FORD MUSTANG 1969 Volume One Chassis

04-02-14

Rear Axle
—
Removable Carrier Type

04-02-14

DIFFERENTIAL

BEARING
Tool—
7
571-4220-A

T66P°4220-P

E1015-B

FIG. 18—Removing Differential

Bearing—Ford

taching bolts. Applying pressure will

contain
the
spring pressure between

the differential case
and
cover until

after
the
bolts
are
removed,
and
there-

by prevent stripping
of the
threads.

3.
Release
the
hydraulic press
ram,

and remove differential case cover.

4.
Remove
the
Belleville spring

(Fig.
54).

5.
Remove
the
steel
and the
bonded

clutch plates.

6. Remove
the
differential clutch

hub,
side gear,
and
thrust washer.

7.
Remove
the
ring gear from
the

differential case.

8. Drive
out the
differential pinion

shaft lock
pin.

9. With
a
brass drift, drive
out the

differential pinion shaft. Then remove

the pinion gears,
the
other side gear,

and thrust washers.
E 1724-A

FIG. 20—Driving
Out
Differential

Pinion Shaft

TRACTION-LOK

DIFFERENTIAL

1.
Remove
the
differential case

from
the
carrier
and
remove
the
bear-

ings from
the
differential case
in the

same manner
as the
conventional
dif-

ferential case.

2.
Remove
ten
bolts securing
the

ring gear
to the
differential case
as-

sembly.
The
ring gear must
be re-

moved
in
order
to
separate
the
case

halves.

3.
Remove
the
ring gear
by
tapping

the gear with
a
soft hammer
or
press

the gear from
the
case.

4.
Place
the
differential case
in a

press
to
load
the
bearing journals
so

that
the
pre-load
of the
springs
is ov-

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

press
is not
available,
two 7/16
inch

bolts
and
nuts
can be
used
in the
ring

gear mounting holes
(one on
each

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

tension.) Then, while
the
case
is
still

under pressure, loosen
the two
Allen

or Phillips head screws which hold
the

case halves together until
one or two

threads
of the
screws remain engaged.

Remove
the
case assembly from
the

press.
Tap on the
cover
to
spring
it

loose; then, remove both screws.

5.
With
the
cover facing down, lift

off
the
case. Remove
the
pre-load

spring plate
and
four pre-load springs.

6. From
the
cover remove
the
side

gear, four clutch plate
ear
guides,

clutch
hub,
friction
and
steel clutch

plates
and
shim(s).

7.
With
a
suitable drift, drive
out

the pinion shaft lock pins from
the

case.

8. With
a
brass drift, drive
out the

long pinion shaft from
the
case. Drive

from
the end
opposite
the
lock
pin

hole.

9. Remove
the two
short pinion

shafts using
a
drift, driving each shaft

from
the
center outward. Lift
out the

center block, then remove
the
pinion

gears,
thrust washers
and
side gear

and thrust washer.

10.
If the
differential bearings
are

removed,
the
bearings
can be
installed

in
one of the
following ways:

a. With
the
differential case
and

cover completely assembled.

b.
On the
case
or
cover when disas-

sembled. However, when pressing
the

bearings
on the
cover,
a
block
of

wood
or
fiber must
be
used
as
shown

in Fig.
21 in
order
to
avoid damage
to

the cover.

E 1709-A

FIG. 79—Removing Differential

Pinion Shaft Lock
Pin
DIFFERENTIAL BEARING

E1892-A

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

04-02-15

Rear
Axle — Removable Carrier Type

04-02-15

REMOVAL AND

DISASSEMBLY OF

DRIVE PINION AND

BEARING RETAINER

I. Turn the carrier assembly

upright and remove the pinion shaft

nut (Fig. 22 and Fig. 23).

2.
Remove the U-joint flange from

the pinion shaft (Figs. 24 and 25).

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

4.
Remove the pinion, bearing, and

retainer assembly from the carrier

housing (Fig. 41). Measure the shim

thickness with a micrometer. Record

this original shim thickness. If a new

gear set is installed during assembly, a

new shim will have to be installed.

The original shim thickness is one of

the factors necessary in determining

the new shim thickness. Extreme care

must be taken not to damage the

mounting surfaces of the retainer and

carrier.

5. Place a protective sleeve (hose)

on the pinion pilot bearing surface.

Press the pinion shaft out of the pin-

ion front bearing cone with the tool

shown in Fig. 27.

O/-T57L-485
7-A

E1485-A

FIG.
22—Removing Pinion Shaft

Nut

E 1486-B

FIG. 23—
U-Joint Flange Holding

Tool

6. Press the pinion shaft out of the

pinion rear bearing cone and roller

(Fig. 28).

PILOT BEARING

1.
Remove the pilot bearing as

shown in Fig. 29. Drive out the pilot

bearing and the bearing retainer to-

gether.
FIG.
24 —
Removing
U-Joint Flange

E1902A

FIG.
25 —Flange Removal Tool

Tool-
7 7
75-AB

Tool—T50T-100-A

|E
1780.
A

FIG.
26—Removing Pinion Seal

PINION BEARING CUPS

Do not remove the pinion bearing

cups from the retainer unless the cups

are worn or damaged. The flange and

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

cups after they are installed in their

bores.
If the cups are worn or dam-

aged, they should be replaced.

Remove the bearing cups as shown

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

as shown in Figs. 33 and 34.

Press
Ram

Tool
-

757L-4674-A
Fiber Block

HOSE

\

1710-A

FIG.
27

Bearing
-Removing
Pinion Front

FIG.
28 —Removing Pinion Rear

Bearing
Cone

After the new cups are installed,

make sure they are seated in the re-

tainer by trying to insert a 0.0015-inch

feeler gauge between the cup and the

bottom of the bore.

Whenever the cups are replaced, the

cone and roller assemblies should also

be replaced.

DRIVE PINION AND

RING GEAR SET

When replacing a ring gear and pin-

ion, note that the original factory in-

stalled shim is of the correct thicknessprocarmanuals.com

04-02-16

Rear Axle — Removable Carrier Type
04-02-16

Tool~T53L-200-A

Tool-T57L-4625-A

or 4625-K

E 1725-A

FIG. 29—Removing Pilot Bearing

to adjust for individual variations in

both the carrier housing dimension

and in the original gear set dimension.

Therefore, to select the correct shim

thickness for the new gear set to be

installed, follow these steps:

1.
Use a micrometer to measure

the thickness of the original shim re-

moved from the axle and use the same

thickness upon installation of the re-

placement carrier assembly or drive

pinion. If further shim change is ne-

cessary, it will be indicated in the

tooth pattern check.

2.
If the original shim is lost, sub-

stitute a nominal shim for the original

and use the tooth pattern check to

determine if further shim changes are

required. Nominal shim thicknesses is

E 1734-A
PINION BEARING

RETAINER

E 1482-B

FIG. 31—Removing Pinion Front

Bearing Cup

indicated in Part 4-3, Specifications.

A new ring gear and pinion should

always be installed in an axle as a

matched set (never separately). Be

sure the same identifying (matching)

number, appears on the bolt hole face

of the ring gear and on the head of

the drive pinion (Fig. 35).

3.
After determining the correct

shim thickness as explained in the

ss
Rom

Too/-T58L-70?-A

or4675-J

FIG. 30—Removing Pinion Front

Bearing Cup
FIG. 32—Removing Pinion Rear

Bearing Cup

foregoing steps, install the new pinion

and ring gear as outlined under As-

sembly.

DIFFERENTIAL
CASE

BEARINGS
AND
RING

GEAR
TEST

If the ring gear runout check (be-

fore disassembly) exceeded specifica-

tions,
the condition may be caused by

a warped gear, a defective case, or ex-

cessively worn differential bearings.

To determine the cause of excessive

runout proceed as follows:

1.
Assemble the two halves of the

differential case together without the

ring gear, and press the two differen-

tial side bearings on the hubs.
Press Ram

Tool -

T57L - 4614-A
Tool -

T57L - 4676-A2

1736-/

FIG. 33—Installing Pinion Front

Bearing Cup

too;-
IB .

T55P-46U
A2V •H"^^

\
Press Ram

Tool-

T57L-46U-A

FIG. 34—Installing Pinion Rear

Bearing Cup

2.
Place the cups on the bearings

and set the differential case in the car-

rier.

3.
Install the bearing caps and ad-

justing nuts as outlined in Steps 11

thru 14 under Assembly and Installa-

tion of Conventional Differential Case

which follows in this section.

4.
Tighten the right nut two notches

beyond the position where it first con-

tacts the bearing cup. Rotate the dif-

ferential case several revolutions in

each direction while the bearings are

MATCHED

GEAR SET

IDENTIFICATION

E 1628-A

FIG. 35— Pinion and Ring Gear

Markingsprocarmanuals.com

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

Too/-T53L-200-A

L-462S-A

4625-K
or
4625-KA

>:
M
E 1726-A

FIG. 36—Installing Pilot Bearing

loaded
to
seat
the
bearings
in
their

cups.
This step
is
important.

5. Again loosen the- right
nut to re-

lease
the
preload. Check
to see
that

the left
nut
contacts
the
bearing
cup.

Using
the
dial indicator set-up shown

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

to 0.008
to
0.012 case spread
for new

bearings
or
0.005
to
0.008
for the ori-

ginal bearings,
if
re-used.

6. Check
the
runout
of
the differen-

tial case flange with
a
dial indicator.

If
the
runout does
not now
exceed

specifications, install
a new
ring gear.

If
the
runout still exceeds specifica-

tions,
the
ring gear
is
true
and the

trouble
is due to
either
a
defective

case
or
worn bearings.

7. Remove
the
differential case

from
the
carrier
and
remove
the
side

bearings from
the
case.

8. Install
new
bearings
on the
case

hubs,
and
again install
the
differential

assembly
in the
carrier without
the

ring gear.

9. Check the case runout again with

the new bearings.
If the
runout
is
now

within limits,
the old
bearings were

excessively worn.
Use the new
bear-

ings
for
assembly.
If the
runout
is
still

excessive,
the
case
is
defective
and

should
be
replaced.
Press,
Ram

REAR BEARING

CONE
AND

ROLLER

Too/-

T57L-46U-A
Fiber B/oc.

DRIVE

PINION

Too/-

T57L-4621-B

1701-A

FIG. 37—Installing Pinion Rear

Bearing Cone

PRESS RAM

Tool - 4621
L

E1903A

FIG. 38—Installing Pinion Rear

Bearing Cone

ASSEMBLY
OF
DIFFERENTIAL

CARRIER

PILOT BEARING

INSTALLATION

1.
Drive
the new
pilot bearing
in-

ward until
it
bottoms,
as
shown
in

Fig.
36.

2.
Using
the
same tool indicated
in

Fig.
36,
install
the new
pilot bearing

retainer with
the
concave side
up.
COLLAPSIBLE PINION

BEARING SPACER

INSTALLATION

1.
Install
the
drive pinion rear bear-

ing cone and roller
on the
pinion shaft

(Figs.
37
m 38).

Place
a new
spacer
on the
pinion

shaft (Fig.
39).

2.
Place
the
bearing retainer
on the

pinion shaft,
and
install
the
front

bearing cone
and
roller. Press
the

front bearing cone and roller into posi-

tion
as
shown
in Fig. 40. Be
careful

not
to
crush
the
bearing spacer.

3.
Lubricate
the
O-ring with axle

lubricant and install
it in its
groove
in

the pinion retainer.
Be
careful
not to

twist
it.
Snap
the
O-ring into position.

4.
Place
the
proper shim
on the

carrier housing
and
install
the
pinion

and retainer assembly, being careful

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

5. Install
the
pinion attaching bolts.

Torque
the
bolts
to
specification.

6. Place
the
slinger over
the
pinion

shaft
and
against
the
front bearing.

7.
Install
a new
seal
in the
bearing

retainer (Fig.
47).

8. Install
the
U-joint flange
(Fig.

49).

9. Start
a new
integral
nut and

washer
on the
pinion shaft.

Press
Ram

L*
Fiber Block

Tool-

T57L-4621

E 1712-A

FIG. 40—Installing Pinion Front

Bearing

FLANGE
O-RING

REAR BEARING

SPACER

SEAL
FRONT BEARING

RETAINER
SHIM
PINION

FIG. 39—Pinion
and
Bearing Retainer
PILOT

BEARING

RETAINER

PILOT

BEARING

E 1782-Aprocarmanuals.com

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

E 1195-C

FIG. 41—Removing
or
Installing

Pinion
and
Retainer Assembly

10.
Hold
the
flange with
the
tool

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

(Mercury),
and
torque
the
pinion shaft

nut
to 175
ft-lbs.
Do not
exceed
175

ft-Ibs
at
this time.

11.
Check
the
pinion bearing
pre-

load
as
shown
in Fig. 42.
Correct

pre-load will
be
obtained when
the

torque required
to
rotate
the
pinion
in

the retainer
is as
specified
in
Part
4-3.

If
the
torque required
to
rotate
the pin-

ion
is
less than specified, tighten
the

pinion shaft
nut a
little
at a
time until

Inch-Pound

Torque Wrench

E1899A

FIG. 42—Checking Pinion Bearing

Preload
the proper preload
is
established.
Do

not overtighten
the nut. If
excessive

preload
is
obtained
as a
result
of
over-

tightening, replace
the
collapsible

bearing spacer.

Do
not
back
off the
pinion shaft
nut

to establish pinion bearing preload.
If

the torque
on the
pinion shaft
nut is

less than
175
ft-lbs after bearing
pre-

load
is
established,
a new
collapsible

spacer must
be
used.

SOLID PINION BEARING

SPACER INSTALLATION

The spacer
is
serviced
in 20
sizes

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

ecting
the
size spacer required
for ob-

taining correct preload
is
included
in

the following assembly procedure.

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

pinion shaft
as
shown
in
Figs.
38 or

39.

2.
Select
a new
solid spacer
of a

larger size (0.485 inch thick),
and
slide

it over
the
pinion shaft against
the

rear bearing.

The pinion bearing preload
can be

accurately measured only when
the

pinion shaft
nut is
torqued
to 180-

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

quired
was
used,
the
specified
180-

220 ft-lbs torque would damage
the

bearings.
For
this reason,
the
largest

spacer should
be
tried first. Then,
if

the bearings
are too
loose,
the
size
of

the spacer
can be
decreased until
the

correct preload
is
obtained.

3.
Position
the
bearing retainer
and

cup assembly
on the
pinion shaft
and

install
the
front bearing cone
and rol-

ler. Press
the
front bearing cone
and

roller assembly into position,
as

shown
in Fig. 38.

4.
Mount
the
retainer
in a
holding

fixture
as
shown
in Fig. 23, and
place

the slinger over
the
pinion shaft
and

against
the
front bearing.

5.
Install
the
U-joint flange with

the tool shown
in Fig. 46.

6. Hold
the
flange with
the
tool

shown
in Fig. 23 or 24, and
install
the

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

ft-lbs.
While tightening
the nut,
rotate

the bearing retainer
to
determine
the

existance
of any
bearing preload

which will
be
indicated
by a
slight

drag
in the
rotation
of the
retainer.

DETERMINING SPACER

SIZE FROM

PRELOAD READING

1.
If
bearing drag indicates
a pre-

load condition exists, apply
an
in-lb

torque wrench
to the
pinion
nut as

shown
in Fig. 42 and
read
the
torque

required
to
turn
the
shaft. Effort

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

2.
If
preload
is the
correct valve,

proceed with assembly procedure

given
in
Final Assembly
of
Pinion
and

Retainer, which follows.

2.
If
preload exists,
but is
below

specification, select
the
correct spacer

from
Fig. 43 and
install, completing

assembly
as
shown
in
Final Assembly

of Pinion
and
Retainer.

DETERMINING SPACER

SIZE FROM
END

PLAY READING

1.
If no
perceptible preload
is
felt

when rotating
the
pinion shaft, install

a dial indicator
as
shown
in Fig. 44,

so that
the
indicator point
is
resting

on
the end of the
pinion gear shaft

(companion flange
end).

2.
Use
both hands
to
squeeze
the

pinion shaft
and the
bearing retainer

together
(Fig. 45).
Record
the
endplay

reading shown
on the
dial indicator.

3.
Disassemble
the
pinion shaft
and

retainer
and
install
the
correct spacer

as shown
in Fig. 43.

4.
Proceed with assembly
of the pin-

ion shaft
and
retainer
as
directed
in

Final Assembly
of
Pinion
and
Retain-

er.

FINAL ASSEMBLY
OF

PINION
AND
RETAINER

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

AS
END
PLAY

READS

(10/1000 inch)

USE THIS

SPACER
0

0.481
1

0.480
2

0.479
3

0.478
4

0.476

If there
is no end
play
and
preload
on the
bearings

IF PRELOAD READS

(in-lbs.)

USE THIS SPACER
2-11

0.482
12-20

0.483
5

0.476
6

0.474
7

0.474
8

0.472
9

0.472
10

0.470
11

0.470
12

0.468
13

0.468
14

0.466
15

0.465

exists:

21-30

0.484
31-45

0.485

FIG. 43— Solid Spacer Selectionprocarmanuals.com

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

POINTER RESTING ON

PINION NUT

E 1505-B

FIG.
44
— End Play Indicator

Installation

pinion shaft as shown in Figs. 37 and

38.

2.
Slide the correct spacer over the

pinion shaft against the rear bearing.

3.
Position the bearing retainer and

cup assembly on the pinion shaft and

install the front bearing cone and rol-

ler. Press the front cone and roller

into position, as shown in Fig. 46.

4.
Lubricate a new O-ring with axle

lubricant and install it in the groove

provided in the pinion retainer. Be

careful not to twist the O-ring. Install

it by snapping it into place.

5.
Place the proper shim on the

carrier housing and install the pinion

and retainer assembly, being careful

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

6. Install the pinion retainer bolts.

Torque the bolts to specification.

7.
Place the slinger over the pinion

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

E 1197-D

FIG. 46—Installing
U-Joint
Flange

8. Install a seal in the bearing re-

tainer, (Fig. 47).

9. Start a new integral nut and

washer on the pinion shaft.

10.
Hold the companion flange with

the tool shown in Fig. 20 or 22 and

torque the pinion nut to specifications

(200 ft-lbs).

11.
With a new seal installed pin-

ion bearing preload should now read

17 to 32 in-lbs for new pinion bearings

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

ginal bearings and a new seal.

ASSEMBLY AND

INSTALLATION OF

DIFFERENTIAL CASE

Conventional

Differential Case

1.
Place a side gear and thrust

washer in the differential case bore

E 1506-B

E 1629-A

FIG. 45— Checking Pinion End

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

parts liberally with axle lubricant dur-

ing assembly.

2.
With a soft-faced hammer, drive

the differential pinion shaft into the

case only far enough to retain a pin-

ion thrust washer and pinion gear.

3.
Place the second pinion and

thrust washer in position, and drive

the pinion shaft into place. Carefully

line up the pinion shaft lock pin holes.

4.
Place the second side gear and

thrust washer in position (Fig. 48),

and install the cover on the differen-

tial case. Install the pinion shaft lock

pin. A pinion or axle shaft spline can

be inserted in the side gear spline to

check for free rotation of the differen-

tial gears.

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

inches long through the differential

case flange, and thread them three or

four turns into the ring gear as a

guide in aligning the ring gear bolt

holes.
Press or tap the ring gear into

position.

6. Install and tighten the ring gear

bolts and washers evenly, and torque

them alternately across the gear to

specification.

7.
If the differential bearings have

been removed, press them on as

shown in Figs. 49 and 50.

8. Wipe a thin coating of lubricant

on the bearing bores so that the dif-

ferential bearing cups will move easily.

9. Place the cups on the bearings.

If the gear set is of the non-hunting or

partial non-hunting type, assemble the

differential case and ring gear assem-

bly in the carrier so that the marked

tooth on the pinion indexes between

the marked teeth on the ring gear as

shown in Fig. 51.

In almost every case of improper

assembly (gears assembled out of

time),
the noise level and probability

of failure will be higher than they

would be with properly assembled

gears.

When installing the hunting type

gear set (no timing marks), assemble

the differential case and ring gear as-

sembly in the carrier without regard

to the matching of any particular gear

teeth.

10.
Slide the assembly along the

bores until a slight amount of back-

lash is felt between the gear teeth.

11.
Set the adjusting nuts in the

bores so that they just contact the

bearing cups. The nuts should be en-

gaged about the same number of

threads on each side.

12.
Carefully position the bearing

caps on the carrier. Match the marks

made when the caps were removed.procarmanuals.com

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