torque FORD MUSTANG 1969 Volume One Chassis

04-02-11
Rear Axle — Removable Carrier Type

04-02-11

If the axle housing is new, install a

new vent. The hose attaching portion

must face toward the front of the ve-

hicle.

2.
If leather-type wheel bearing ser-

vice seals are to be installed, soak the

new rear wheel bearing oil seals in

SAE 10 oil for 1/2 hour before instal-

lation. Wipe a small amount of an oil

resistant sealer on the outer edge of

each seal before it is installed. Do not

put any of the sealer on the sealing

lip.
Install the oil seals in the ends of

the axle housing with one of the tools

shown in Fig. 10 and 12.

3.
Position the replacement axle

housing under the vehicle, and raise

the axle with a hoist or floor jack.

Connect the suspension lower arms to

their mounting brackets on the axle

housing with pivot bolts and nuts. Do

not tighten the bolts and nuts at this

point.

4.
Position the suspension upper

arm in its mounting bracket on the

axle housing, and install the adjusting

bolt, eccentric washers, lock washer

and nut. Leave the bolt and nut loose

at this point.

5.
Position the brake lines to the

axle housing, and secure with the re-

taining clips.

6. Install the brake backing plates

on the axle housing flanges.

7.
Connect the track bar to the

mounting stud, install the washer and

attaching nut, and torque to specifica-

tions.

8. Position the rear coil springs and

insulators in the pockets provided.

9. Connect the lower studs of the

two rear shock absorbers to the

mounting brackets on the axle hous-

ing. Install the attaching nuts, and

torque to specifications.

10.
Connect the vent tube to the

vent on the housing. If axle housing is

new, install a new vent.

11.
Clean the mating surfaces of

the axle housing and differential car-

rier. Position the carrier on the

mounting studs on the housing using a

new gasket between carrier and hous-

ing. Install the copper washers and the

carrier-to-housing attaching nuts, and

torque to specifications.

12.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, and

then raise the axle assembly to con-

trolled curb height (Fig. 15). Hold the

axle at controlled curb height by plac-

ing blocks or pieces of steel pipe be-

tween the axle housing and the bumper

rear screw on the side rail. (See speci-

fications for dimensions.)
FRAME

TIGHTEN ARM

ATTACHING BOLTS

AT 5-45/64 INCH

HEIGHT POSITION
5-45/64 INCH

HEIGHT FOR

INSTALLATION

OF ARMS

E 1600-B

FIG. 75 -Axle Normal Curb

Height and Controlled Height

for Arm Installation

13.
With the axle at controlled curb

height, torque the suspension upper

and lower arm front pivot bolts and

nuts to specifications. Torque the

lower arm-to-axle housing pivot bolts

and nuts to specifications.

14.
Remove the oil seal replacer

tool from the transmission extension

housing. Position the drive shaft so

that the front U-joint slip yoke splines

to the transmission output shaft.

15.
Connect the drive shaft to the

U-joint flange, aligning the scribe

marks made on the drive shaft end

yoke and the axle U-joint flange dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

16.
Carefully slide the two axle

shaft assemblies in the axle housing.

The shorter shaft goes into the left

side of the housing. Use care in slid-

ing the axle shafts into the housing so

that the rough forging of the shaft will

not damage the oil seal. Start the axle

splines into the differential side gear,

and push the shaft in until the rear

wheel bearing bottoms in the housing.

17.
Install the rear wheel bearing

retainers on the attaching bolts on the

axle housing flanges. Install the nuts

on the bolts and torque to specifica-

tions.

18.
If the rear brake shoes were

backed off, adjust the brakes as out-

lined in Part 2-1, and install rubber

plugs in the adjuster slots.

19.
Install the two rear brake

drums and the drum attaching (Tin-

nerman) nuts.

20.
Install the rear wheels and tires.

21.
Fill the rear axle to the bottom

of the filler plug hole located in either

the carrier casting or housing cover

with specified lubricant. Be sure that

the axle is in operating position.

22.
Road test the vehicle to be sure

that pinion and driveshaft angles are
correct. Any shudder during heavy ac-

celeration, or deceleration may require

a pinion and driveshaft angle re-

adjustment as detailed in Driveshaft

and Pinion Angle Adjustment, Group

3,
Part 3-2.

AXLE HOUSING (LEAF

SPRING SUSPENSION)

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly. Disconnect

the drive shaft at the drive pinion

flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in

Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-

fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tool shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with

mechanic's wire. The hydraulic brake

lines and the parking brake cables are

still attached to the brake backing

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 16).

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operation*.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install theprocarmanuals.com

04-02-13

Rear Axle
—
Removable Carrier Type
04-02-13

lower insulators. Torque
the
spring

clip nuts
to
specification.

2.
Place
the
brake backing plates
in

their normal position
on the
axle

housing.

3.
Install
new
axle shaft
oil
seals

with
the
tool shown
in Fig. 10.
Soak

the
new
seals
in
light weight engine
oil

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

ing them. Installation without
use of

the proper tool will distort
the
seal

and cause leakage. Coat
the
outside
edges
of the new oil
seal with
a non-

hardening type
of
sealer such
as Per-

matex
No. 2 or its
equivalent.

4.
Install
the
axle shafts, brake

drums
and
wheels
as
outlined
in Sec-

tion
2.

5.
Attach
the
hydraulic brake line

T fitting
to the
axle housing,
and se-

cure
the
hydraulic brake line
in its re-

tainer
on the
axle housing.

6. Install vent tube
to
brake tube

junction
and
install vent hose
to
vent
tube.

7.
Raise
the
axle housing
and con-

nect
the
shock absorbers.

8. Connect
the
rear
end of the
drive

shaft
to the
axle U-joint flange, align-

ing
the
scribe marks made
on the

drive shaft
end
yoke
and the
axle
U-

joint flange.

9. Fill
the
axle with
the
proper

grade
and
amount
of
lubricant.

10.
Road test
the
vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY
OF

DIFFERENTIAL CARRIER

CONVENTIONAL

DIFFERENTIAL

A disassembled view
of the
rear

axle assembly
is
shown
in Fig. 17.

After mounting
the
carrier
in a

holding fixture, disassemble
the car-

rier
as
outlined
in the
following proce-

dures:

1.
Mark
one
differential bearing

cap
and the
mating bearing support

with punch marks
to
help position
the

parts properly during assembly
of the

carrier. Also, mark
one of the
bearing

adjusting nuts
and the
carrier with

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

ing assembly.

2.
Remove
the
adjusting
nut
locks,

bearing caps,
and
adjusting nuts. Then

lift
the
differential case assembly
out

of
the
carrier.

(Remove
the
bearing caps
by tap-

ping
the
caps lightly with
a
soft
mal-

let).

3.
Remove
the
differential bearings

with
the
tools shown
in Fig. 18.

4.
Mark
the
differential case, cover,

and ring gear
for
assembly
in the
orig-

inal position.

5.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the gear from
the
case
or tap it off

with
a
soft-faced hammer.

6. With
a
drift, drive
out the
differ-

AXLE HOUSING-4010

DIFFERENTIAL

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

and separate
the
2-piece differential

case.

7.
Drive
out the
pinion shaft with
a

brass drift
(Fig. 20).

8. Remove
the
gears
and
thrust

washers
(Fig. 48).

LIMITED-SLIP DIFFERENTIAL

1.
Remove
the
differential case

from
the
carrier
and
remove
the
bear-

ings from
the
differential case
in the

same manner
as the
conventional
dif-

ferential case.

2.
Place
the
differential case
in a

hydraulic press,
and
apply about
one

ton pressure across
the
case bearing

hubs while removing
the
ring gear
at-

FLAT WASHER (LIMITED SLIP ONLY)

DRIVE GEAR ATTACHING BOLT

DIFFERENTIAL CASE COVER -4206

DIFFERENTIAL PINION GEAR-4215

THRUST WASHER-4230

ADJUSTING NUT-4067

CARRIER HOUSING-4025

DRIVE PINION-4610
PINION BEARING

SPACER-4662

PINION FRONT

BEARING-4621

RING GEAR

PILOT BEARING-4A242

FIG. 17—Rear Axle Disassembled—Typical
PILOT BEARING

RETAINER-4627

PINION REAR

BEARING CUP-4616
DEFLECTOR-4859

PINION RETAINER-4668

SEAL-4676
FLANGE_4858
E1750-Aprocarmanuals.com

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

Too/-T53L-200-A

L-462S-A

4625-K
or
4625-KA

>:
M
E 1726-A

FIG. 36—Installing Pilot Bearing

loaded
to
seat
the
bearings
in
their

cups.
This step
is
important.

5. Again loosen the- right
nut to re-

lease
the
preload. Check
to see
that

the left
nut
contacts
the
bearing
cup.

Using
the
dial indicator set-up shown

in Fig.
10,
Part 4-1, adjust the preload

to 0.008
to
0.012 case spread
for new

bearings
or
0.005
to
0.008
for the ori-

ginal bearings,
if
re-used.

6. Check
the
runout
of
the differen-

tial case flange with
a
dial indicator.

If
the
runout does
not now
exceed

specifications, install
a new
ring gear.

If
the
runout still exceeds specifica-

tions,
the
ring gear
is
true
and the

trouble
is due to
either
a
defective

case
or
worn bearings.

7. Remove
the
differential case

from
the
carrier
and
remove
the
side

bearings from
the
case.

8. Install
new
bearings
on the
case

hubs,
and
again install
the
differential

assembly
in the
carrier without
the

ring gear.

9. Check the case runout again with

the new bearings.
If the
runout
is
now

within limits,
the old
bearings were

excessively worn.
Use the new
bear-

ings
for
assembly.
If the
runout
is
still

excessive,
the
case
is
defective
and

should
be
replaced.
Press,
Ram

REAR BEARING

CONE
AND

ROLLER

Too/-

T57L-46U-A
Fiber B/oc.

DRIVE

PINION

Too/-

T57L-4621-B

1701-A

FIG. 37—Installing Pinion Rear

Bearing Cone

PRESS RAM

Tool - 4621
L

E1903A

FIG. 38—Installing Pinion Rear

Bearing Cone

ASSEMBLY
OF
DIFFERENTIAL

CARRIER

PILOT BEARING

INSTALLATION

1.
Drive
the new
pilot bearing
in-

ward until
it
bottoms,
as
shown
in

Fig.
36.

2.
Using
the
same tool indicated
in

Fig.
36,
install
the new
pilot bearing

retainer with
the
concave side
up.
COLLAPSIBLE PINION

BEARING SPACER

INSTALLATION

1.
Install
the
drive pinion rear bear-

ing cone and roller
on the
pinion shaft

(Figs.
37
m 38).

Place
a new
spacer
on the
pinion

shaft (Fig.
39).

2.
Place
the
bearing retainer
on the

pinion shaft,
and
install
the
front

bearing cone
and
roller. Press
the

front bearing cone and roller into posi-

tion
as
shown
in Fig. 40. Be
careful

not
to
crush
the
bearing spacer.

3.
Lubricate
the
O-ring with axle

lubricant and install
it in its
groove
in

the pinion retainer.
Be
careful
not to

twist
it.
Snap
the
O-ring into position.

4.
Place
the
proper shim
on the

carrier housing
and
install
the
pinion

and retainer assembly, being careful

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

5. Install
the
pinion attaching bolts.

Torque
the
bolts
to
specification.

6. Place
the
slinger over
the
pinion

shaft
and
against
the
front bearing.

7.
Install
a new
seal
in the
bearing

retainer (Fig.
47).

8. Install
the
U-joint flange
(Fig.

49).

9. Start
a new
integral
nut and

washer
on the
pinion shaft.

Press
Ram

L*
Fiber Block

Tool-

T57L-4621

E 1712-A

FIG. 40—Installing Pinion Front

Bearing

FLANGE
O-RING

REAR BEARING

SPACER

SEAL
FRONT BEARING

RETAINER
SHIM
PINION

FIG. 39—Pinion
and
Bearing Retainer
PILOT

BEARING

RETAINER

PILOT

BEARING

E 1782-Aprocarmanuals.com

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

E 1195-C

FIG. 41—Removing
or
Installing

Pinion
and
Retainer Assembly

10.
Hold
the
flange with
the
tool

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

(Mercury),
and
torque
the
pinion shaft

nut
to 175
ft-lbs.
Do not
exceed
175

ft-Ibs
at
this time.

11.
Check
the
pinion bearing
pre-

load
as
shown
in Fig. 42.
Correct

pre-load will
be
obtained when
the

torque required
to
rotate
the
pinion
in

the retainer
is as
specified
in
Part
4-3.

If
the
torque required
to
rotate
the pin-

ion
is
less than specified, tighten
the

pinion shaft
nut a
little
at a
time until

Inch-Pound

Torque Wrench

E1899A

FIG. 42—Checking Pinion Bearing

Preload
the proper preload
is
established.
Do

not overtighten
the nut. If
excessive

preload
is
obtained
as a
result
of
over-

tightening, replace
the
collapsible

bearing spacer.

Do
not
back
off the
pinion shaft
nut

to establish pinion bearing preload.
If

the torque
on the
pinion shaft
nut is

less than
175
ft-lbs after bearing
pre-

load
is
established,
a new
collapsible

spacer must
be
used.

SOLID PINION BEARING

SPACER INSTALLATION

The spacer
is
serviced
in 20
sizes

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

ecting
the
size spacer required
for ob-

taining correct preload
is
included
in

the following assembly procedure.

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

pinion shaft
as
shown
in
Figs.
38 or

39.

2.
Select
a new
solid spacer
of a

larger size (0.485 inch thick),
and
slide

it over
the
pinion shaft against
the

rear bearing.

The pinion bearing preload
can be

accurately measured only when
the

pinion shaft
nut is
torqued
to 180-

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

quired
was
used,
the
specified
180-

220 ft-lbs torque would damage
the

bearings.
For
this reason,
the
largest

spacer should
be
tried first. Then,
if

the bearings
are too
loose,
the
size
of

the spacer
can be
decreased until
the

correct preload
is
obtained.

3.
Position
the
bearing retainer
and

cup assembly
on the
pinion shaft
and

install
the
front bearing cone
and rol-

ler. Press
the
front bearing cone
and

roller assembly into position,
as

shown
in Fig. 38.

4.
Mount
the
retainer
in a
holding

fixture
as
shown
in Fig. 23, and
place

the slinger over
the
pinion shaft
and

against
the
front bearing.

5.
Install
the
U-joint flange with

the tool shown
in Fig. 46.

6. Hold
the
flange with
the
tool

shown
in Fig. 23 or 24, and
install
the

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

ft-lbs.
While tightening
the nut,
rotate

the bearing retainer
to
determine
the

existance
of any
bearing preload

which will
be
indicated
by a
slight

drag
in the
rotation
of the
retainer.

DETERMINING SPACER

SIZE FROM

PRELOAD READING

1.
If
bearing drag indicates
a pre-

load condition exists, apply
an
in-lb

torque wrench
to the
pinion
nut as

shown
in Fig. 42 and
read
the
torque

required
to
turn
the
shaft. Effort

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

2.
If
preload
is the
correct valve,

proceed with assembly procedure

given
in
Final Assembly
of
Pinion
and

Retainer, which follows.

2.
If
preload exists,
but is
below

specification, select
the
correct spacer

from
Fig. 43 and
install, completing

assembly
as
shown
in
Final Assembly

of Pinion
and
Retainer.

DETERMINING SPACER

SIZE FROM
END

PLAY READING

1.
If no
perceptible preload
is
felt

when rotating
the
pinion shaft, install

a dial indicator
as
shown
in Fig. 44,

so that
the
indicator point
is
resting

on
the end of the
pinion gear shaft

(companion flange
end).

2.
Use
both hands
to
squeeze
the

pinion shaft
and the
bearing retainer

together
(Fig. 45).
Record
the
endplay

reading shown
on the
dial indicator.

3.
Disassemble
the
pinion shaft
and

retainer
and
install
the
correct spacer

as shown
in Fig. 43.

4.
Proceed with assembly
of the pin-

ion shaft
and
retainer
as
directed
in

Final Assembly
of
Pinion
and
Retain-

er.

FINAL ASSEMBLY
OF

PINION
AND
RETAINER

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

AS
END
PLAY

READS

(10/1000 inch)

USE THIS

SPACER
0

0.481
1

0.480
2

0.479
3

0.478
4

0.476

If there
is no end
play
and
preload
on the
bearings

IF PRELOAD READS

(in-lbs.)

USE THIS SPACER
2-11

0.482
12-20

0.483
5

0.476
6

0.474
7

0.474
8

0.472
9

0.472
10

0.470
11

0.470
12

0.468
13

0.468
14

0.466
15

0.465

exists:

21-30

0.484
31-45

0.485

FIG. 43— Solid Spacer Selectionprocarmanuals.com

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

POINTER RESTING ON

PINION NUT

E 1505-B

FIG.
44
— End Play Indicator

Installation

pinion shaft as shown in Figs. 37 and

38.

2.
Slide the correct spacer over the

pinion shaft against the rear bearing.

3.
Position the bearing retainer and

cup assembly on the pinion shaft and

install the front bearing cone and rol-

ler. Press the front cone and roller

into position, as shown in Fig. 46.

4.
Lubricate a new O-ring with axle

lubricant and install it in the groove

provided in the pinion retainer. Be

careful not to twist the O-ring. Install

it by snapping it into place.

5.
Place the proper shim on the

carrier housing and install the pinion

and retainer assembly, being careful

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

6. Install the pinion retainer bolts.

Torque the bolts to specification.

7.
Place the slinger over the pinion

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

E 1197-D

FIG. 46—Installing
U-Joint
Flange

8. Install a seal in the bearing re-

tainer, (Fig. 47).

9. Start a new integral nut and

washer on the pinion shaft.

10.
Hold the companion flange with

the tool shown in Fig. 20 or 22 and

torque the pinion nut to specifications

(200 ft-lbs).

11.
With a new seal installed pin-

ion bearing preload should now read

17 to 32 in-lbs for new pinion bearings

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

ginal bearings and a new seal.

ASSEMBLY AND

INSTALLATION OF

DIFFERENTIAL CASE

Conventional

Differential Case

1.
Place a side gear and thrust

washer in the differential case bore

E 1506-B

E 1629-A

FIG. 45— Checking Pinion End

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

parts liberally with axle lubricant dur-

ing assembly.

2.
With a soft-faced hammer, drive

the differential pinion shaft into the

case only far enough to retain a pin-

ion thrust washer and pinion gear.

3.
Place the second pinion and

thrust washer in position, and drive

the pinion shaft into place. Carefully

line up the pinion shaft lock pin holes.

4.
Place the second side gear and

thrust washer in position (Fig. 48),

and install the cover on the differen-

tial case. Install the pinion shaft lock

pin. A pinion or axle shaft spline can

be inserted in the side gear spline to

check for free rotation of the differen-

tial gears.

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

inches long through the differential

case flange, and thread them three or

four turns into the ring gear as a

guide in aligning the ring gear bolt

holes.
Press or tap the ring gear into

position.

6. Install and tighten the ring gear

bolts and washers evenly, and torque

them alternately across the gear to

specification.

7.
If the differential bearings have

been removed, press them on as

shown in Figs. 49 and 50.

8. Wipe a thin coating of lubricant

on the bearing bores so that the dif-

ferential bearing cups will move easily.

9. Place the cups on the bearings.

If the gear set is of the non-hunting or

partial non-hunting type, assemble the

differential case and ring gear assem-

bly in the carrier so that the marked

tooth on the pinion indexes between

the marked teeth on the ring gear as

shown in Fig. 51.

In almost every case of improper

assembly (gears assembled out of

time),
the noise level and probability

of failure will be higher than they

would be with properly assembled

gears.

When installing the hunting type

gear set (no timing marks), assemble

the differential case and ring gear as-

sembly in the carrier without regard

to the matching of any particular gear

teeth.

10.
Slide the assembly along the

bores until a slight amount of back-

lash is felt between the gear teeth.

11.
Set the adjusting nuts in the

bores so that they just contact the

bearing cups. The nuts should be en-

gaged about the same number of

threads on each side.

12.
Carefully position the bearing

caps on the carrier. Match the marks

made when the caps were removed.procarmanuals.com

04-02-20
Rear Axle — Removable Carrier Type

0402-20

THRUST WASHER

E1175-B

FIG. 48—Assembling Differential Case

13.
Install the bearing cap bolts

and alternately torque them. The 9

3/8 inch ring gear size axle requires

60-70 ft-lbs. The 8 3/4 inch and 9

inch ring gear size axles require 70-85

ft-lbs.

14.
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 of incor-

rectly positioned caps. Tightening the

bolts to the specified torque is done to
be sure that the cups and adjusting

nuts are seated. Loosen the cap bolts,

and torque them to only 25 ft. lbs be-

fore making adjustments.

15.
Adjust the backlash between the

DIFFERENTIAL

BEARING

CONE AND

ROLLER

E 1700-A

FIG. 49—
Installing
Differential

Bearing
1376-A

FIG. 50—Installing Differential

bearing
ring gear and pinion as outlined in

Part 4-1, Section 2.

16.
Be sure to make a final tooth

pattern check before installing the

carrier assembly in the axle housing.

Limited-Slip

Differential Case

1.
Place the inner side gear and

thrust washer in the differential case

(Fig. 52). Lubricate all parts liberally

with limited-slip axle lubricant during

assembly.

2.
With a soft-faced hammer, drive

the pinion shaft into the case only far

enough to retain a pinion thrust wash-

er 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 in holes.

4.
Install the pinion shaft lock pin.

The lock pin must not extend beyond

the surface of the case.

5. Insert two 2-inch 7/16 (NF)

bolts 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. Clamp the differential case in a

soft-jawed vise. Install the differential

outer side gear on the differential pin-

ion gears. Place the clutch hub on

the side gear. Place the thrusi: washer

on the huh

Limited-Slip dutch

Plate Installation

Prior to clutch plate installation,

the friction bonded plates must be

soaked in C6AZ-19570-C (ESW-

M2C-104-A) differential lubricant for

approximately 1/2 hour. In addition,

the differential lubricant must be lib-

erally applied to all components to

be assembled.

1.
Place the clutch hub into posi-

tion in a soft-jawed vise.

2.
First, install a steel clutch plate

in the cavity of the differential case

opposite the ring gear and then a

bonded friction plate (Fig. 53). Any

tab on the steel plates can be inserted

into any cavity in the differential case,

however when the first steel plate is

inserted the others must be placed in

the same manner (Fig. 54) so the tabs

with slots line up. Install the remain-

ing plates: a steel plate, bonded fric-

tion plate, a steel plate, bonded fric-

tion plate and lastly a steel plate.

Make sure the bonded friction plate

inner-spline teeth properly engage the

hub spline.procarmanuals.com

04-02-21
Rear Axle
—
Removable Carrier Type
04-02-21

SITION IN WHICH GEARS WERE LAPPED

FIG. 51—Gear
Set
Timing Marks

3.
Center
the
Belleville spring
on

the clutch pack (spring concave-side

facing downward
on the
pack)
to pre-

vent trapping
the
spring between
the

left
and
right handcase
in an
eccentric

position
(Fig. 54).
Improper location

of
the
Belleville spring will cause
ex-

tremely high torque
and
differential

chatter.
Be
sure
the
slots
in the
rabbit

ears
of the
steel plates
are in
proper

alignment.

4.
Carefully
set the
differential case

cover over
the
right hand case
(Fig.

55).
At
this point,
no
force
or
pressure

should
be
applied
to the
cover.
The

cover contains
two 3/16
inch holes
by

which
the
clutch plates
can be
proper-

ly aligned. Insert
the
shank ends
of
two
1/8
inch drill bits into
the
holes,

and work
the
drill bits back-and forth

until
the
plates
are
centered
(Fig. 55).

When
the
clutch plates
are
centered,

the weight
of the
cover will cause
it to

fall into position. Remove
the
drill

bits.

5.
Install
the
ring gear
to
differen-

tial case bolts,
and
tighten them even-

ly
and
alternately across
the
diameter

of
the
ring gear. Tighten
the
bolts
to

specification.

6. Prior
to
installation
of the

limited-slip differential into
the ve-

hicle,
a
differential torque check must

be made. Check
the
torque required
to

rotate
one
side gear while
the
other

side gear
is
held
(Fig. 56). The
initial

PINION GEAR

DIFFERENTIAL

CASE
_
LUBRICATOR

HOLE / CLUTCH HUB

THRUST /

PINION \\WASHERS/

SHAFT
BELLEVILLE SPRING

STEEL
PLATE.

BONDED PLATES

CASE COVER

STEEL PLATES

RING GEAR
SIDE GEARS

LOCK
PIN

E 1738-A
STEEL PLATE THRUST WASHER

E 1189-

FIG. 53—Installing Steel Clutch

Plates
and
Friction Plates

BELLEVILLE SPRING

E 1711-A

FIG.
54
— Belleville
Spring

Installation

breakaway torque required
to
start
the

side gear turning
may
exceed
300 ft-

lbs.
Observe only
the
torque required

for continuous even rotation. There

should
be no
abnormal roughness
or

binding.
In
some instances
the
rotat-

ing torque
may
reach
250
ft-lbs, this

condition
is
acceptable,
if
rotation
is

smooth.
If the
results
of the
bench

check
are not
within specified limits,

internal trouble
may be
present
and

should
be
corrected before installing

the assembly
in the
vehicle. Some

possible torque problems
as
follows:

1/8" DRILL

DIFFERENTIAL

CASE COVER

E 1191-C

FIG. 52—Limited-Slip Differential Assembly
FIG.
55—
Differential Cover

Installationprocarmanuals.com

04-02-22

Rear Axle — Removable Carrier Type
04-02-22

Too/-T59L-4204-A

or
44211

and
44211-A

EH92-C

FIG. 56—Checking Differential

Torque

High Torque

a. Insufficient lubricant on the

clutch plates.

b.
A clutch plate wedged in be-

tween the case halves.

c. An improperly centered Belleville

spring.

Low Torque

a. Weak Belleville spring.
b.
Improper amount of clutch

plates installed.

Under no circumstances should the

Belleville spring be ground down to

reduce torque. The torque required to

keep the side gear turning with new

clutch plates is 155 to 195 ft-lbs. On

reused clutch plates, the torque re-

quired is 75 ft-lbs minimun.

7.
If the differential bearings have

been removed, press them on as

shown in Figs. 49 and 50.

8. Install the side bearings on the

differential case, and install the case

in the carrier as described in steps 7

through 16 under Assembly and In-

stallation of Conventional Differential

Case. Adjust and check backlash be-

tween the ring gear and pinion as di-

rected under Differential Bearing Pre-

load Adjustments.

ASSEMBLY OF

TRACTION-LOK

DIFFERENTIAL CASE

1.
Lubricate all parts with Ford

Hypoid Lubricant (Ford Part No.

C6AZ-19580-C), during assembly of

differential.

2.
Mount the differential case in a

soft jawed vise and place a side gear

thrust washer and side gear in the

counterbore of the case.

CENTER BLOCK

PRELOAD SPRINGS

PRELOAD PLATE

PINION GEAR

DIFFERENTIAL CASE

E1893-
A

. 57—Center Block and Pre-Load Springs Installation
3.
Install the pinion thrust washers

and place the pinion gears on the side

gear; aligning the holes in the washers

and gears with the holes in the case.

4.
Install the center block so that

the shaft holes are aligned with the

holes in the pinion gears and case.

The center block has two machined

sides and two rough sides.

5.
With a brass drift, drive in the

long pinion shaft from the outside of

the case aligning the lock pin holes in

the shaft with the holes in the case.

The center block should be positioned

so the long shaft is driven through the

rough side and short shafts driven

through the machined side (Fig. 57).

6. With a suitable drift, install the

shaft lock pins. Make sure the pinion

and side gears move freely.

7.
Place the four pre-load springs in

the holes provided in the center block.

8. Position a pre-load plate over the

four springs, making sure the springs

are properly seated. The pre-load

plate straddles the center block over

its narrower or machined width.

9. Mount the differential cover in a

soft jawed vise or holding fixture.

10.
Insert shim(s) of 0.050 total

thickness in the cover cavity.

11.
Install the composite plate (fric-

tion material on one side and steel on

the opposite) on the back side of the

clutch hub with the friction material

against the hub; next, install a friction

plate, then steel, friction, stee, fric-

tion, steel, friction, and lastily a steel

plate (Figures 3 and 58). When new

clutch plates are used, soak the plates

in Ford Hypoid Lubricant (Ford Part

No.
C6AZ-19580-C), or equivalent lu-

bricant, for approximately 30 minutes

before installation.

12.
Place the clutch hub with the

clutch plates into the clutch ear cavi-

ties in the differential cover. Make

sure that the splines on the last fric-

ion plate are engaged on the hub.

13.
Obtain locally a 5/8 inch x

2 1/2 inch or 9/16 inch x 2 1/2

inch bolt, nut and two I 1/2 inch

outside diameter flat washers approx.

1/8 inch in thickness. These parts are

required to compress the clutch pack

in order to obtain the proper shim

selection.

Install a flat washer on the bolt,

and place the bolt through the clutch

hub.
Hold the bolt in position and

turn the cover over. Place a flat wash-

er on the bolt and then install the nut.

Be sure the washers are centered, and

torque the nut 10 to 15 ft-lbs (Fig.

59).

14.
Place the shim template tool

(Ford Tool No. T68P-4946-A) in the

clutch hub. Some clearance should beprocarmanuals.com

04-02-23
Rear Axle — Removable Carrier Type

04-02-23

observed between the shim tool and

the cover-to-case mating surface.

Using a feeler gauge, determine the

exact amount of clearance. Refer to

the shim pack thickness chart specifi-

cations which will indicate the correct

amount of shim(s) to subtract from

the 0.050 shim originally installed. In

order to correctly select the proper

shim(s), the shim template tool and

the chart must be used.

15.
After the proper shim selection

is determined, remove the bolt, nut

and flat washers. If it is necessary to

revise the shim thickness, remove the

clutch hub and clutch plates.

16.
Install the selected shim(s) in

the cover cavity, reinstall the compo-

nents as outlined in Steps 11 and 12.

17.
Install the four steel clutch ear

guides and side gear.

18.
Place both assemblies in a

press,
and press the two halves togeth-

er; then, insert the two Allen or Phil-

lips head screws, and tighten evenly

until tight. If a press is not available,

any two stock bolts and nuts may be

used opposite each other in the ring

gear retaining holes to compress both

halves.

19.
Install the ring gear and ring

gear bolts and washers. Tighten evenly

and alternately across the diameter of

the ring gear. Torque the bolts to

65-80 ft-lbs.

20.
Prior to installation of the tor-

que sensitive locking differential into a

vehicle, a bench torque check must be

made. Check the torque required to

rotate one side gear while the other is

held stationary (Fig. 56). The initial

break-away torque may exceed 250

ft-lbs.
The rotating torque required to

keep the side gear turning with new

clutch plates is 100 to 250 ft-lbs. With

re-used clutch plates, the minimum

torque required is 40 ft-lbs. (The tor-

que may fluctuate 10-40 ft-lbs.).
DIFFERENTIAL COVER

SHIM
-COMPOSITE PLATE

CLUTCH HUB

SIDE GEAR

FRICTION PLATES

E1894-A

FIG. 58— Clutch Pack Installation

CLEARANCE CHECK AREA

SHIM TEMPLATE

E1895-A

59—Shim Template Tool Applicationprocarmanuals.com

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