light FORD MUSTANG 1969 Volume One Chassis
Page 215 of 413
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
Page 216 of 413
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
Page 221 of 413
04-03-01
Rear Axles — Integral Carrier Type
04-03-01
PART 4-3 Rear Axles-Integral Carrier Type
(Except Ford Light Duty
WER
Axle)
COMPONENT INDEX
AXLE HOUSING
Cleaning and Inspection
Removal and Installation
AXLE SHAFT
Cleaning and Inspection
Removal and Installation
CONVENTIONAL DIFFERENTIAL CASE
Cleaning and Inspection
Disassembly and Overhaul
Removal and Installation
DIFFERENTIAL BEARINGS AND RING
GEAR
Cleaning and Inspection
Removal and Installation
LIMITED SLIP DIFFERENTIAL CASE
Disassembly and Overhaul
PINION AND RING GEAR
Cleaning and Inspection
Removal and Installation
PINION BEARING CUPS
Cleaning and Inspection
Removal and Installation
PINION OIL SEAL
Removal and Installation
REAR WHEEL BEARINGS AND SEALS
Cleaning and Inspection
Removal and Installation
U-JOINT FLANGE
Cleaning and Inspection
Removal and Installation
MODEL APPLICATION
All
Models
01-09
01-10
01-10
01-10
01-10
01-10
01-10
01-10
Ford
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Mercury
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Meteor
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Cougar
03-06
03-02
03-08
03-07
03-08
03-08
03-09
03-08
03-04
03-02
03-05
Fairlane
03-06
03-02
03-08
03-07
03-08
03-08
03-09
03-08
03-04
03-02
03-05
Falcon
03-06
03-02
03-08
03-07
03-08
03-08
03-09
03-08
03-04
03-02
03-05
Montego
03-06
03-02
03-08
03-07
03-08
03-08
03-09
03-08
03-04
03-02
03-05
Mustang
03-06
03-02
03-08
03-07
03-08
03-08
03-09
03-08
03-04
03-02
03-05
Lincoln-
Continental
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
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
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.
DESCRIPTION
The rear axle assembly is an integral-
type housing, hypoid design, with the
centerline of the pinion set below the
centerline of the ring gear (Fig. 1).
The semi-floating axle shafts are re-
tained in the housing by ball bearings
and a bearing retainer at the axle hous-
ing outer ends.
The differential assembly is mount-
ed on two opposed tapered roller
bearings. The bearings are retained in
the housing by removable caps. Dif-
ferential bearing preload and drive
gear backlash is adjusted by nuts lo-
cated behind each differential bearing
cup.
The drive pinion assembly is mount-
ed on two opposed tapered roller
bearings. Pinion bearing preload is
adjusted by a collapsible spacer on the
pinion shaft. Pinion and ring gear
tooth contact is adjusted by shims be-
tween the rear bearing cone and
pinion gear.
A cover on the rear of the differen-
tial housing provides access for inspec-
tion and removal and installation of
the differential assembly and drive
pinion.
procarmanuals.com
Page 224 of 413
04-03-04
Rear Axles — Integral Carrier Type
04-03-04
1.
Remove the wheel cover, wheel
and tire from the brake drum.
2.
Remove the Tinnerman nuts that
secure the brake drum to the axle
housing flange, and then remove the
drum from the flange.
3.
Working through the hole pro-
vided in each axle shaft flange, re-
move the nuts that secure the wheel
bearing retainer plate. Then pull the
axle shaft assembly out of the axle
housing (Fig. 2). The brake backing
plate must, not be dislodged. Install
one nut to hold the plate in place after
the axle shaft is removed.
4.
If the rear wheel bearing is to be
replaced, loosen the inner retainer
ring by nicking it deeply with a cold
chisel in several places (Fig. 3). It will
then slide off easily.
5.
Remove the bearing from the
axle shaft with the tool shown in Fig.
4 or 5. If the push-puller operation
shown in Fig. 5 is used, be sure that
the puller arms contact the flat sur-
face of the axle shaft flange rather
than the bolt heads. Also with this
method, be careful not to damage or
burr the oil seal journal as the bearing
breaks loose.
6. Whenever a rear axle shaft is re-
placed the oil seal must be replaced.
Remove the seal with the tools shown
in Fig. 8. Soak new oil seals in SAE
10 oil for 1/2 hour before installing.
7.
Inspect the machined surfaces 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.
Carefully remove any burrs or rough
spots.
Replace worn or damaged
parts.
8. Lightly coat wheel bearing bores
with axle lubricant.
9. Place the retainer plate on the
axle shaft, and press the new wheel
bearing on the shaft with the tool
shown in Fig. 4 or 5. The bearing
should seat firmly against the shaft
shoulder. Do not attempt to press on
both the bearing and the inner retain-
er ring at the same time.
10.
Using the bearing installation
tool, press the bearing inner retainer
ring on the shaft until the retainer
seats firmly against the bearing.
11.
Wipe all lubricant from the in-
side of the axle housing in the area of
the oil seal before installing the new
seal.
12.
Wipe a small amount of oil res-
istant sealer on the outer edge of the
seal before it is installed. Do not put
sealer on the sealing lip.
13.
Rear wheel oil seals with syn-
thetic sealing elements have been in-
corporated in production. However,
only leather seals will be used as re-
placements for the synthetic sealing
element seals. Install the new oil seal
with the tools shown in Fig. 8. Instal-
lation without use of the proper tool
will distort the seal and cause leakage.
Be sure the new seal has been soaked
in SAE 10 oil for 1/2 hour.
14.
Carefully slide the axle shaft
into the housing so that the rough
forging of the shaft will not damage
the oil seal. Start the axle splines into
the side gear, and push the shaft in
until the bearing bottoms in the housing.
15.
Install the bearing retainer plate
on the mounting bolts at the axle
housing, and install the attaching nuts.
Torque the nuts to specifications.
16.
Install the brake drum and the
drum retaining nuts.
17.
Install the wheel and tire on the
drum, and install the wheel cover.
REMOVAL AND REPLACEMENT
OF DRIVE PINION OIL SEAL
Synthetic seals must not be cleaned,
soaked or washed in cleaning solvent.
Replacement of the pinion oil seal
involves removal and installation of
only the pinion shaft nut and the uni-
versal joint flange. However, this op-
eration disturbs the pinion bearing
preload, and this preload must be
carefully reset when assembling.
1.
Raise the vehicle and install safe-
ty stands. Remove the rear wheels and
brake drums.
2.
Make scribe marks on the drive
shaft end yoke and the axle U-joint
flange to insure proper position of the
drive shaft at assembly (Fig. 14). Dis-
connect the drive shaft from the axle
U-joint flange. Be careful to avoid
dropping the loose universal joint
bearing cups. Hold the cups on the
spider with tape. Mark the cups so
that they will be in their original posi-
tion in relation to the flange when
they are assembled. Remove the drive
shaft from the transmission extension
housing. Install an oil seal replacer
tool in the transmission extension
housing to prevent transmission leak-
age.
Refer to the transmission group
for the appropriate tool.
3.
Install an in-lb torque wrench on
the pinion nut Fig. 6. Record the tor-
que required to maintain rotation of
the pinion shaft through several revo-
lutions. \
4.
While holding the flange with the
tool shown in Fig. 9, remove the inte-
gral pinion nut and washer.
5.
Clean the pinion bearing retainer
around the oil seal. Place a drain pan
under the seal, or raise the front of
the vehicle higher than the rear.
KJ
E
I582-A
Tool - 1175-AB
and T50T-100-A
^___ or
J
775-
AE
Torque Wrench
^ mm i e
icot
A
E 1681-A
FIG. 6—Checking Pinion FiG 7_Removing
pjnjon
Sea,
Bearing Preload
,Tool-T58L-101-A or U75-AE
Tool-T50T-100-A
REMOVAL
Tool-60K-1177-B
or 1177-BorC
INSTALLATION E1214-D
FIG. 8—Removing and Installing Axle Shaft Sealprocarmanuals.com
Page 226 of 413
04-03-06
Rear Axles — Integral Carrier Type
04-03-06
9. Install a new integral nut and
ivasher on the pinion shaft. (Apply a
small amount of lubricant on the
washer side of the nut.)
10.
Hold the flange with the tool
shown in Fig. 9 while the nut is being
tightened.
11.
Tighten the pinion shaft nut,
rotating the pinion occasionally to in-
sure proper bearing seating, (Fig. 6)
and take frequent preload readings
until the preload is at the original rec-
orded reading established in step 3.
12.
After original preload has been
reached, tighten the pinion nut slowly,
until an additional preload of 6 to 12
in-lbs has been added.
The preload should not exceed the
amount shown above, or bearing fail-
ure may result.
Under no circumstances should the
pinion nut be backed off to lessen pre-
load. If this is done, a new pinion
bearing spacer must be installed. (In
addition, the U-joint flange must
never be hammered on, or pneumatic-
-tools used.)
13.
Remove the oil seal replacer
tool from the transmission extension
housing. Install the front end of the
drive shaft on the transmission output
shaft.
14.
Connect the rear end of the
drive shaft to the axle U-joint flange,
aligning the scribe marks made on the
drive shaft end yoke and the axle U-
joint flange (Fig. 14).
15.
Check the lubricant level. Make
sure the axle is in running position.
Add whatever amount of specified lu-
bricant is required to reach the lower
edge of the filler plug hole, located in
the carrier casting or housing cover.
REMOVAL AND INSTALLATION
REAR AXLE HOUSING
REMOVAL
1.
Raise the vehicle and support it
with safety stands under the rear
frame member.
2.
Drain the lubricant from the
axle.
3.
Make scribe marks on the drive
shaft end yoke and the axle U-joint
flange to insure proper position of the
drive shaft at assembly (Fig. 14). Dis-
connect the drive shaft at the drive
pinion flange.
4.
Disconnect the lower end of the
shock absorbers.
5.
Remove the wheels, brake drums
and both axle shafts as outlined in the
foregoing Section 2.
6. Remove vent hose front vent
tube (Corbin clamp) and remove vent
tube from brake tube junction and
axle housing.
7.
Remove the hydraulic brake T-
fitting from the axle housing. Do not
open the hydraulic brake system lines.
Remove the hydraulic brake line from
its retaining clip on the axle housing.
8. Remove both axle shaft oil seals
with the tools shown in Fig. 8.
9. Remove both brake backing
plates from the axle housing and sus-
pend them above the housing with me-
chanic's wire. The hydraulic brake
SCRIBE MARKS
5/16-24
4 REQ'D.
12-15
LB.
FT.
U-BOLT - 4529 2 REQ'D.
E 1783-A
FIG. 14—Drive Shaft-to-Axle
U-Joint
Connection
El231-A
FIG. 73—Rear Axle Installation—Typical
lines and the parking brake cables are
still attached to the brake carrier
plates.
10.
Support the rear axle housing
on a jack, and then remove the spring
clip nuts. Remove the spring clip
plates (Fig. 13)
11.
Lower the axle housing and re-
move it from under the vehicle.
12.
If the axle housing is being re-
placed, transfer all the differential and
pinion parts to the new housing. See
Section 4, Major Repair Operations.
INSTALLATION
1.
Raise the axle housing into posi-
tion so that the spring clip plates can
be installed. On a Montego or Fair-
lane,
position the spring upper insula-
tors and retainers between the axle
housing and springs and install the
lower insulators. Torque the spring
clip nuts to specification.
2.
Place the brake backing plates in
their normal position on the axle
housing. Use new gaskets on each side
of the brake backing plates.
3.
Install new axle shaft oil seals
with the tool shown in Fig. 8. Soak
the new seals in light weight engine oil
(SAE 10) for 1/2 hour before install-
ing them. Installation without use of
the proper tool will distort the seal
and cause leakage. Coat the outside
edges of the new oil seal with a non-
hardening type of sealer such as Per-
matex No. 2 or its equivalent.
4.
Install the axle shafts, brake
drums and wheels as outlined in Sec-
tion 2.
5.
Attach the hydraulic brake line
T fitting to the axle housing, and se-
cure the hydraulic brake line in its re-
tainer on the axle housing.
6. Install vent tube to brake tubeprocarmanuals.com
Page 230 of 413
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
Page 232 of 413
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
Page 233 of 413
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
Page 234 of 413
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
Page 235 of 413
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