gas FORD MUSTANG 1969 Volume One Chassis

03-10-04
Ford-Thompson Power Steering Pump

03-10-04

OUTLET FITTING

GASKET
Wood Block

0-RING SEAL

G1345-
-500-
A

G1603- A

FIG. 6—Gasket Locations
FIG.
7—Installing
Reservoir

on Pump—Typical
2.
Apply vaseline to the reservoir

O-ring seal and to the inside edge of

the new reservoir flange. Do not twist

the O-ring seal.

3.
Position the reservoir over the

pump and align the notch in the reser-

voir flange with the notch in the outer

diameter of the plate and bushing as-

sembly.

4.
Install the reservoir on the pump

and O-ring seal with a plastic or rub-

ber hammer and a block of wood as

shown in Fig. 7. Tap at the rear of the

reservoir and on the outer edges only.

5.
Inspect the assembly to be sure

the reservoir is evenly seated on the

pump housing plate.

6. Position the service identification

tag on the outlet fitting and install the

outlet fitting hex nut. Torque the nut

to specification (Part 3-13). Do not

exceed specification.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

Disassembly of the pump and its

subassemblies must be made on a

clean work bench. In repairing any

hydraulically operated unit, cleanliness

is of utmost importance. Clean the ex-

terior of the unit with a suitable sol-

vent and drain as much of the fluid as

possible.

If only the reservoir is to be re-

moved, plug the inlet and outlet open-

ings with masking tape or plugs. Do

not immerse the shaft oil seal in sol-

vent. If only the rotor shaft seal is to

be replace, see Rotor Shaft Seal Re-

placement outlined in this section.

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mount-

ed holding fixture Tool T57L-5OO-A

(Fig. 8).

2.
Position the pump assembly,

with pulley assembled, on the adapter

plate, pulley facing down.

3.
Remove the outlet fitting nut and

the service identification tag.

4.
Invert the pump assembly and,

using a block of wood and a rubber or

plastic hammer, remove the pump res-

ervoir and seal by tapping around the

flange of the reservoir and on the und-

erside of the filler neck.

5.
Again invert the pump assembly,

loosen and remove the pump housing

retention bolts and remove the pump

housing.
6. If necessary, remove the fol-

lowing components from the pump

housing: the housing cover, the O-ring

seal and the pressure springs. These

components normally will remain in

the pump housing when it is removed.

7.
Remove and discard the pump

cover gasket.

8. Remove the retainer end plate

and upper pressure plate (in some

pumps, the end plate and upper pres-

sure plate are integral).

9. Remove the loose fitting dowel

pin. Be careful not to bend the fixed

dowel pin which remains in the hous-

ing plate assembly.

10.
Remove the rotor assembly

being careful to prevent the springs

and slippers from falling out and be-

coming lost. Do not disassemble fur-

ther unless the lower pressure plate,

housing plate, rotor shaft and/or seal

is to be replaced.

11.
Invert the pump assembly and,

using Tool T63L-1O3OO-B, remove the

pulley.

12.
Clean any rust, road dirt, burrs,

scoring, etc. from the pulley end of

the rotor shaft prior to removal of the

shaft from the housing plate. The

shaft must come out without restric-

tions to prevent scoring or damage to

the bushing. Remove the pump rotor

shaft.

13.
Remove the lower pressure

plate.
PARTS REPAIR OR

REPLACEMENT

ROTOR SHAFT

SEAL REPLACEMENT

Removal

1.
Remove the pulley from the

rotor shaft as described under Power

Steering Pump Pulley Removal.

2.
Position the pump assembly in

T57L-500-A

T69P-3A674-A

•
G1604-A

FIG. 8—Adapter Plate Installationprocarmanuals.com

03-10-07
Ford-Thompson Power Steering Pump

03-10-07

15.
Place small amounts of vaseline

on the pump housing plate to hold the

cover gasket in place. Install the gas-

ket on the pump housing plate.

16.
Insert the pressure plate springs

into the pockets in the pump valve as-

sembly. Vaseline may be placed in the

spring pockets to hold the springs in

position (Fig. 17).

17.
Using Tool T69P-3B586-A,

plug the intake hole in the housing

(Fig. 17).

18.
Lubricate the inside of the

housing and the housing cover seal

with C1AZ-19582-A lubricant. Fabri-

cate two studs (3/8-16x1.55 ) to be

used as positioning guides. Install one

in the housing plate bolt hole closest

to the drain hole and one in the bolt

hole diametrically opposite.

19.
Align the small diameter lube

hole in the housing rim with the lube

hole in the housing plate.

20.
Install the housing, applying an

even, downward pressure. The pres-
sure plate springs must not be jarred

and moved out of position. Remove

the guide studs.

21.
Install the housing retaining

bolts finger tight.

22.
Remove Tool T69P-3B586-A.

23.
Torque the retaining bolts even-

ly to 28-32 ft-lbs until the housing

flange contacts the gasket.

24.
Install a 3/8x16 hex head

screw, finger tight, into the end of the

rotor shaft. Using a torque wrench,

check the input torque of the shaft

(Fig. 18). The torque should not ex-

ceed 15 in-lbs. If it does, loosen the

retaining bolts slightly, rotate the

rotor shaft, retorque the bolts evenly

and again check the shaft torque. The

pump must not be used if the shaft

torque exceeds 15 in-lbs.

25.
Release the pin in the bench

holding fixture and agitate the pump

assembly back and forth. If there is a

rattle, the pressure plate springs have
fallen out of their seats and must be

reinstalled.

26.
Install the reservoir O-ring on

the housing plate being careful not to

twist the O-ring. Apply vaseline to the

seal and to the ID of the reservoir

flange.

27.
Install the reservoir, aligning

the notch in the reservoir flange with

the notch in the OD of the pump

housing plate and bushing assembly.

Using only a plastic or rubber ham-

mer, tap at the rear on the outer cor-

ners of the reservoir to avoid damage.

28.
Inspect the assembly to deter-

mine if the reservoir is seated on the

housing plate.

29.
Install the service identification

tag on the outlet valve fitting.

30.
Install the outlet valve fitting

nut and torque to 43-47 ft-lbs.

31.
Invert the pump assembly.

32.
If the pulley was removed, in-

stall the correct pulley using Tool

T65P-3A733-A.procarmanuals.com

03-11-02
Eaton Power Steering Pump

03-11-02

gasket. Withdraw the fluid with a suc-

tion gun.

2.
Remove the reservoir bracket-

to-cylinder block upper cap screw and

the lower cap screw and spacer.

3.
Disconnect the reservoir infet line

and the outlet line at the reservoir,

and remove the reservoir.

Installation

1.
Connect the reservoir-to-pump

line (outlet line) at the reservoir, but

do not tighten the clamp.

2.
Attach the reservoir and bracket

to the cylinder block with the upper

cap screw and the lower cap screw

and spacer. Tighten the cap screws.

3.
Tighten the outlet line clamp at

the reservoir. Connect the reservoir

inlet line to the reservoir.

4.
Fill the reservoir with the speci-

fied automatic transmission fluid. Run

the engine, and bleed the system by

cycling the steering gear with the

windshield wipers turned on. Check

for leaks, and recheck the fluid level.
WITH AIR CONDITIONING

Removal

1. Raise the front of the vehicle.

Remove the reservoir-to-pump line

(outlet line) clamp at the reservoir,

but do not disconnect the line at this

time.

2.
Disconnect the reservoir inlet line

at the reservoir.

3.
Remove the reservoir bracket to

the cylinder block upper cap screw.

Support the reservoir and remove the

lower cap screw and spacer.

4.
With a drain pan under the res-

ervoir, disconnect the outlet line hose

from the reservoir tube and allow the

fluid to drain.

5.
Remove the reservoir cover re-

taining nut and the cover. Position the

cover and the reservoir out of the way

and allow them to rest in the engine

compartment.

6. Lower the front of the vehicle.

Remove the fan shroud.

7.
Remove the reservoir and the
cover by manipulating them through

the opening between the radiator and

the compressor drive belt.

Installation

1.
Position the reservoir in the en-

gine compartment. Loosely attach the

reservoir and bracket to the cylinder

block with the upper cap screw.

2.
Install the fan shroud, then raise

the front of the vehicle.

3.
Connect the reservoir-to-pump

line (outlet line) at the reservoir.

4.
Install the reservoir bracket-

to-cylinder block lower cap screw and

spacer. Tighten both the upper and

the lower cap screws.

5.
Connect the reservoir inlet line at

the reservoir. Install the clamps on

both lines. Lower the car, and install

the reservoir cover and attaching nut.

6. Fill the reservoir with the speci-

fied automatic transmission fluid. Run

the engine, and bleed the system by

cycling the steering gear with the

windshield wipers turned on. Check

for leaks, and recheck the fluid level.

3 MAJOR REPAIR OPERATIONS

INSULATOR (2)

WASHER (2)

MOUNTING BOLT (2)

COVER

BOLT (7)
DOWEL
PIN (2)

ROTOR

ROTOR
SHAFT

COVER
SEAL
PLUG

O RING

VALVE
ASSEMBLY

VALVE
SPRING

INSULATOR

HOUSING

CAM RING

PRESSURE
PLATE
,
PUMP

i
HOUSING

SEAL

ROLL

PIN

INSULATOR

RETAINER
RING
TUBE SEAT

O RING

SCREW
(2)

G12O8-B

FIG.
1
— Power Steering Pumpprocarmanuals.com

04-02-08
Rear Axle — Removable Carrier Type

04-02-08

REMOVAL AND INSTALLATION

CARRIER ASSEMBLY

REMOVAL

1.
Raise the vehicle on a hoist and

remove the two rear wheels and tires.

2.
Remove the two brake drums (3

Tinnerman nuts at each drum) from

the axle shaft flange studs. If diffi-

culty is experienced in removing the

drums, remove the brake adjuster

knockout slug or rubber plug (if so

equipped) and back off the brake

shoes.

3.
Working through the hole pro-

vided in each axle shaft flange, re-

move the nuts that secure the rear

wheel bearing retainer plate. Pull each

axle shaft assembly out of the axle

housing using axle shaft remover,

Tool 4235-C. (Fig. 4). Care must be

exercised to prevent damage to the

production-type synthetic oil seal, if so

equipped. Any roughing or cutting of

the seal element during removal or in-

stallation can result in early seal fail-

ure.
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. Whenever a

rear axle shaft is replaced, the wheel

bearing oil seals must be replaced.

Remove the seals with tool 1175AB.

4.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position at as-

sembly. Disconnect the drive shaft at

the rear axle U-joint. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their orig-

inal position relative to the flange

when they are assembled. Remove the

drive shaft from the transmission ex-

tension housing. Install an oil seal re-

placer tool in the housing to prevent

transmission leakage. Refer to the

transmission group for the appropriate

tool.

5.
Clean area around carrier to

housing surfaced with a wire brush and

wipe clean, to prevent dirt entry into

the housing. Place a drain pan under

the carrier and housing, remove the

carrier attaching nuts, and drain the

axle.
Remove the carrier assembly

from the axle housing.

INSTALLATION

Synthetic production-type wheel

bearing seals must not be cleaned,

soaked or washed in cleaning solvent.

1.
Clean the axle housing and

shafts using kerosene and swabs. To

avoid contamination of the grease in
the sealed ball bearings, do not allow

any quantity of solvent directly on the

wheel bearings. Clean the mating sur-

faces of the axle housing and carrier.

2.
Position the differential carrier

on the studs in the axle housing using

a new gasket between carrier and

housing. Install the carrier-to-housing

attaching nuts, and torque them to

specifications.

3.
Remove the oil seal replacer tool

from the transmission extension hous-

ing. Position the drive shaft so that

the front U-joint slip yoke splines to

the transmission output shaft.

4.
Connect 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 dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

5.
If the synthetic, production-type

wheel bearing seals were replaced with

service-type leather seals, 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 rear axle housing with one of the

tools shown in Figs. 10 and 12.

Tool

T65F-1177.A

E 1571-A

FIG. 12—Rear Axle Shaft Bearing

Seal Installation

6. Install the two axle shaft assem-

blies in the axle housing. Care must

be exercised to prevent damage to the

oil seals. The shorter shaft goes into

the left side of the housing.

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

differential side gear, and push the

shaft in until the bearing bottoms in

the housing.
7.
Install the bearing retainers on

the attaching bolts on the axle housing

flanges. Install the nuts on the bolts

and torque to specifications.

8. 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.

9. Install the two rear brake drums

and the drum Tinnerman nuts.

10.
Install the rear wheels and tires.

11.
Fill the rear axle with specified

lubricant.

AXLE HOUSING (COIL

SPRING SUSPENSION)

REMOVAL

1.
Remove the carrier assembly

from the axle housing as outlined in

Differential Carrier Removal and In-

stallation.

2.
Position safety stands under the

frame rear members, and support the

axle housing with either a floor jack

or hoist.

3.
Disengage the brake line from

the clips that retain the line to the

axle housing.

4.
Disconnect the vent tube from

the rear axle housing.

5.
Remove the brake backing plate

assemblies from the axle housing, and

support them with wire. Do not dis-

connect the brake line.

6. Disconnect the lower studs of the

two rear shock absorbers from the

mounting brackets on the axle housing

(Fig. 13 and 14).

7.
Remove the attaching nut and

washer, and disconnect the track bar

from the mounting stud on the axle

housing bracket.

8. Lower the axle housing until the

coil springs are released. Lift out the

coil springs and insulators.

9. Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

10.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and the two eccentric washers (Fig.

13 and 14).

11.
Lower the axle housing and re-

move it from under the vehicle.

INSTALLATION

1.
Transfer the track bar mounting

stud from the old to the new housing.procarmanuals.com

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

04-03-06

Rear Axles — Integral Carrier Type

04-03-06

9. Install a new integral nut and

ivasher on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 9 while the nut is being

tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, (Fig. 6)

and take frequent preload readings

until the preload is at the original rec-

orded reading established in step 3.

12.
After original preload has been

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

in-lbs has been added.

The preload should not exceed the

amount shown above, or bearing fail-

ure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. (In

addition, the U-joint flange must

never be hammered on, or pneumatic-

-tools used.)

13.
Remove the oil seal replacer

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

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

15.
Check the lubricant level. Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole, located in

the carrier casting or housing cover.

REMOVAL AND INSTALLATION

REAR AXLE HOUSING

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft at the drive

pinion flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in the

foregoing Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

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

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tools shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with me-

chanic's wire. The hydraulic brake

SCRIBE MARKS

5/16-24

4 REQ'D.

12-15
LB.
FT.

U-BOLT - 4529 2 REQ'D.

E 1783-A

FIG. 14—Drive Shaft-to-Axle

U-Joint
Connection

El231-A

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

still attached to the brake carrier

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 13)

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operations.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install the

lower insulators. Torque the spring

clip nuts to specification.

2.
Place the brake backing plates in

their normal position on the axle

housing. Use new gaskets on each side

of the brake backing plates.

3.
Install new axle shaft oil seals

with the tool shown in Fig. 8. Soak

the new seals in light weight engine oil

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

ing them. Installation without use of

the proper tool will distort the seal

and cause leakage. Coat the outside

edges of the new oil seal with a non-

hardening type of sealer such as Per-

matex No. 2 or its equivalent.

4.
Install the axle shafts, brake

drums and wheels as outlined in Sec-

tion 2.

5.
Attach the hydraulic brake line

T fitting to the axle housing, and se-

cure the hydraulic brake line in its re-

tainer on the axle housing.

6. Install vent tube to brake tubeprocarmanuals.com

04-03-07
Rear Axles — Integral Carrier Type

04-03-07

junction and install vent hose to vent

tube.

7.
Raise the axle housing and con-

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

shaft to the axle U-joint flange, align-

ing the scribe marks made on the

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

9. Fill the axle with the proper

grade and amount of lubricant.

10.
Road test the vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

All service operations on the differ-

ential case assembly and the drive pin-

ion assembly can be performed with

the housing in the vehicle.

REMOVAL OF

DIFFERENTIAL

CASE AND DRIVE PINION

1.
Raise the vehicle and support it

on the underbody, so that the rear

axle drops down as far as the springs

and shock absorbers permit.

2.
Remove the cover from the car-

rier casting rear face, and drain the

lubricant.

3.
Perform the Inspection Before

Disassembly of Carrier in Part 4-1,

Section 3.

4.
Remove both rear wheels.

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

vided in the axle shaft flange, remove

the nuts that attach the wheel bearing

retainers to the axle housing.

7.
Pull the axle shafts with the tool

shown in Fig. 2. Care must be exer-

cised to prevent damage to the oil

seals.
Install a nut on one of the brake

backing plate attaching bolts to hold

the plate to the axle housing after the

shaft has been removed. Remove both

seals with the tool shown in Fig. 8.

8. Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

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

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

9. Remove the differential bearing

adjusting nut locks (Fig. 15).

10.
Mark one differential bearing

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

sition the parts properly during as-

sembly.

11.
Remove the differential bearing

cap bolts and bearing caps. Hold the

differential case assembly in the hous-

ing after the caps are removed.

12.
Remove the differential case

and bearing cups (Fig. 17).

13.
Hold the drive pinion flange

and remove the pinion nut (Fig. 9).

14.
Remove the pinion flange (Fig.

10).

DIFFERENTIAL PINION GEAR

AND THRUST WASHER

COVER AND GASKET
DIFFERENTIAL SIDE GEAR

AND THRUST WASHER

SHAFT RETAINER DIFFERENTIAL

PINION SHAFT DIFFERENT|AL

DIFFERENTIAL CASE CASE COVER
BEARING ADJUSTING NUT

PINION AND RING GEAR

AXLE SHAFT
BEARING

DRIVE GEAR ATTACHING BOLT

ADJUSTING NUT LOCK

BEARING CAP

PINION LOCATING SHIMS

BEARING AND CUP

WHEEL BEARING RETAINER

GASKET
BEARING AND CUP

SEAL

AXLE SHAFT SEAL

BEARING PRELOAD SPACER/
AXLE HOUSING

FILLER PLUG

'WHEEL BEARING

WHEEL BEARING RETAINER

DEFLECTOR FLANGE

E1908A

FIG. 75—Disassembled Rear Axleprocarmanuals.com

04-04-02
Rear Axle
—
Ford Light-Duty (WER)
04-04-02

DIFFERENTIAL

PINION-4215
RING GEAR
-

4209
LEFT AXLE

SHAFT
-
4235

1

DRIVE PINION
-

4209

SEAL
-
4676

FLANGE-4851

DEFLECTOR -4859

SEAL-
1177

f\G.
7
—Rear Axle Assembly—Light Duty
(WER)
Axle
E 1632-A

IN-VEHICLE ADJUSTMENTS AND REPAIRS

REAR AXLE SHAFT, WHEEL

BEARING
AND OIL
SEAL

REPLACEMENT

REMOVAL

Synthetic wheel bearing seals
are

used
for
production
and as
service
re-

placements. Removal
and
insertion
of

rear axle shafts must
be
performed

with caution.
The
entire length
of the

shaft (including spline)
up to the
seal

journal must pass through
the
seal

without contact.
Any
roughing
or cut-

ting
of the
seal element during axle

removal
or
installation will result
in

early seal failure.

1.
Raise
the
vehicle
on a
hoist.
2.
Remove
the
wheel(s)
and
tire(s)

from
the
brake drum(s).

3.
Position
a
drain
pan and
loosen

the cover
to
differential housing
re-

taining bolts. Drain
the
housing.

4.
Remove
the
attaching (Tinner-

man) nuts that secure
the
brake

drum(s)
to the
axle shaft flange(s),

and then remove
the
drum(s).

5.
Remove
the
differential housing

cover bolts, cover
and
gasket. Discard

the gasket. Remove
the
drain
pan.

6. Position safety stands under
the

rear frame member. Lower
the
hoist

and allow
the
axle
to
lower
as far as

possible.

7.
Working through
the
differential

case opening, remove
the
pinion shaft
lock bolt
and the
pinion shaft
(Fig. 2).

8. Push
the
axle shaft(s) inward

toward
the
center
of the
axle housing.

Remove
the
C-lock(s)
(Fig. 3)
from

the inner
end of the
axle(s). Remove

the axle shaft(s) from
the
housing.
Ex-

treme care must
be
used
to
avoid
con-

tact
of the
axle shaft seal
lip
with
any

portion
of the
axle shaft except
the

seal journal.

9. Remove
the
bearing
and oil
seal

from
the
housing
as
shown
in Fig. 4.

10.
Inspect
the
machined surface
of

the axle shaft
and the
axle housing
for

rough spots
or
other irregularities

which would affect
the
sealing action

of
the oil
seal. Check
the
axle shaft

splines
for
burrs, wear
or
damage.procarmanuals.com

04-04-03
Rear Axle
—
Ford Light-Duty (WER)

04-04-03

LOCK BOLT

DIFFERENTIAL PINION SHAFT
E 1596- A

FIG.
2—Differential pinion shaft

and Lock Bolt

AXLE SHAFT

LOCK

E 1597-A

FIG. 3—Removal
and
Installation

of C-Locks
and
Axle Shaft

Carefully remove
any
burrs
or
rough

spots.
Replace worn
or
damaged

parts.
A
brownish yellow color
on the

bearing journal
of the
shaft
is
normal

and
the
shaft need
not be
replaced.

Slight pitting
and
wear
is
also normal.

INSTALLATION

1.
Lightly coat
the
wheel bearing

rollers with axle lubricant. Install
the

bearings
in the
axle housing with
the

tool shown
in Fig. 5. The
bearing

should seat firmly against
the
shoul-

der.

2.
Wipe
all
lubricant from
the oil

seal bore before installing
the
seal.

3.
Inspect
the
original seal
for

nicks,
scuffs
or
abnormal wear,
and

replace
it if
necessary.
The new
seals

are pre-packed with lubricant
and do

not require
an oil
soak before installa-

tion.

4.
Install
the oil
seal with
the
tool

shown
in Fig. 6.
Installation without

the
use of the
proper tool will distort

the seal
and
cause leakage.

5. Replace
the
O-ring
in the
C-lock

groove
on the
axle shaft.

6. Slide
the
axle shaft(s) into place
Tool
-
T66L-12132

Tool
-
7507- 700-A

\

1

T50T-100-A
BEARING

Tool - 766L-72J32-8

(THREAD
REDUCING

ADAPTER PART ONLY)

SEAL

FIG. 4—Removal
of
Axle Seal
or

in
the
axle housing. Exercise care that

splines
or any
portion
of the
axle

shaft(s)
do not
damage
the oil
seal(s)

and that they engage with
the
splines

of
the
differential side gear(s).

7. Install
the
axle shaft C-lock(s)

on
the
inner
end of the
shaft(s)
(Fig.

3)
and
push
the
shaft(s) outward
so

that
the
shaft locks seat
in the
conter-

bore(s)
of the
differential side gear(s).

8. Position
the
differential pinion

gears
and
thrust washers
180
degrees

apart
to the
differential side gears.

Revolve
the
gear assembly until
the

holes
in the
differential case
are a-

ligned with the pinion gears.

9. Position
the
differential pinion

shaft through
the
case
and
pinions,
a-

ligning
the
hole
in the
shaft with
the

lock bolt hole. Install
the
lock bolt

Tool
-
760K-7697.fi
E 1598.A

Axle Bearing

and torque
it to
specification.

10.
Install
the
brake drum
and

tighten
the
attaching (Tinnerman)

nuts.

11.
Install
the
wheel
and
tire
on the

brake drum.

12.
Clean
the
gasket mounting
sur-

faces
of the
rear axle differential

housing
and the
cover. Install
a new

cover gasket, cover
and the
attaching

bolts.
Torque
the
bolts
to
specifica-

tion.

13.
Raise
the
rear axle. Make sure

the rear axle
is in
running position.

Add
the
amount
of
specified lubricant

required
to
reach
to the
bottom
of the

filler plug hole. Install
the
filler plug

and torque
it to
specification.

14.
Remove
the
safety support

stands
and
lower
the
vehicle.

7oo/

765F-7 777-A

E 1571-A

FIG. 5—Installation
of
Axle

Shaft Bearing
FIG.
6—Rear
Axle Shaft Bearing

Seal Installationprocarmanuals.com

04-04-04
Rear Axle — Ford Light-Duty (WER)

04-04-04

REMOVAL AND INSTALLATION

AXLE HOUSING

Refer to Fig. 7.

REMOVAL

1.
Raise the vehicle on a hoist.

2.
Remove the wheels and tires

from the brake drums.

3.
Position a drain pan and loosen

the rear axle cover to housing attach-

ing bolts. Drain the housing.

4.
Remove the attaching (Tinner-

man) nuts that secure the brake drums

to the axle shaft flanges, and then re-

move the drums (Fig. 7).

5.
Remove the axle housing cover

bolts,
cover and gasket. Discard the

gasket. Remove the drain pan.

6. Disconnect the drive shaft at the

drive pinion companion flange. Re-

move the drive shaft from the trans-

mission extension housing. Install an

oil seal replacer tool in the transmis-

sion housing to prevent leakage. Refer

to the transmission group for the ap-

propriate tool.

7.
Disconnect the lower end of the

shock absorbers at the mounting

brackets.

8. Disconnect the track bar from

the axle housing stud. If the axle

housing is to be replaced, transfer the

stud to the new housing.

9. Position safety stands under the

rear frame members. Lower the vehi-

cle with the hoist and allow the axle

to lower far enough to relieve rear

spring tension.

10.
Remove the pinion shaft lock

bolt and pinion shaft (Fig. 2), differ-

ential pinion gears and thrust washers.

11.
Push the axle shaft(s) inward

toward the center of the axle housing.

Remove the C-locks from the inner

ends of the axles (Fig. 3). Remove the

axle shafts from the housing. Extreme

care must be used to avoid contacting

the axle shaft seal lip with any portion

of the axle shaft other than the seal

journal.

12.
Disconnect the vent hose from

the rear vent tube and remove all

brake lines from the axle housing re-

taining clips.

13.
Remove the brake backing

plate attaching nuts and the plates

from the axle housing. Suspend the

plates above the axle housing with

mechanics wire. The hydraulic brake

lines and the parking brake cables will

remain attached to the brake backing

plates.
14.
Support the rear axle housine

on a jack.

15.
Remove the right and left rear

springs and insulators.

16.
Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

17.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and two eccentric washers.

18.
Lower the rear axle to the floor

with the jack and remove the axle

from under the vehicle.

19.
Remove the wheel bearings and

oil seals with the tool shown in Fig. 4.

20.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. Refer

to Section 4, Major Repair Operation

for the procedure.

INSTALLATION

1.
Lightly coat the wheel bearing

rollers with axle lubricant. Install

wheel bearings in the axle housing

with the tool shown in Fig. 5. The

bearings should seat firmly against the

shoulder.

2.
Wipe all lubricant from the oil

seal bore before installing the seal. If

axle housing is being replaced, new

seals must be installed.

3.
Inspect the original seal for

nicks,
scuffs or abnormal wear, and

replace if necessary. New seals are

pre-packed with lubricant and do not

require an oil soak.

4.
Install the seal with the tool

shown in Fig. 6. Installation without

the use of the proper tool will distort

the seal and cause leakage.

5. Raise the rear axle into position

under the vehicle with a hoist or floor

jack. Connect the suspension lower

arms to their mounting brackets on

the axle housing with pivot bolts and

nuts.
Do not tighten the mounting

bolts at this point.

6. Position the suspension upper

arm in its mounting bracket on the

axle housing and install the adjusting

bolt, eccentric washers, lock washer

and nut. Do not tighten the mounting

bolt at this point.

7.
Place the rear coil springs and

insulators into position in the pockets

provided.
8. Place the brake backing plates

on the axle housing flanges, install 4

attaching bolts and nuts and torque

them to specifications.

9. Position the brake lines to the

axle housing and secure them with the

retaining clips. If the axle housing is

new, install a new vent. When install-

ing the new axle vent apply a small

amount of Locktite (C5AZ-19554-B)

to prevent oil leakage between vent

and axle housing. Connect the vent

tube to the vent.

10.
Install the pinion side gears and

thrust washer.

11.
Slide the axle shafts into place

in the axle housing. Exercise care that

splines or any portion of the axle

shafts do not damage the oil seals and

that they engage with the splines of

the differential side gears.

12.
Install the axle shaft C-lock O-

ring and C-lock on the inner end of

the shaft and push the shaft outward

so that the shaft lock seats in the

counterbore of the differential side

gear.

13.
Position the pinion differential

gears and thrust washers 180 degrees

apart to the differential side gears.

Revolve the gear assembly until the

holes in the differential case are al-

igned with the pinion gears.

14.
Position the differential pinion

shaft through the case and pinions, al-

igning the hole in the shaft with the

lock bolt hole. Install the lock bolt

and tighten it to specification.

15.
Clean the gasket mounting sur-

face of the rear axle housing and the

cover. Install a new cover gasket,

cover and the attaching bolts. Torque

the bolts to specification.

16.
Raise the rear axle on a hoist

and remove the safety stands.

17.
Connect the track bar to the

mounting stud. Install the washer and

nut. Torque the nut to specification.

18.
Connect the two rear shock ab-

sorbers to the mounting brackets on

the axle housing and torque the at-

taching nuts to specification.

19.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, then

raise the axle assembly to the con-

trolled height (Fig. 8). Hold the axle

at the controlled height by placing

blocks or pieces of steel pipe between

the axle housing and the bumper rear

screw on the side rail.procarmanuals.com