firmly

against
the
pinion shaft shoulder (Fig.

19).

PRESS RAM

Tool T54P-3044-A

Detail
7
2.
Place
a new
pinion bearing
pre-

load spacer
on the
pinion shaft.

3.
Lubricate
the
pinion rear bearing

with axle lubricant.

4.
Lubricate
the
pinion front bear-

ing cone
and
place
it in the
housing.

5.
Install
a new
pinion
oil
seal
in

the carrier casting (Fig.
11).

6. Insert
the
drive pinion shaft

flange into
the
seal
and
hold
it
firmly

against
the
pinion front bearing cone.

From
the
rear
of the
carrier casting,

insert
the
pinion shaft into
the
flange.

7.
Start
a new
pinion shaft
nut.

Hold
the
flange with
the
tool shown
in

Fig.
9 and
tighten
the
pinion shaft

nut.
As the
pinion shaft
nut is
tight-

ened,
the
pinion shaft
is
pulled into

the front bearing cone
and
into
the

flange.

As
the
pinion shaft
is
pulled into

the front bearing cone, pinion shaft

end play
is
reduced. While there
is

still
end
play
in the
pinion shaft,
the

flange
and
cone will
be
felt
to
bottom.

This indicates that
the
bearing cone

and flange have bottomed
on the col-

lapsible spacer.

From this point,
a
much greater

torque must
be
applied
to
turn
the

pinion shaft
nut,
since
the
spacer must

be collapsed. From this point, also,

the
nut
should
be
tightened very slow-

ly
and the
pinion shaft
end
play

checked often,
so
that
the
pinion bear-

ing preload does
not
exceed
the
limits

(Fig.
6).

FIG. 24—Differential Bearing

Installation
If
the
pinion shaft
nut is
tightened

to
the
point that pinion bearing
pre-

load exceeds
the
limits,
the
pinion

shaft must
be
removed
and a
new
col-

lapsible spacer installed.
Do not de-

crease
the
preload
by
loosening
the

pinion shaft
nut.
This will remove
the

compression between
the
pinion front

and rear bearing cones
and the col-

lapsible spacer
and may
permit
the

front bearing cone
to
turn
on the pin-

ion shaft.

&
As
soon
as
there
is
preload
on

the bearings, turn
the
pinion shaft
in

both directions several times
to set the

bearing rollers.

9. Adjust
the
bearing preload
to

specification. Measure
the
preload

with
the
tool shown
in Fig. 6.

10.
Apply
a
thin coating
of
lubri-

cant
on the
bearing bores
so
that
the

differential bearing cups will move

easily.

11.
Place
the
cups
on the
bearings

and
set the
differential case assembly

in
the
carrier casting (Fig.
17).

If
the
gear
set is of the
non-hunting

or partial non-hunting type, assemble

the differential case
and
ring gear
as-

sembly
in the
carrier
so
that
the

marked tooth
on the
pinion indexes

between
the
marked teeth
on the
ring

gear
as
shown
in Fig. 25.

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.

12.
Slide
the
case assembly along

the bores until
a
slight amount
of

backlash
is
felt between
the
gear teeth.

Hold
the
differential case
in
place.

13.
Set the
adjusting nuts
in the

PAINT MARKING INDICATES POSITION
IN
WHICH GEARS WERE LAPPED

E 1335-B

FIG. 25—Typical Gear
Set
Timing Marks
7oo/—T60K-4067-A or 4067 E

E1916A

FIG. 26—Backlash
and
Bearing

Pre-Load Adjustmentprocarmanuals.com

04-03-11
Rear Axles — Integral Carrier Type

04-03-11

bores so that they just contact the

bearing cups.

14.
Carefully position the bearing

caps on the carrier casting. Match the

marks made when the caps were re-

moved.

15.
Install the bearing cap bolts

and lockwashers. As the bolts are

tightened, turn the adjusting nut with

the tool shown in Fig. 26.

16.
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 or incor-

rectly positioned caps. Tightening the

bolts to the specified torcfue is done to

be sure that the cups and adjusting

nuts are seated. Loosen the cap bolts,

and torque them to only 5 ft-lbs be-

fore making adjustments. Refer to

Part 4-1 for backlash and bearing pre-

load adjustment procedures.
LIMITED-SLIP DIFFERENTIAL

For integral carrier limited-slip dif-

ferentials see the repair procedures for

removable carrier limited-slip differen-

tials,
Part 4-2. These procedures are

good for the differential case only.

When the limited slip differential case

has been repaired replace the case

using the procedure for the conven-

tional intergral carrier differendal case

in this part.procarmanuals.com

04-04-01

Rear Axle — Ford Light-Duty (WER)
04-04-01

PART 4-4 Rear Ax/e-Ford Light-Duty (WER)

COMPONENT INDEX

AXLE HOUSING

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

DESCRIPTION

DIFFERENTIAL CASE

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND DRIVE

GEAR

Cleaning and Inspection

Removal and Installation

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING CUPS

Cleaning and Inspection

Removal and Installation
MODEL APPLICATION
AN
Models
Ford

01-09

04-04

01-10

04-06

04-01

01-10

04-07

04-06

01-10

04-08

01-10

04-08

01-10

04-08
Mercury
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Meteor
01-09

04-04

01-10

04-06

04-01

01-10

04-07

04-06

01-10

04-08

01-10

04-08

01-10

04-08
Cougar
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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

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

DESCRIPTION

A light-duty, integral-carrier, con-

ventional-type rear axle assembly (Fig.

1) is used in Ford and Meteor passen-

ger vehicles equipped with 240-IV and

302 2V engines and related transmis-

sions.
The axle (model WER) incor-

porates the following features:

The hypoid gear set consists of an

8.50 inch diameter ring gear and an

overhung drive pinion which is sup-

ported by two opposed tapered roller

bearings. A drive pinion pilot bearing

is not used in this axle.

The differential carrier is the non-

removable type, with a stamped bolt-

on cover. The filler hole is tapped in
the front portion of the carrier casting

and uses a
1/2-14
tapered pipe plug

with a 3/8 inch square female drive. A

bumper pad is machined on the pinion

nose portion of the carrier. The rub-

ber bumper is mounted on the vehicle

underbody.

The differential case is a one-piece

design, with openings allowing assem-

bly of the internal components and lu-

bricant flow. The differential pinion

shaft is retained with a threaded bolt

(lock) assembled to the case.

The axle housing assembly consists

of tube assemblies pressed and welded

into the differential casting. The brake
backing plate retainer is welded in-

board of the outer edges of the tubes,

and allows assembly of the backing

plate, independent of the axle shafts.

The roller-type wheel bearings have

no inner race, and contact the bearing

journals of the axle shafts.

The axle shafts do not use an inner

or outer bearing retainer. They are

held in the axle by means of C-locks,

positioned in a slot on the splined end.

These C-locks also fit into a machined

recess in the differential side gears

within the differential case. There is

no retainer bolt access hole in the axle

shaft flange.
procarmanuals.com

04-04-02
Rear Axle
—
Ford Light-Duty (WER)
04-04-02

DIFFERENTIAL

PINION-4215
RING GEAR
-

4209
LEFT AXLE

SHAFT
-
4235

1

DRIVE PINION
-

4209

SEAL
-
4676

FLANGE-4851

DEFLECTOR -4859

SEAL-
1177

f\G.
7
—Rear Axle Assembly—Light Duty
(WER)
Axle
E 1632-A

IN-VEHICLE ADJUSTMENTS AND REPAIRS

REAR AXLE SHAFT, WHEEL

BEARING
AND OIL
SEAL

REPLACEMENT

REMOVAL

Synthetic wheel bearing seals
are

used
for
production
and as
service
re-

placements. Removal
and
insertion
of

rear axle shafts must
be
performed

with caution.
The
entire length
of the

shaft (including spline)
up to the
seal

journal must pass through
the
seal

without contact.
Any
roughing
or cut-

ting
of the
seal element during axle

removal
or
installation will result
in

early seal failure.

1.
Raise
the
vehicle
on a
hoist.
2.
Remove
the
wheel(s)
and
tire(s)

from
the
brake drum(s).

3.
Position
a
drain
pan and
loosen

the cover
to
differential housing
re-

taining bolts. Drain
the
housing.

4.
Remove
the
attaching (Tinner-

man) nuts that secure
the
brake

drum(s)
to the
axle shaft flange(s),

and then remove
the
drum(s).

5.
Remove
the
differential housing

cover bolts, cover
and
gasket. Discard

the gasket. Remove
the
drain
pan.

6. Position safety stands under
the

rear frame member. Lower
the
hoist

and allow
the
axle
to
lower
as far as

possible.

7.
Working through
the
differential

case opening, remove
the
pinion shaft
lock bolt
and the
pinion shaft
(Fig. 2).

8. Push
the
axle shaft(s) inward

toward
the
center
of the
axle housing.

Remove
the
C-lock(s)
(Fig. 3)
from

the inner
end of the
axle(s). Remove

the axle shaft(s) from
the
housing.
Ex-

treme care must
be
used
to
avoid
con-

tact
of the
axle shaft seal
lip
with
any

portion
of the
axle shaft except
the

seal journal.

9. Remove
the
bearing
and oil
seal

from
the
housing
as
shown
in Fig. 4.

10.
Inspect
the
machined surface
of

the axle shaft
and the
axle housing
for

rough spots
or
other irregularities

which would affect
the
sealing action

of
the oil
seal. Check
the
axle shaft

splines
for
burrs, wear
or
damage.procarmanuals.com

04-04-03
Rear Axle
—
Ford Light-Duty (WER)

04-04-03

LOCK BOLT

DIFFERENTIAL PINION SHAFT
E 1596- A

FIG.
2—Differential pinion shaft

and Lock Bolt

AXLE SHAFT

LOCK

E 1597-A

FIG. 3—Removal
and
Installation

of C-Locks
and
Axle Shaft

Carefully remove
any
burrs
or
rough

spots.
Replace worn
or
damaged

parts.
A
brownish yellow color
on the

bearing journal
of the
shaft
is
normal

and
the
shaft need
not be
replaced.

Slight pitting
and
wear
is
also normal.

INSTALLATION

1.
Lightly coat
the
wheel bearing

rollers with axle lubricant. Install
the

bearings
in the
axle housing with
the

tool shown
in Fig. 5. The
bearing

should seat firmly against
the
shoul-

der.

2.
Wipe
all
lubricant from
the oil

seal bore before installing
the
seal.

3.
Inspect
the
original seal
for

nicks,
scuffs
or
abnormal wear,
and

replace
it if
necessary.
The new
seals

are pre-packed with lubricant
and do

not require
an oil
soak before installa-

tion.

4.
Install
the oil
seal with
the
tool

shown
in Fig. 6.
Installation without

the
use of the
proper tool will distort

the seal
and
cause leakage.

5. Replace
the
O-ring
in the
C-lock

groove
on the
axle shaft.

6. Slide
the
axle shaft(s) into place
Tool
-
T66L-12132

Tool
-
7507- 700-A

\

1

T50T-100-A
BEARING

Tool - 766L-72J32-8

(THREAD
REDUCING

ADAPTER PART ONLY)

SEAL

FIG. 4—Removal
of
Axle Seal
or

in
the
axle housing. Exercise care that

splines
or any
portion
of the
axle

shaft(s)
do not
damage
the oil
seal(s)

and that they engage with
the
splines

of
the
differential side gear(s).

7. Install
the
axle shaft C-lock(s)

on
the
inner
end of the
shaft(s)
(Fig.

3)
and
push
the
shaft(s) outward
so

that
the
shaft locks seat
in the
conter-

bore(s)
of the
differential side gear(s).

8. Position
the
differential pinion

gears
and
thrust washers
180
degrees

apart
to the
differential side gears.

Revolve
the
gear assembly until
the

holes
in the
differential case
are a-

ligned with the pinion gears.

9. Position
the
differential pinion

shaft through
the
case
and
pinions,
a-

ligning
the
hole
in the
shaft with
the

lock bolt hole. Install
the
lock bolt

Tool
-
760K-7697.fi
E 1598.A

Axle Bearing

and torque
it to
specification.

10.
Install
the
brake drum
and

tighten
the
attaching (Tinnerman)

nuts.

11.
Install
the
wheel
and
tire
on the

brake drum.

12.
Clean
the
gasket mounting
sur-

faces
of the
rear axle differential

housing
and the
cover. Install
a new

cover gasket, cover
and the
attaching

bolts.
Torque
the
bolts
to
specifica-

tion.

13.
Raise
the
rear axle. Make sure

the rear axle
is in
running position.

Add
the
amount
of
specified lubricant

required
to
reach
to the
bottom
of the

filler plug hole. Install
the
filler plug

and torque
it to
specification.

14.
Remove
the
safety support

stands
and
lower
the
vehicle.

7oo/

765F-7 777-A

E 1571-A

FIG. 5—Installation
of
Axle

Shaft Bearing
FIG.
6—Rear
Axle Shaft Bearing

Seal Installationprocarmanuals.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

04-04-06
Rear Axle — Ford Light-Duty (WER)

04-04-06

20.
With the axle at controlled

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.

21.
Remove the oil seal replacer

from the transmission extension hous-

ing. Install the drive shaft in the ex-

tension housing. Align the scribe

marks on the cups, flange and drive

shaft and connect the drive shaft at

the drive pinion flange. Torque the at-

taching bolts to specification
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.8—
Axle
Normal Curb Height

and Controlled Height for Arm

Installation
22.
Install the brake drum and at-

taching (Tinnerman) nuts.

23.
Install the wheel and tire on the

brake drum. Install the wheel covers.

24.
Adjust the drive shaft and pin-

ion angle to specification.

25.
Add the amount of specified lu-

bricant required to reach to the bot-

tom of the filler plug hole. Make sure

the rear axle is in running position.

Install the filler plug and torque it to

specification.

26.
Lower the vehicle.

4 MAJOR REPAIR OPERATIONS

DISASSEMBLY OF AXLE
The rear axle components are

shown in Fig. 9.

DIFFERENTIAL SIDE GEAR

AXLE SHAFT C-WASHER \

DIFFERENTIAL PINION SHAFT

THRUST WASHER

BEARING ASSEMBLY

CUP
THRUST WASHER

^^ DIFFERENTIAL PINION GEAR

BEARING ADJUSTING NUT

DIFFERENTIAL

PINION SHAFT

LOCK BOLT

LOCK WASHER
BOLT

LOCK WASHER

ADJUSTING NUT LOCK

DRIVE GEAR ATTACHING BOLT

BEARING CAP

AXLE HOUSING ASSEMBLY

PINION AND RING GEAR

PINION LOCATING SHIM(S)

BEARING CUP

BOLT

NUT

BEARING CUP

COLLAPSIBLE SPACER

AXLE SHAFT

E 1572-C

FIG. 9—Disassembled Light-Duty (WER) Rear Axleprocarmanuals.com

04-04-07
Rear Axle — Ford Light-Duty (WER)
04-04-07

RUNOUT CHECK

E 1573-A

FIG. 70—Checking Backlash and Runout—Light-Duty (WER) Axle

All service operations on the differ-

ential case assembly can be performed

with the axle housing in the vehicle.

1.
Raise the vehicle on a hoist.

2.
Position the drain pan under the

axle housing. Loosen the housing

cover attaching bolts. Drain the lubri-

cant from the housing.

3.
Make scribe marks on the drive

shaft end yoke and the rear axle shaft

companion flange to insure proper po-

sition of the drive shaft at assembly.

Disconnect the driveshaft from the

rear axle companion flange. Be care-

ful to avoid dropping the loose univer-

sal joint bearing cups. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their origi-

nal position in relation to the flange

when they are reassembled. Remove

the drive shaft from the transmission

extension housing. Install an oil seal

replacer tool in the transmission ex-

tension housing to prevent transmis-

sion leakage. Refer to the transmis-

sion group for the appropriate tool.

4.
Raise the vehicle and place

jack-type stands under the rear frame

crossmember. Lower the vehicle on a

hoist and allow the axle to lower as

far as possible.

5.
Remove the axle housing cover

and gasket. Discard the gasket.

6. Perform the Inspection Before

Disassembly of Carrier procedure.

Refer to Part 4-1, Section 3 of this

Shop Manual.

7.
Remove the attaching (Tinner-

man) nuts that secure the rear brake

drums to the axle shaft flanges, and

then remove the drums.

8. Working through the differential

case opening, remove the pinion shaft

lock bolt and pinion shaft (Fig. 2).

9. Push the axle shafts inward

toward the center of the axle housing.

Remove the C-locks (Fig. 3) from the

inner ends of the rear axles. Remove

the axle shafts from the housing. Ex-

treme care must be used to avoid con-

tacting the axle shaft seal lip with any
portion of the axle shaft except the

seal journal.

10.
Remove the bearings and oil

seals from the axle housing as shown

in Fig. 4.

11.
Remove the pinion side gears

and the side gear thrust washers.

12.
Remove both side bearing ad-

justing nut locks (bolts).

13.
Install a dial indicator (Fig. 10),

and check and record the backlash

and ring gear runout.

14.
Mark one differential bearing

cap and the case to help in positioning

the parts properly during assembly.

15.
Remove the bearing cap retain-

ing bolts. Remove the bearing caps,

cups,
adjusting nuts and case assem-

bly.

16.
Hold the drive pinion flange

and remove the pinion nut (Fig. 11).

Discard the nut.

17.
Remove the pinion flange (Fig.

12).

18.
Drive the pinion out of the

front bearing cone and remove it from

the carrier housing. Remove and dis-

card the bearing spacer.

19.
With a hammer and drift re-

move the pinion shaft oil seal out

through the front of the carrier hous-

ing.

20.
Remove the pinion rear bearing

from the drive pinion shaft (Fig. 13).

21.
Measure the shim which is

found under the bearing cone with a

Tool-T57L-485T-A

or 4851-K

El 906A
Tool
-
T6SL-485UA
\

E 1574-A

FIG. 12—Drive Pinion Flange

Removal

1575-A

FIG. 13—Pinion Rear Bearing

Removal

00/
- T57L-4220-A

FIG. 11—Typical Drive Pinion

Shaft Nut Removal
E 1576-A

FIG. 14—Differential Bearing

Removal

micrometer. Record the thickness of

the shim.

DISASSEMBLY OF

DIFFERENTIAL CASE

1.
If the 2 differential side bearings

are to be removed from the differen-

tial case, use the tool shown in Fig.

14.procarmanuals.com