FORD MUSTANG 1969 Volume One Chassis

04-03-01

Rear Axles — Integral Carrier Type

04-03-01

PART 4-3 Rear Axles-Integral Carrier Type

(Except Ford Light Duty
WER
Axle)

COMPONENT INDEX

AXLE HOUSING

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

CONVENTIONAL DIFFERENTIAL CASE

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND RING

GEAR

Cleaning and Inspection

Removal and Installation

LIMITED SLIP DIFFERENTIAL CASE

Disassembly and Overhaul

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING CUPS

Cleaning and Inspection

Removal and Installation

PINION OIL SEAL

Removal and Installation

REAR WHEEL BEARINGS AND SEALS

Cleaning and Inspection

Removal and Installation

U-JOINT FLANGE

Cleaning and Inspection

Removal and Installation
MODEL APPLICATION
All
Models

01-09

01-10

01-10

01-10

01-10

01-10

01-10

01-10
Ford
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mercury
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Cougar
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Fairlane
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Falcon
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Montego
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Mustang
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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

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

DESCRIPTION

The rear axle assembly is an integral-

type housing, hypoid design, with the

centerline of the pinion set below the

centerline of the ring gear (Fig. 1).

The semi-floating axle shafts are re-

tained in the housing by ball bearings

and a bearing retainer at the axle hous-

ing outer ends.

The differential assembly is mount-

ed on two opposed tapered roller
bearings. The bearings are retained in

the housing by removable caps. Dif-

ferential bearing preload and drive

gear backlash is adjusted by nuts lo-

cated behind each differential bearing

cup.

The drive pinion assembly is mount-

ed on two opposed tapered roller

bearings. Pinion bearing preload is

adjusted by a collapsible spacer on the
pinion shaft. Pinion and ring gear

tooth contact is adjusted by shims be-

tween the rear bearing cone and

pinion gear.

A cover on the rear of the differen-

tial housing provides access for inspec-

tion and removal and installation of

the differential assembly and drive

pinion.
procarmanuals.com

04-03-02
Rear Axles — Integral Carrier Type

04-03-02

RING GEAR

4209

DRIVE PINION

BEARINGS

4630

4621
FLANGE-4676

E1905A

FIG. 7—Typical Rear Axle Assembly

IN-VEHICLE ADJUSTMENT
AND
REPAIR

REAR AXLE SHAFT, WHEEL

BEARING
AND OIL
SEAL

REPLACEMENT

Synthetic wheel bearing seals
are

used
for
production purposes only.

>Tool-T60K-4234-A

or 4235-D

Tool-T50T-W0-A
or 8-/66

* El904A

FIG. 2—Removing Axle Shaft

E 1731-A

FIG. 3—Removing Rear Wheel

Bearing Retainer Ring
Removal
and
insertion
of
rear axle

shafts must
be
performed with
cau-

tion.
The
entire length
of the
shaft
(in-

cluding spline)
up to the
seal journal

must pass through
the
seal without

contact.
Any
roughing
or
cutting
of

the seal element during axle removal

or installation will result
in
early seal

failure. Leather seals only will
be
used
as service replacements
for
synthetic

wheel bearing seals.

The rear axle shafts, wheel bear-

ings,
and oil
seal
can be
replaced

without removing
the
differential
as-

sembly from
the
axle housing.
Re-

moval
of the
wheel bearings from
the

axle shafts make them unfit
for fur-

ther
use.

E1421-B

FIG. 4—Removing and Installing Rear Wheel Bearing—

Montego—Cougarprocarmanuals.com

04-03-03

Rear Axles
—
Integral Carrier Type

04-03-03

1
Bridge

Side Rail

I f

MUSTANG, COUGAR,

FAIRLANE. MONT EGO

AND FALCON WITH-

8 CYLINDER ENGINE
FALCON WITH-

6 CYLINDER ENGINE

Tool-T60K-1225-A

Press
Ram

FOR

ADJUSTABLE

BED PRESS

Press
Ram

BEARING
Support
Plate
—*

BEARING INSTALLATION

VIEW
2

<•
Support
Plate
»

BEARING
REMOVAL

VIEW
1
FOR FIXED

BED PRESS
Press
Ram

Press
Ram

BEARING
^-Support
Flange-*

BEARING REMOVAL

VIEW
3

Adapter
Ring

t—
Support
Plate
—>

BEARING INSTALLATION

VIEW 4

FOR

PUSH-PULLER

OPERATION

BEARING REMOVAL

VIEW
5

BEARING

BEARING

INSTALLATION

VIEW
6

E1211-D

FIG.
5—Removing
and
Installing Rear Wheel Bearing—Falcon, Mustang
and
Fairlaneprocarmanuals.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

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

04-03-08
Rear Axles — Integral Carrier Type

04-03-08

15.
With
a
soft-faced hammer,

drive
the
pinion
out of the
front bear-

ing cone
and
remove
it
through
the

rear
of the
carrier casting.

16.
Drive against
the
pinion front

bearing cone
and
drive
the
pinion

flange seal
and the
bearing cone
out

of
the
front
of the
carrier casting.

17.
To
remove
and
install
the pin-

ion rear bearing cone
use the
tools
in

Fig.
18 and 19.

18.
Measure
the
shim which
is

found under
the
bearing cone with
a

MARKINGS

E1909A

FIG. 16—Typical Differential

Bearing Cap Marking

E1910A

FIG. 77—Differential Case

Removal or Installation

1368-A
micrometer. Record
the
thickness
of

the shim.

DISASSEMBLY
OF

DIFFERENTIAL CASE

1.
If the
differential bearings
are to

be removed,
use the
tools shown
in

Fig.
20.

Press
Ram

REAR BEARING

CONE
AND

ROLLER
Fiber

Block

E1911A

FIG. 79—Installing Pinion Rear

Bearing Cone

Tool-

4221-AL

FIG. 18—Removing Pinion Rear

Bearing Cone
DIFFERENTIAL

BEARING

E1912A

FIG. 20—Differential Bearing

Removal
2.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the ring gear from
the
case
or tap it

off with
a
soft-faced hammer.

3.
With
a
drift, drive
out the
differ-

ential pinion shaft lock
pin (Fig. 21).

4.
Drive
out the
pinion shaft with
a

brass drift. Remove
the
gears
and

thrust washers.

PARTS REPAIR
OR

REPLACEMENT

Clean
and
inspect
all the
parts
as

outlined
in
Part 4-1, Section
3.
Before

assembling
the
carrier, repair
or re-

place
all
parts
as
indicated
by the in-

spection.

The principal replacement opera-

tions
are
covered
in the
following
pro-

cedures.
All
other repair
or
replace-

ment operations
are
performed during

Cleaning
and
Inspection Part
4-1,

Section
3, or
during
the
Assembly
in

this section.

PINION BEARING CUPS

Do
not
remove
the
pinion bearing

cups from
the
carrier casting unless

the cups
are
worn
or
damaged.

If
the
pinion bearing cups
are to be

replaced, drive them
out of the
carrier

E1913A

FIG. 21—Differential Pinion

Shaft Lock Pin Removalprocarmanuals.com

04-03-09
Rear Axles — Integral Carrier Type

04-03-09

E1914A

FIG. 22—Pinion Bearing Cup Removal or Installation

\

MATCHED

GEAR SET

IDENTIFICATION

E 1628-A

FIG. 23—Pinion and Ring

Gear Marking

casting with a drift. Install the new

cups with the tool shown in Fig. 22.

Make sure the cups are properly seat-

ed in their bores. If a 0.0015-inch feel-

er gauge can be inserted between a

cup and the bottom of its bore at any

point around the cup the cup is not

properly seated.

Whenever the cups are replaced, the

cone and roller assemblies should also

be replaced.

DRIVE PINION AND GEAR

SET

Individual differences in machining

the carrier casting and the gear set re-

quire a shim between the pinion rear

bearing cone and the pinion gear to

locate the pinion for correct tooth

contact with the ring gear.

When replacing a ring gear and pin-

ion it should be noted that the original

factory installed shim is of the correct

thickness to adjust for individual vari-

ations in both the carrier casting di-

mension and in the original gear set

dimension; therefore, to select the cor-

rect shim thickness for the new gear
set to be installed, follow these steps:

1.
With a micrometer, measure the

thickness of the original shim removed

from the axle and use the same thick-

ness upon installation of the replace-

ment carrier assembly or drive pinion.

2.
If further shim change is neces-

sary, it will be indicated in the tooth

pattern check.

3.
If the original shim is lost, sub-

stitute a nominal shim for the original

and use the tooth pattern check to de-

termine if further shim changes are re-

quired. Nominal shim thickness is in-

dicated in Part 4-5, Specifications.

A new ring gear and pinion should

always be installed in an axle as a

matched set (never separately). Be

sure the same identifying (matching)

number, painted in white, appears on

the bolt hole face of the ring gear and

on the head of the drive pinion

(Fig. 23).

4.
After determining the correct

shim thickness as explained in the

foregoing steps, install the new pinion

and ring gear as outlined under As-

sembly.

DIFFERENTIAL CASE,

BEARINGS, AND RING

GEAR

If the ring gear runout checK (be-

fore disassembly) exceeded specifica-

tions,
the condition may be caused by

a warped gear, a defective case, or ex-

cessively worn differential bearings.

To determine the cause of excessive

runout proceed as follows:

1.
Assemble the two halves of the

differential case together without the

ring gear, and press the two differen-

tial side bearings on the case hubs.

2.
Place the cups on the bearings

and set the differential case in the car-

rier.
3.
Install the bearing caps and ad-

justing nuts as outlined in steps 11

thru 14 under Installation of Drive

Pinion and Differential Case in this

section.

4.
Tighten the right nut two notches

beyond the position where it first con-

tacts the bearing cup. Rotate the dif-

ferential case several revolutions in

each direction while the bearings are

loaded to seat the bearings in their

cups.
This step is important.,

5.
Again loosen the right nut to re-

lease the preload. Check to see that

the left nut contacts the bearing cup.

Using the dial indicator set-up shown

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

to 0.008 to 0.012 case spread for new

bearings or 0.005 to 0.008 for the

original bearings, if reused.

6. Check the runout of the differen-

tial case flange with a dial indicator.

If the runout does not now exceed

specifications, install a new ring gear.

If the runout still exceeds specifica-

tions,
the ring gear is true and the

trouble is due to either a defective

case or worn bearings.

7.
Remove the differential case

from the carrier and remove the side

bearings from the case.

8. Install new bearings on the case

hubs,
and again install the differential

assembly in the carrier without the

ring gear.

9. Check the case runout again with

the new bearings. If the runout is now

within limits, the old bearings were

excessively worn. Use the new bear-

ings for assembly. If the runout is still

excessive, the case is defective and

should be replaced.

ASSEMBLY

Refer to Part 4-1 for Cleaning and

Inspection before starting assembly

operations.

ASSEMBLY OF

DIFFERENTIAL CASE

1.
Lubricate all the differential

parts with axle lubricant, before they

are installed in the case.

2.
Place the side gears and thrust

washers in the case.

3.
Place the two pinion gears and

thrust washers exactly opposite each

other in the case openings and in

mesh with the side gears.

4.
Turn the pinions and thrust

washers until the holes in the pinion

gears align with the pinion shaft holes

in the case.

5.
Start the pinion shaft into the

differential case. Carefully align the

shaft lock pin hole with the pin holeprocarmanuals.com

04-03-10
Rear Axles
—
Integral Carrier Type

04-03-10

in
the
case. Drive
the
shaft into place

and install
the
lock
pin
(Fig.
21).

6. Place
the
ring gear
on the
differ-

ential case
and
install
the
bolts.
Tor-

que
the
bolts
to
specification.

7.
If the
differential bearings have

been removed, press them
on as

shown (Fig.
24).

INSTALLATION
OF
DRIVE

PINION
AND
DIFFERENTIAL

CASE

1.
Place
the
shim
and
pinion rear

bearing cone
on the
pinion shaft.

Press
the
bearing
and
shim firmly

against
the
pinion shaft shoulder (Fig.

19).

PRESS RAM

Tool T54P-3044-A

Detail
7
2.
Place
a new
pinion bearing
pre-

load spacer
on the
pinion shaft.

3.
Lubricate
the
pinion rear bearing

with axle lubricant.

4.
Lubricate
the
pinion front bear-

ing cone
and
place
it in the
housing.

5.
Install
a new
pinion
oil
seal
in

the carrier casting (Fig.
11).

6. Insert
the
drive pinion shaft

flange into
the
seal
and
hold
it
firmly

against
the
pinion front bearing cone.

From
the
rear
of the
carrier casting,

insert
the
pinion shaft into
the
flange.

7.
Start
a new
pinion shaft
nut.

Hold
the
flange with
the
tool shown
in

Fig.
9 and
tighten
the
pinion shaft

nut.
As the
pinion shaft
nut is
tight-

ened,
the
pinion shaft
is
pulled into

the front bearing cone
and
into
the

flange.

As
the
pinion shaft
is
pulled into

the front bearing cone, pinion shaft

end play
is
reduced. While there
is

still
end
play
in the
pinion shaft,
the

flange
and
cone will
be
felt
to
bottom.

This indicates that
the
bearing cone

and flange have bottomed
on the col-

lapsible spacer.

From this point,
a
much greater

torque must
be
applied
to
turn
the

pinion shaft
nut,
since
the
spacer must

be collapsed. From this point, also,

the
nut
should
be
tightened very slow-

ly
and the
pinion shaft
end
play

checked often,
so
that
the
pinion bear-

ing preload does
not
exceed
the
limits

(Fig.
6).

FIG. 24—Differential Bearing

Installation
If
the
pinion shaft
nut is
tightened

to
the
point that pinion bearing
pre-

load exceeds
the
limits,
the
pinion

shaft must
be
removed
and a
new
col-

lapsible spacer installed.
Do not de-

crease
the
preload
by
loosening
the

pinion shaft
nut.
This will remove
the

compression between
the
pinion front

and rear bearing cones
and the col-

lapsible spacer
and may
permit
the

front bearing cone
to
turn
on the pin-

ion shaft.

&
As
soon
as
there
is
preload
on

the bearings, turn
the
pinion shaft
in

both directions several times
to set the

bearing rollers.

9. Adjust
the
bearing preload
to

specification. Measure
the
preload

with
the
tool shown
in Fig. 6.

10.
Apply
a
thin coating
of
lubri-

cant
on the
bearing bores
so
that
the

differential bearing cups will move

easily.

11.
Place
the
cups
on the
bearings

and
set the
differential case assembly

in
the
carrier casting (Fig.
17).

If
the
gear
set is of the
non-hunting

or partial non-hunting type, assemble

the differential case
and
ring gear
as-

sembly
in the
carrier
so
that
the

marked tooth
on the
pinion indexes

between
the
marked teeth
on the
ring

gear
as
shown
in Fig. 25.

In almost every case
of
improper

assembly (gears assembled
out of

time),
the
noise level
and
probability

of failure will
be
higher than they

would
be
with properly assembled

gears.

When installing
the
hunting type

gear
set (no
timing marks), assemble

the differential case
and
ring gear
as-

sembly
in the
carrier without regard

to
the
matching
of any
particular gear

teeth.

12.
Slide
the
case assembly along

the bores until
a
slight amount
of

backlash
is
felt between
the
gear teeth.

Hold
the
differential case
in
place.

13.
Set the
adjusting nuts
in the

PAINT MARKING INDICATES POSITION
IN
WHICH GEARS WERE LAPPED

E 1335-B

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

E1916A

FIG. 26—Backlash
and
Bearing

Pre-Load Adjustmentprocarmanuals.com