differential FORD MUSTANG 1969 Volume One Chassis
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Page 197 of 413
04-01-10
General Axle Service
04-01-10
The pattern taken during disassem-
bly should be helpful in judging if
gears can be re-used. Worn gears can-
not be rebuilt to correct a noisy condi-
tion. Gear scoring is the result of ex-
cessive shock loading or the use of an
incorrect lubricant. Scored gears can-
not be re-used.
Examine the teeth and thrust surfa-
ces of the differential gears. Wear on
the hub of the differential gear can
cause a chucking noise known as
chuckle when the vehicle is driven at
low speeds. Wear of splines, thrust
surfaces, or thrust washers, can con-
tribute to excessive drive line back-
lash.
BEARING CUPS AND
CONE AND ROLLER
ASSEMBLIES
Check bearing cups for rings,
scores, galling, or excessively worn
wear patterns. Pinion cups must be
solidly seated. Check by attempting to
insert a 0.0015-inch feeler between
these cups and the bottoms of their
bores.
When operated in the cups, cone
and roller assemblies must turn with-
out roughness. Examine the roller
ends for wear. Step-wear on the roller
ends indicates the bearings were not
preloaded properly, or the rollers were
slightly misaligned.
If inspection reveals either a defec-
tive cup or a defective cone and roller
assembly, both parts should be re-
placed to avoid early failure.
DIFFERENTIAL BEARING
ADJUSTING NUTS
Temporarily install the bearing caps
and test the fit of the adjusting nuts in
their threads. The nuts should turn
easily when the caps are tightened to
25 ft-lbs. The faces of the nuts that
contact the bearing cups must be
smooth and square. Replace the nuts
or examine the threads in the carrier
if their fit is not proper. Be sure that
the bearing caps and adjusting nuts
are on the side they were machined to
fit. Observe the punch marks and
scribe marks made during disassem-
bly.
U-JOINT FLANGE
Be sure that the eai» of the flange
have not been damaged in removing
the drive shaft or in removing the
flange from the axle. The end of the
flange that contacts the front pinion
bearing inner race as well as the flat
surface of the pinion nut counterbore
must be smooth. Polish these surfaces
if necessary. Roughness aggravates
backlash noises and causes wear of
the flange and pinion nut with a resul-
tant loss in pinion bearing preload.
PINION RETAINER
Be sure that the pinion bearing cups
are seated. Remove any chips or burrs
from the mounting flange. Clean the
groove for the O-ring seal and all lu-
bricant passages. If the cups were re-
moved, examine the bores carefully.
Any nicks or burrs in these bores
must be removed to permit proper
seating of the cups.
CARRIER HOUSING
Make sure that the differential
bearing bores are smooth and the
threads are not damaged. Remove any
nicks or burrs from the mounting sur-
faces of the carrier housing.
DIFFERENTIAL CASE
Make sure that the hubs where the
bearings mount are smooth. Carefully
examine the differential case bearing
shoulders, which may have been dam-
aged when the bearings were removed.
The bearing assemblies will fail if they
do not seat firmly against the shoul-
ders.
Check the fit (free rotation) of
the differential side gears in their
counterbores. Be sure that the mating
surfaces of the two parts of the case
are smooth and free from nicks or
burrs.
LIMITED SLIP AND
TRACTION-LOK
DIFFERENTIAL PARTS
Inspect the clutch plates for uneven
or extreme wear. The dog-eared clutch
plates must be free from burrs, nicks
or scratches which could cause excess-
ive or erratic wear to the bonding ma-
terial of the internally splined clutch
plates.
The internally splined clutch
plates should be inspected for condi-
tion of the bond, bonding material,
and wear. Replace the bonded plates
if their thickness is less than 0.085
inch or if the bonded material is
scored or badly worn. Inspect the
bonded plate internal teeth for wear.
Replace them, if excessive wear is evi-
dent. Bonded plates should be re-
placed as a set only
Examine all thrust surfaces and
hubs for wear. Abnormal wear on
these surfaces can contribute to a
noisy axle.
Inspect the Belleville spring (limited
slip) for proper free height of 1/4
inch.
LUBRICANT LEVEL
The lubricant level should be
checked every 6000 miles with the ve-
hicle in normal curb attitude. The lu-
bricant level should be at the lower
edge of the filler plug hole located in
either the carrier casting or housing
cover. It is unnecessary to periodically
drain the axle lubricant. The factory
fill should remain in the housing for
the life of the vehicle, except when re-
pairs are made. The specified lubri-
cant should be installed when the axle
is overhauled.procarmanuals.com
Page 198 of 413
04-02-01
Rear Axle
—
Removable Carrier Type
04-02-01
PART
4-2
Rear Axle—Removable Carrier Type
COMPONENT INDEX
AXLE HOUSING (Coil Spring Suspension)
Cleaning and Inspection
Removal and Installation
AXLE HOUSING (Leaf Spring Suspension)
Cleaning and Inspection
Removal and Installation
AXLE SHAFT
Cleaning and Inspection
Removal and Installation
CONVENTIONAL DIFFERENTIAL
Cleaning and Inspection
Disassembly and Overhaul
Removal and Installation
DIFFERENTIAL BEARINGS AND RING
GEAR
Adjustment
Cleaning and Inspection
Removal and Installation
DIFFERENTIAL CARRIER
Cleaning and Inspection
Disassembly and Overhaul
Removal and Installation
LIMITED SLIP DIFFERENTIAL
Cleaning and Inspection
Description
Disassembly and Overhaul
Removal and Installation
PILOT BEARING
Cleaning and Inspection
Removal and Installation
PINION AND RING GEAR
Cleaning and Inspection
Removal and Installation
PINION BEARING
Cleaning and Inspection
Removal and Installation
PINION BEARING RETAINER
Cleaning and Inspection
Removal and Installation
PINION SPACER (Collapsible)
Removal and Installation
PINION OIL SEAL
Removal and Installation
MODEL APPLICATION
All
Models
01-10
02-04
01-10
02-13
02-08
02-19
01-10
02-19
01-10
02-13
02-08
01-10
02-03
02-13
02-13
01-10
02-15
01-10
02-15
01-10
02-15
01-10
02-15
02-04
J
01-09
02-08
N/A
N/A
02-17
Mercury
01-09
02-08
N/A
N/A
N/A
Meteor
01-09
02-08
N/A
N/A
02-17
Cougar
N/A
N/A
01-09
02-11
02-17
Fairlane
N/A
N/A
01-09
02-11
02-17
Falcon
N/A
N/A
01-09
02-11
02-17
Montego
N/A
N/A
01-09
02-11
02-17
Mustang
N/A
N/A
01-09
02-11
02-17
Lincoln-
Continental
N/A
N/A
01-09
02-11
N/A
Thunderbird
01-09
02-08
N/A
N/A
N/A
Continental-
Mark
III
01-09
02-08
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.
procarmanuals.com
Page 199 of 413
04-02-02
Rear Axle — Removable Carrier Type
04-02-02
COMPONENT INDEX
PINION SPACER (Solid)
Determining Spacer Size
Removal and Installation
REAR WHEEL BEARINGS AND SEALS
Cleaning and Inspection
Removal and Installation
TRACTION-LOK DIFFERENTIAL
Cleaning and Inspection
Description
Disassembly and Overhaul
Removal and Installation
U-JOINT FLANGE
Cleaning and Inspection
Removal and Installation
MODEL APPLICATION
All
Models
02-18
02-18
01-10
02-04
01-10
02-07
Ford
N/A
N/A
N/A
N/A
Mercury
N/A
N/A
N/A
N/A
Meteor
N/A
N/A
N/A
JN/A
Cougar
01-10
02-03
02-22
02-13
Fairlane
01-10
02-03
02-22
02-13
Falcon
01-10
02-03
02-22
02-13
Montego
01-10
02-03
02-22
02-13
Mustang
01-10
02-03
02-22
02-13
Lincoln-
Continental
N/A
02-03
N/A
N/A
Thunderbird
N/A
N/A
N/A
N/A
Continental-
Mark
III
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.
1 DESCRIPTION
CONVENTIONAL AXLE
The rear axle is of the banjo-
housing, hypoid gear type using an 8
3/4, 9 or 9 3/8 inch ring gear, in
which the centerline of the pinion is
mounted below the centerline of the
ring gear (Fig. 1).
The pinion gear and the pinion
bearings are assembled in a pinion re-
tainer, which is bolted to the carrier.
The pinion is straddle mounted; that
LEFT AXLE SHAFT
4235
DRIVE PINION
4209
TAPERED ROLLER
BEARINGS 4621
SEAL - 4676
FIG.
1
—
Rear
Axle Assembly—Integral Pinion Gear and Shaft—8-3/4, 9, or 9-3/8 Inch Ring Gear—Typical
procarmanuals.com
Page 200 of 413
04-02-03
Rear Axle — Removable Carrier Type
04-02-03
is,
it is supported by bearings both in
front of and to the rear of the pinion
gear. Two opposed tapered roller
bearings support the pinion shaft in
front of the pinion gear with a col-
lapsible spacer for 8-3/4 inch or 9
inch ring gear, and a solid spacer used
with the 9 3/8 inch ring gear. A
straight roller (pilot) bearing supports
the pinion shaft at the rear of the pi-
nion gear. Pinion and ring gear tooth
contact is adjusted by adding or re-
moving shims from between the pinion
retainer and the carrier housing.
The differential assembly is mount-
ed on two opposed tapered roller
bearings, which are retained in the
carrier by removable caps. The entire
carrier assembly is bolted to the axle
housing.
Ball bearing assemblies (rear wheel
bearings) are pressed onto the outer
ends of the axle shafts and set in the
outer ends of the axle housing. These
bearings support the semi-floating
axle shafts at the outer ends. The
inner ends of the shafts spline to the
differential side gears. Bearing retain-
er plates hold the shafts in the hous-
ing. The left and right axle shafts are
not interchangeable, the left shaft
being shorter than the right.
CASE
COVER
BELLEVILLE
SPRING
CLUTC
HUB
STEEL
PLATES
BONDED
PLATES
E1741-A
FIG. 2—Limited-Slip Differential
LIMITED-SUP DIFFERENTIAL
The axle assembly, except for the
differential case and its internal com-
ponents, is identical to the convention-
al axle.
A constant-friction locking differen-
tial,
which employs clutch plates to
control differential action, is available
as optional equipment (Fig. 2).
Four steel clutch plates are locked
into the differential cover. Three
bronze, bonded clutch plates are
splined to a clutch hub which, in turn,
is splined to the left axle shaft. A
Belleville spring washer maintains a
constant pressure between the steel
and bonded clutch plates so that the
clutch is always engaged.
TRACTION-LOK
DIFFERENTIAL
The Traction-Lok (torque sensitive)
locking differential (Fig. 3) employs a
multiple disc clutch to control differ-
ential action. Shim(s), which control
side gear mounting distance, four
steel, four friction and one composite
plate (steel on one side and friction
material on the other) stacked on a
clutch hub, and four ear guides are
housed in the differential cover. Lo-
cated in the differential case between
the side gears is a one-piece pre-load
plate and block (four-pinion) and four
calibrated pre-load springs, which
apply an initial force to the clutch
pack. Additional clutch capacity is
derived from the side gear thrust
loads.
The four friction plates are
splined to the clutch hub which in turn
is splined to the left axle shaft, and
the eared steel plates are dogged to
the case; thus, the clutch is always en-
gaged.
PINION SHAFT
4211
PINION SHAFT
RETAINING PINS
359475-S
DIFFERENTIAL
CASE-4204
CASE-TO-COVER
RETAINING SCREWS
50025-S2
SIDE GEAR
THRUST WASHER
4228
CENTER BLOCK
(SHORT PINION PINION
SHAFT SEAT) SHAFT
4420 44207
7
PINION GEAR
THRUST WASHER
4230
PINION GEARS
4215
PINION GEAR
THRUST WASHER
4230
PINION SHAFT
44207
SHIM(S)
(AS REQ'D.)
4A324
DIFFERENTIAL
CASE COVER
4204
PINION GEAR
THRUST WASHER
4230
PRE-LOAD SPRING
PINION GEAR PLATE-4A326
THRUST WASHER
4230
CLUTCH PLATE
EAR GUIDES
(4)
4A323
E 1896-A
FIG. 3—Traction-Lok Differentialprocarmanuals.com
Page 201 of 413
04-02-04
Rear Axle — Removable Carrier Type
04-02-04
IN-VEHICLE ADJUSTMENTS AND REPAIRS
REAR AXLE SHAFT, WHEEL
BEARING AND OIL SEAL
REPLACEMENT
The rear axle shafts, wheel bear-
ings,
and oil seal can be replaced
without removing the differential as-
sembly from the axle housing.
REMOVAL OF
AXLE SHAFT
Synthetic wheel bearing seals are
used in production only. 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 cutting of the
seal element during axle removal or
installation will result in early seal fai-
lure.
Leather seals only will be used as
service replacement for synthetic
wheel bearing seals.
1.
Remove the wheel cover, wheel
and tire from the brake drum.
2.
Remove the nuts that secure the
brake drum to the axle shaft flange,
then remove the drum from 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. 4). The brake backing
plate must not be dislodged. Install
one nut to hold the plate in place after
the axle shaft is removed.
Too/-4235-C
E1032-D
FIG. 4—Removing Axle Shaft
REMOVAL OF REAR
WHEEL BEARING AND
SEAL
Synthetic seals must not be cleaned,
soaked or washed in cleaning solvents.
Removal of the wheel bearings from
the axle shaft makes them unfit for
further use.
1.
On all models except Ford, Mer-
cury or Meteor, 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. 5). It will then slide off easily.
E 1731-A
FIG. 5—Removing Rear Wheel
Bearing Retainer Ring
On Ford, Mercury and Meteor mo-
dels,
it is necessary to first drill a 1/4
inch hole not more than 5/16 inch
deep in the retainer ring surface bef-
ore using the cold chisel.
2.
Remove the bearing from the
axle shaft with the tool shown in Fig.
6 or Fig. 7.
3.
Whenever a rear axle shaft is re-
placed, the oil seal must be replaced.
Remove the seal with Tool 1175-AB
and a slide hammer (Fig. 8). If new
leather-type wheel bearing service
seals are to be installed, soak new oil
seals in SAE 10 oil for 1/2 hour
before installing.
INSTALLATION OF REAR
WHEEL BEARING AND
SEAL
1.
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 twist. Care-
fully remove any burrs or rough spots.
Replace worn or damaged parts.
2.
Lightly coat wheel bearing bores
with axle lubricant.
3.
Place the retainer plate on the
axle shaft, and press the new wheel
bearing on the shaft with the tool
shown in Fig. 6 or Fig. 9. Do not at-
tempt to press on both the bearing
and the inner retainer ring at the same
time.
4.
Using the bearing installation
tool (Tool 4621-A or 4234-4), press
the bearing inner retainer ring on the
shaft until the retainer seats firmly
against the bearing. On Ford, Mercu-
ry, or Meteor models, before assem-
bling the retainer onto the axle shaft,
the shaft journal and the inside di-
ameter of the retainer should be wiped
clean with a dry cloth. These parts
must not be degreased or lubricated.
5. Rear wheel oil seals with synthe-
tic sealing elements have been incor-
porated in production only. However,
leather seals only will be used as re-
placements for the synthetic sealing
elements. Install the new oil seal with
the tools shown in Figs. 10 and 12. Be
sure the new seal has been soaked in
SAE 10 oil for 1/2 hour before in-
stalling it. Wipe a small amount of oil
resistant sealer on the outer edge of
the seal before it is installed. Do not
put sealer on the sealing lip.
INSTALLATION OF
AXLE SHAFT
1.
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.
2.
Install the bearing retainer plate
and the nuts that secure it. Torque the
nuts to specifications.
3.
Install the brake drum and the
drum attaching (Tinnerman) nuts.
4.
Install the wheel and tire on the
drum. Install the wheel cover.
DRIVE PINION OIL SEAL
REPLACEMENT
COLLAPSIBLE SPACER
Synthetic seals must not be cleaned,
soaked or washed in cleaning solvent.
The drive pinion oil seal can be re-
placed without removing the differen-
tial carrier assembly from the axle
housing.
1.
Raise the vehicle and install
safety stands. Remove both 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. 11). 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 fluidprocarmanuals.com
Page 205 of 413
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
Page 208 of 413
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
Page 210 of 413
04-02-13
Rear Axle
—
Removable Carrier Type
04-02-13
lower insulators. Torque
the
spring
clip nuts
to
specification.
2.
Place
the
brake backing plates
in
their normal position
on the
axle
housing.
3.
Install
new
axle shaft
oil
seals
with
the
tool shown
in Fig. 10.
Soak
the
new
seals
in
light weight engine
oil
(SAE
10) for 1/2
hour before install-
ing them. Installation without
use of
the proper tool will distort
the
seal
and cause leakage. Coat
the
outside
edges
of the new oil
seal with
a non-
hardening type
of
sealer such
as Per-
matex
No. 2 or its
equivalent.
4.
Install
the
axle shafts, brake
drums
and
wheels
as
outlined
in Sec-
tion
2.
5.
Attach
the
hydraulic brake line
T fitting
to the
axle housing,
and se-
cure
the
hydraulic brake line
in its re-
tainer
on the
axle housing.
6. Install vent tube
to
brake tube
junction
and
install vent hose
to
vent
tube.
7.
Raise
the
axle housing
and con-
nect
the
shock absorbers.
8. Connect
the
rear
end of the
drive
shaft
to the
axle U-joint flange, align-
ing
the
scribe marks made
on the
drive shaft
end
yoke
and the
axle
U-
joint flange.
9. Fill
the
axle with
the
proper
grade
and
amount
of
lubricant.
10.
Road test
the
vehicle.
MAJOR REPAIR OPERATIONS
DISASSEMBLY
OF
DIFFERENTIAL CARRIER
CONVENTIONAL
DIFFERENTIAL
A disassembled view
of the
rear
axle assembly
is
shown
in Fig. 17.
After mounting
the
carrier
in a
holding fixture, disassemble
the car-
rier
as
outlined
in the
following proce-
dures:
1.
Mark
one
differential bearing
cap
and the
mating bearing support
with punch marks
to
help position
the
parts properly during assembly
of the
carrier. Also, mark
one of the
bearing
adjusting nuts
and the
carrier with
AXLE SHAFT-4725
RETAINER RING-1100
scribe marks
for
proper location
dur-
ing assembly.
2.
Remove
the
adjusting
nut
locks,
bearing caps,
and
adjusting nuts. Then
lift
the
differential case assembly
out
of
the
carrier.
(Remove
the
bearing caps
by tap-
ping
the
caps lightly with
a
soft
mal-
let).
3.
Remove
the
differential bearings
with
the
tools shown
in Fig. 18.
4.
Mark
the
differential case, cover,
and ring gear
for
assembly
in the
orig-
inal position.
5.
Remove
the
bolts that attach
the
ring gear
to the
differential case. Press
the gear from
the
case
or tap it off
with
a
soft-faced hammer.
6. With
a
drift, drive
out the
differ-
AXLE HOUSING-4010
DIFFERENTIAL
PINION SHAFT-4211
ential pinion shaft lock
pin (Fig. 19),
and separate
the
2-piece differential
case.
7.
Drive
out the
pinion shaft with
a
brass drift
(Fig. 20).
8. Remove
the
gears
and
thrust
washers
(Fig. 48).
LIMITED-SLIP DIFFERENTIAL
1.
Remove
the
differential case
from
the
carrier
and
remove
the
bear-
ings from
the
differential case
in the
same manner
as the
conventional
dif-
ferential case.
2.
Place
the
differential case
in a
hydraulic press,
and
apply about
one
ton pressure across
the
case bearing
hubs while removing
the
ring gear
at-
FLAT WASHER (LIMITED SLIP ONLY)
DRIVE GEAR ATTACHING BOLT
DIFFERENTIAL CASE COVER -4206
DIFFERENTIAL PINION GEAR-4215
THRUST WASHER-4230
ADJUSTING NUT-4067
CARRIER HOUSING-4025
DRIVE PINION-4610
PINION BEARING
SPACER-4662
PINION FRONT
BEARING-4621
RING GEAR
PILOT BEARING-4A242
FIG. 17—Rear Axle Disassembled—Typical
PILOT BEARING
RETAINER-4627
PINION REAR
BEARING CUP-4616
DEFLECTOR-4859
PINION RETAINER-4668
SEAL-4676
FLANGE_4858
E1750-Aprocarmanuals.com
Page 211 of 413
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
Page 213 of 413
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