brake FORD MUSTANG 1969 Volume One Chassis

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

04-03-05
Rear Axles — Integral Carrier Type

04-03-05

6. Using the tool shown in Fig. 10,

remove the pinion U-joint flange.

7.
Using the tool shown in Fig. 7,

remove the drive pinion oil seal.

8. Clean the oil seal seat.

9. Pinion oil seals have pre-applied

oil resistant sealer. Install the seal in

the retainer using the tool shown in

Fig. 11.

10.
Check splines on the pinion

shaft to be sure they are free of burrs.

If burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion. Wipe the pinion

shaft clean.

11.
Apply a small amount of lubri-

cant to the U-joint splines.

12.
Align the punch mark on the

U-joint flange with the mark on the

end of the pinion shaft, and install the

flange.

13.
Install a new integral nut and

washer on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

14.
Hold the flange with the tool

shown in Fig. 9 while tightening the

nut.

15.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, and take

frequent preload readings (Fig. 6)

until the preload is at the original rec-

orded reading established in step 3.

16.
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 indicated above, or bearing

failure may result. Under no circum-

stances should the pinion nut be

backed-off to lessen preload. If this is

done, a new pinion bearing spacer

must be installed. In addition, the U-

joint flange must never be hammered

on, or power tools used.

17.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the
drive shaft on the transmission output

shaft.

18.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the punch marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

19.
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 the housing

cover.

REMOVAL AND INSTALLATION

OF THE ORIGINAL U-JOINT

FLANGE

Use procedure as outlined under

drive pinion oil seal replacement.

Tool-T53T-4857-A

or
4851 -A

E1223-B

FIG. 10—Typical Drive Pinion

Flange Removal

El 906A
Tool-T55P-4676-A

or 4676-G

E1907A
INSTALLATION OF A NEW

UNIVERSAL JOINT FLANGE

1.
Raise the vehicle and install safe-

ty stands. Remove both rear wheels

and brake drums.

2.
Disconnect 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 fluid

leakage. 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. Syn-

thetic seals must not be cleaned,

soaked or washed in cleaning solvents.

6. Using the tool shown in Fig. 10,

remove the U-joint flange.

7.
Check splines on the pinion shaft

to be sure they are free of burrs. If

burrs are evident, remove them by

using a fine crocus cloth, working in

rotational motion, then wipe clean.

Apply a small amount of lubricant

to U-joint splines.

8. Install the U-joint flange using

the tool shown in Fig. 12.

FIG. 9—Removing or Installing

Drive Pinion Nut
FIG.
11
— Typical Drive Pinion

Flange Seal Installation
FIG. 12—U-Joint Flange

Installationprocarmanuals.com

04-03-06

Rear Axles — Integral Carrier Type

04-03-06

9. Install a new integral nut and

ivasher on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 9 while the nut is being

tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, (Fig. 6)

and take frequent preload readings

until the preload is at the original rec-

orded reading established in step 3.

12.
After original preload has been

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

in-lbs has been added.

The preload should not exceed the

amount shown above, or bearing fail-

ure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. (In

addition, the U-joint flange must

never be hammered on, or pneumatic-

-tools used.)

13.
Remove the oil seal replacer

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

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

15.
Check the lubricant level. Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole, located in

the carrier casting or housing cover.

REMOVAL AND INSTALLATION

REAR AXLE HOUSING

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft at the drive

pinion flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in the

foregoing Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

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

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tools shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with me-

chanic's wire. The hydraulic brake

SCRIBE MARKS

5/16-24

4 REQ'D.

12-15
LB.
FT.

U-BOLT - 4529 2 REQ'D.

E 1783-A

FIG. 14—Drive Shaft-to-Axle

U-Joint
Connection

El231-A

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

still attached to the brake carrier

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 13)

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operations.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install the

lower insulators. Torque the spring

clip nuts to specification.

2.
Place the brake backing plates in

their normal position on the axle

housing. Use new gaskets on each side

of the brake backing plates.

3.
Install new axle shaft oil seals

with the tool shown in Fig. 8. Soak

the new seals in light weight engine oil

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

ing them. Installation without use of

the proper tool will distort the seal

and cause leakage. Coat the outside

edges of the new oil seal with a non-

hardening type of sealer such as Per-

matex No. 2 or its equivalent.

4.
Install the axle shafts, brake

drums and wheels as outlined in Sec-

tion 2.

5.
Attach the hydraulic brake line

T fitting to the axle housing, and se-

cure the hydraulic brake line in its re-

tainer on the axle housing.

6. Install vent tube to brake tubeprocarmanuals.com

04-03-07
Rear Axles — Integral Carrier Type

04-03-07

junction and install vent hose to vent

tube.

7.
Raise the axle housing and con-

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

shaft to the axle U-joint flange, align-

ing the scribe marks made on the

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

9. Fill the axle with the proper

grade and amount of lubricant.

10.
Road test the vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

All service operations on the differ-

ential case assembly and the drive pin-

ion assembly can be performed with

the housing in the vehicle.

REMOVAL OF

DIFFERENTIAL

CASE AND DRIVE PINION

1.
Raise the vehicle and support it

on the underbody, so that the rear

axle drops down as far as the springs

and shock absorbers permit.

2.
Remove the cover from the car-

rier casting rear face, and drain the

lubricant.

3.
Perform the Inspection Before

Disassembly of Carrier in Part 4-1,

Section 3.

4.
Remove both rear wheels.

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

vided in the axle shaft flange, remove

the nuts that attach the wheel bearing

retainers to the axle housing.

7.
Pull the axle shafts with the tool

shown in Fig. 2. Care must be exer-

cised to prevent damage to the oil

seals.
Install a nut on one of the brake

backing plate attaching bolts to hold

the plate to the axle housing after the

shaft has been removed. Remove both

seals with the tool shown in Fig. 8.

8. Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

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

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

9. Remove the differential bearing

adjusting nut locks (Fig. 15).

10.
Mark one differential bearing

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

sition the parts properly during as-

sembly.

11.
Remove the differential bearing

cap bolts and bearing caps. Hold the

differential case assembly in the hous-

ing after the caps are removed.

12.
Remove the differential case

and bearing cups (Fig. 17).

13.
Hold the drive pinion flange

and remove the pinion nut (Fig. 9).

14.
Remove the pinion flange (Fig.

10).

DIFFERENTIAL PINION GEAR

AND THRUST WASHER

COVER AND GASKET
DIFFERENTIAL SIDE GEAR

AND THRUST WASHER

SHAFT RETAINER DIFFERENTIAL

PINION SHAFT DIFFERENT|AL

DIFFERENTIAL CASE CASE COVER
BEARING ADJUSTING NUT

PINION AND RING GEAR

AXLE SHAFT
BEARING

DRIVE GEAR ATTACHING BOLT

ADJUSTING NUT LOCK

BEARING CAP

PINION LOCATING SHIMS

BEARING AND CUP

WHEEL BEARING RETAINER

GASKET
BEARING AND CUP

SEAL

AXLE SHAFT SEAL

BEARING PRELOAD SPACER/
AXLE HOUSING

FILLER PLUG

'WHEEL BEARING

WHEEL BEARING RETAINER

DEFLECTOR FLANGE

E1908A

FIG. 75—Disassembled Rear Axleprocarmanuals.com

04-04-01

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

CLIP -

353473-S8'
.CROSS MEMBER
NUT-33847-S8-.

9/16-12

100-130 LB. FT.
.LOCK WASHER -

34785-S7

HOSE -4A001

BOLT-

380826-S2
NUT - 34664-S -

3/8-24
2REQ'D

15-25 LB. FT.
NUT - 375022-S2

70-90 LB. FT. NUT 0PT

90-120 LB. FT. BOLT
UPPER ARM ADJUST

ING CAM - 5A637

2 REQ'D.

NUT - 33847-S8

9/16-12

100-130 LB. FT.

SPRING MUST BE POSITIONED

AS SHOWN FOR R.H. SIDE

NUT - 55754-S7 -

9/16-12

80-105 LB. FT.
LOCK WASHER -

34785-S7

WASHER -

44741-S8
BUMPER

4002

2 REQ'D.

VIEW FOR PASSENGER

CARS SAME AS VIEW Z

EXCEPT AS SHOWN

SPRING MUST BE

POSITIONED AS

SHOWN FOR L.H. SIDE

BOLT -

304685-S

8 REQ'D
BOLT - 381877-S2

4 REQ'D.

9-13 LB. FT.

BRAKE DRUM -

1126 2 REQ'D

NUT - 34445-S7

20-30 LB. FT.
TIRE - 1508

2 REQ'D.
LOWER ARM -

5A648

NUT-

375022-S2

2 REQ'D.

70-90 LB. FT. NUT rtnT

90-120 LB. FT. BOLT "0PT
DRIVE SHAFT -

4602 ASSY.

USING SPECIAL TOOL,

ASSEMBLE NUTS TO NUT -

HOLD DRUM ASSEMBLY - 372188-S32

SECURELY AGAINST 6 REQ'D.

FLANGE
NUT -

375032-S36

1/2-13

2 REQ'D.

50-85 LB. FT
PRONGS MUST BE

SECURELY LOCKED /'

PLACE
2209 ASSY. R.H.

2210 ASSY. L.H.

MUST BE USED

FROM THE SAME

SUPPLIER IN

AXLE SETS
HUB CAP-

1130

2 REQ'D.

NUT -

1012

10 REQ'D.

70-115 LB. FT.

VIEWN

VIEW W

VIEW R
NUT - 375022-S2

2 REQ'D

70-90 LB FT. NUT _ nPT

90-120 LB. FT. BOLT
VIEW T

BOLT -*

304907-S2

9/16-12

80-105 LB. FT.
'NUT - 55754-S7

9/16-12

60-85 LB. FT.

VIEW V

E 1633-A

FIG.
7—Rear
Axle Installation—WER Axleprocarmanuals.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