wheels FORD MUSTANG 1969 Volume One Chassis

03-12-07
Wheels And Tires

03-12-07

Tool - 7277- K

F 1263-A

FIG. 17—Installing Front Wheel Bearing Cup

13.
Pack the bearing cone and roll-

er assemblies with wheel bearing

grease. A bearing packer is desirable

for this operation. If a packer is not

available, work as much lubricant as

possible between the rollers and cages.

Lubricate the cone surfaces with

grease.

14.
Place the inner bearing cone

and roller assembly in the inner cup.

Apply a light film of grease to the lips

of the grease retainer and install the

new grease retainer with the tool

shown in Fig. 18. Be sure the retainer

is properly seated.

15.
Install the hub and rotor as-

sembly on the wheel spindle. Keep the

hub centered on the spindle to prevent

damage to the grease retainer or the

spindle threads.

16.
Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle, then install the ad-

justing nut.

17.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

18.
Install the caliper to the spindle

and torque the attaching bolts to spe-

cifications as detailed in Group 2.

19.
Install the wheel and tire on the

hub.

20.
Install the hub cap or wheel

cover.

21.
Before driving the vehicle,

pump the brake pedal several times to

obtain normal brake lining to rotor

clearance and restore normal brake

pedal travel.
FRONT HUB AND DRUM

ASSEMBLY REPLACEMENT

When the hub and drum assembly

is replaced, new bearings and a grease

retainer must be installed in the new

assembly. The new grease retainer

should be soaked in light engine oil at

least 30 minutes before installation.

1.
Raise the vehicle until the wheel

and tire clears the floor. Pry off the

hub cap or wheel cover, and remove

the wheel and tire from the hub and

drum assembly.

2.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock

adjusting nut, and flat washer from

the spindle. Remove the outer bearing

cone and roller assembly (Fig. 1).

3.
Pull the hub and drum assembly

off the wheel spindle.

4.
Remuve the grease retainer and

the inner bearing cone and roller as-

sembly from the hub with Tool

1175AE.

5.
Remove the protective coating

from the new hub and drum with car-

buretor degreaser.

6. Pack the inside of the hub with

specified wheel bearing grease. Add

lubricant to the hub only until the

grease is flush with the inside diame-

ter of both bearing cups (Fig. 15).

7.
All old grease should be com-

pletely cleaned from the bearings be-

fore repacking them with new grease.

Pack the bearing cone and roller

assemblies with wheel bearing grease.

A bearing packer is desirable for this

operation. If a packer is not available,

work as much lubricant as possible

between the rollers and cages. Lubri-

cate the cone surfaces with grease.
8. Place the inner bearing cone and

roller assembly in the inner cup, and

install the new grease retainer with the

reverse end of the tool shown in Fig.

6. Be sure that the retainer is properly

seated.

9. Adjust the brake shoes as out-

lined in Group 2.

10.
Install the new hub and drum

assembly on the wheel spindle. Keep

the hub centered on the spindle to pre-

vent damage to the grease retainer.

11.
Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle; then, install the ad-

justing nut (Fig. 1).

12.
Position the wheel and tire on

the new hub and drum assembly. In-

stall the wheel hub nuts and tighten

them alternately in order to draw the

wheel evenly against the hub and

drum.

13.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

14.
Install the hub cap or wheel

cover.

FRONT HUB AND ROTOR

ASSEMBLY REPLACEMENT

When the hub and rotor assembly is

replaced, new bearings and a grease

retainer must be installed in the new

assembly.

1.
Raise the vehicle until the wheel

and tire clear the floor. Pry off the

hub cap or wheel cover, and remove

the wheel and tire from the hub and

rotor assembly.

2.
Remove 2 bolts and washers that

attach the caliper to the spindle. Re-

move the caliper from the rotor and

wire it to the underbody to prevent

damage to the brake hose.

3.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock,

adjusting nut, and flat washer from

the spindle; then, remove the outer

bearing cone and roller assembly,

(Fig. 2).

4.
Pull the hub and rotor off the

spindle.

5.
Remove the protective coating

from the new hub and rotor with car-

buretor degreaser.

6. Grease and install the inner

bearing cone and roller assembly in

the inner bearing cup. Apply a light

film of grease on the grease retainerprocarmanuals.com

03-12-08

Wheels And Tires

03-12-08

Tool -
7
775 - AH

F1443-A

FIG.
18
— Installing Grease

Retainer
and install the grease retainer.

7.
Install the new hub and rotor as-

sembly to the wheel spindle. Keep the

hub centered on the spindle to prevent

damage to the grease retainer.

8. Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle; then, install the ad-

justing nut.

9. Install the caliper to the spindle

and tighten the attaching bolts to spe-

cifications as detailed in Group 2.

10.
Position the wheel and tire on

the new hub and rotor. Install the

wheel hub nuts and tighten them alter-

nately in order to draw the wheel

evenly against the hub and rotor.

11.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

12.
Install the hub cap or wheel

cover.

13.
Before driving the vehicle,

pump the brake pedal several times to

obtain normal brake lining to rotor

clearance and restore normal brake

pedal travel.
LIFE GUARD

TIRE REPAIRS

REPAIR OF OUTER TIRE

Outside Repairs

All outside repairs are made in the

same manner as on conventional tube-

less tires.

Inside Repairs

1.
Remove the anti-friction treat-

ment on the inside of the tire with

rubber solvent.

2.
Buff the inside area of the tire.

3.
Apply a hot cure patch only.

REPAIR OF AIR

CONTAINER

Air containers are repaired in the

same manner as conventional inner

tubes.

REPAIR OF LIFE GUARD

A damaged life guard that may

pinch the air container should be re-

place. No repairs are required for

small punctures in the life guard.procarmanuals.com

03-13-01
Specifications

03-13-01

PART 3-13 Specifications

FRONT
WHEEL
ALIGNMENT

Vehicle

Model

Mustang,
Cougar

Fairlane, Falcon

Mont
ego

Ford,
Mercury

Meteor

Thunderbird,

Mark III

Lincoln

Continental
Dimension

"C"

Inches

(I) 6.30

® 6.50

©4.20

® 4.20

©5.87
Dimension

"D"

Inches

©5.50 (Mustang)

6.35 (Cougar)

©6.72

©6.70

©6.70

©8.39
Alignment

Factors

Caster©

Camber©

Toe-in-Inches

Caster©

Camber©

Toe-in-Inches

Caster©

Camber©

Toe-in-Inches

Caster©

Camber®

Toe-in-Inches

Caster®

Camber®

Toe-in-Inches
Min.

-3/4°

+1/4°

1/16

-1
3/4°

•1/2°

1/8

0°

•1/4°

1/16

0°

•1/4°

1/16

-1/2°

•1/4°

0
Max.

+1 1/4°

+1 3/4°

5/16

+1/4°

+1°

3/8

+2°

+11/4°

5/16

+2°

+1 1/4°

5/16

-2
1/2°

+11/4°

1/4
Desired

+1/4°

+3/4°

3/16

•3/4°

+1/4°

3/16

+1°

+1/2°

3/16

+1°

+1/2°

3/16

•11/2°

+1/2°

1/8

©Maximum difference between wheels not to exceed 1/2° (setting). Maximum checking difference not to exceed 1° with caster and camber
with-

in specifications.

©Maximum difference between wheels not to exceed 1/2°.

©Vertical distance between bottom surface of spring tower on centerline of rebound bumper bolt and point on flat surface of upper suspension

arm midway between ball joint rivets.

©Shortest vertical distance between point on side member and axle housing.

©Distance from corner of lower flange sidemember front to center of bolt head (strut mounting bolt).

©Vertical distance between bottom of sidemember at center of axle bumper bracket and top of axle housing.

©Vertical distance between point on underside of crossmember pocket and point on top of drag strut.

©Distance from axle housing to surface on sidemember immediatly behind axle bumper.

WHEELBASEAND TREAD WIDTH-INCHES

FRONT WHEEL TURNING ANGLE

Vehicle Model

Mustang

Cougar

Fairlane, Montego

Falcon (except Station Wagon)

Falcon Station Wagon

Ford

Mercury, Meteor

Thunderbird (2-Door)

Thunderbird (4-Door), Mark HI

Lincoln Continental
Wheelbase

108.0

111.1

116.0

110.9

113.0

121.0

124.0

114.7

117.2

126.0
Tread

Front

58.5

58.5

58.8

58.8

58.8

63.0

63.0

62.0

62.0

62.4
Width

Rear

58.5

58.5

5«.5

58.5

58.5

64.0

64.0

62.0

62.0

61.0
Vehicle Model

Mustang,
Cougar

Fairlane, Falcon, Montego

Ford,
Mercury, Meteor

Thunderbird, Mark III

Lincoln Continental
Turning Angle of Outside Wheel

With Inside Wheel Turned 20°

18.68°

With Power Steering 17.88°

With Manual Steering 18.1°

With Power Steering 19.14°

With Manual Steering 18.96°

19.26°

17.71°

BALL JOINTS -RADIAL PLAY

STEERING WHEEL TURNING EFFORT

Vehicle Model

Cougar, Fairlane,

Falcon,
Montego,

Mustang

Ford,
Mercury,

Meteor, Thunderbird,

Mark III, Lincoln

Continental
Description

Lower Ball Joint

Upper Ball Joint

Lower Ball Joint

Upper Ball Joint
Radial Play-Max. Allowable

Replace if perceptibly loose

0.250
Inch

0.250
Inch

Replace if perceptibly loose
Vehicle Model

Ford,
Mercury, Meteor

Cougar, Fairlane, Falcon,

Montego, Mustang

Lincoln Continental, Mark III,

Thunderbird
Lbs.
Effort

5.0

6.5

3.75procarmanuals.com

04-01-03
General Axle Service

04-01-03

Tool-759L 4204-A,

T65K 4204-
A,

T66L-4204-A,

OR

Tool-44211-A

E1897-A

FIG. 3—Limited-Slip Differential Check

Using
a
torque wrench
of at
least

200 ft-lbs capacity, rotate
the
axle

shaft.
Be
sure that
the
transmission
is

in neutral,
one
rear wheel
is on the

floor,
and the
other rear wheel
is

raised
off the
floor.
The
torque
re-

quired
to
continuously rotate
the
shaft

should
be at
least
75
ft-lbs
or 40
ft-lbs

(Traction-Lok).
The
initial breakaway

torque
may
be
higher than
the
contin-

uous turning torque,
but
this
is nor-

mal.
The
axle shaft should turn with

^ven pressure throughout
the
check

without slipping
or
binding.

If
the
torque reading
is
less than

specified, check
the
differential
for

improper assembly.

A vehicle equipped with
a
limited-

slip differential will always have both

wheels driving.
If,
while
the
vehicle
is

being serviced, only
one
wheel
is

raised
off the
floor
and the
rear axle

is driven
by the
engine,
the
wheel
on

the floor will drive
the
vehicle
off the

stand
or
jack.

GEAR TOOTH CONTACT

PATTERN CHECK

When rolling
a
tooth pattern,
use

the special compound (tube) packed

with each service ring gear
and
pinion

set.

Paint
all
gear teeth
and
roll
a pat-

tern
as
described
in
Section
3.
After

diagnosing
the
tooth pattern
as ex-

plained here, make
the
appropriate

adjustments
as
outlined
in
Section
2.

In making
a
final gear tooth
con-

tact pattern check,
it is
necessary
to

recognize
the
fact that there
are
three

different types
of
gear sets, hunting,

non-hunting
and
partial non-hunting.

Each type
is
determined
by the num-
ber
of
teeth
in the
gears.
The non-

hunting
and
partial non-hunting types

can
be
identified
by the
paint timing

marks
on the
pinion
and
ring gear

teeth. (Part 4-2,
Fig. 51).
See
Part
4-5

for complete identification specifica-

tions.

ACCEPTABLE TOOTH

PATTERNS (ALL AXLES)

Figure
4
shows acceptable tooth

patterns
for all
axles.
Any
combina-

tion
of
drive
and
coast patterns will
be

acceptable.

In general, desirable tooth patterns

should have
the
following character-

istics:

1.
The
drive pattern should
be
fair-

ly well centered
on the
tooth.

2.
The
coast pattern should
be
fair-

ly well centered
on the
tooth.

3.
Some clearance between
the pat-

tern
and the top of the
tooth
is
desir-

able.

4.
There should
be no
hard lines

where
the
pressure
is
high.

The individual gear
set
need
not

conform exactly
to the
ideal pattern

to
be
acceptable.

Any combination
of
drive
and
coast

patterns shown
in Fig. 4 are
accep-

table.

Hunting Gear
Set

In
a
hunting-type gear
set, any one

pinion gear tooth comes into contact

with
all
ring gear teeth.
In
this type,

several revolutions
of
the
ring gear
are

required
to
make
all
possible gear

combinations.
Any combination
of
drive
and
coast

patterns shown
in
Fig.
4
will
be
acceep-

table.

Non-Hunting Gear
Set

In
a
non-hunting type gear
set, any

one pinion gear tooth comes into
con-

tact with only
a few
ring gear teeth.

In this type, only
one
revolution
of
the

ring gear
is
required
to
make
all
poss-

ible tooth contact combinations.
Any

combination
of
drive
and
coast
pat-

terns shown
in Fig. 4
will
be
accept-

able.

Partial Non-Hunting

Gear
Set

In
a
partial non-hunting type gear

set,
any one
pinion tooth comes into

contact with only part
of
the
ring gear

teeth,
but
more than
one
revolution
of

the ring gear
is
required
to
make
all

possible gear tooth combinations.
Any

combination
of
drive
and
coast
pat-

terns shown
in Fig. 4
will
be
accept-

able.

SHIM
AND
BACKLASH

CHANGES

Since each gear
set
rolls
a
charac-

teristic pattern,
the
patterns shown
in

Fig.
4 are
considered acceptable
and

should
be
used
as a
guide.
The
drive

pattern
is
rolled
on the
convex side
of

the tooth,
and the
coast pattern
is

rolled
on the
concave side.

The movement
of
tooth contact
pat-

terns with changes
in
shimming
can
be

summarized
as
follows:

Removable Carrier Type Axle

1.
Thicker shim with
the
backlash

set
to
specifications moves
the
pinion

further from
the
ring gear:

2.
Thinner shim with
the
backlash

set
to
specifications moves
the
pinion

closer
to the
ring gear:

If
the
patterns
are not
correct,

make
the
changes
as
indicated.
The

pinion need
not be
disassembled
to

change
a
shim.
All
that
is
required
is

to remove
the
pinion, bearing,
and re-

tainer assembly
and
install
a
different

shim. When reinstalling
the
pinion

and retainer assembly
of a
non-
hunt-

ing
or
partial non-hunting gear
set, be

sure that
the
marked tooth
on the pi-

nion indexes between
the
marked teeth

on
the
ring gear
(Fig.
51,
Part
4-2).

Refer
to
Pinion
and
Ring Gear Tooth

Contact Adjustment, Section
2.procarmanuals.com

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

04-02-07
Rear Axle — Removable Carrier Type

04-02-07

burrs are evident, remove them with a

fine crocus cloth, working in a rota-

tional motion, then wipe clean. Apply

a small quantity of lubricant to U-

joint splines.

9. Install the U-joint flange using

the tool shown in Fig. 46.

10.
Install a new integral attaching

nut and washer on the pinion shaft.

11.
Tighten the pinion attaching

nut, rotating the pinion several times

to seat the bearing, then torque the pin-

ion nut to 180-200 ft-lbs. Hold the

flange with the tool shown in Fig. 22

or Fig. 23 while the nut is being tight-

ened.

12.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission output

shaft.

13.
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.

14.
Check the lubricant level, and

add whatever amount of specified lu-

bricant is necessary to reach the lower

edge of the filler plug hole. Make sure

the axle is in running position when

the level is checked

ORIGINAL U-JOINT FLANGE

(IN VEHICLE REPLACEMENT)

Use procedure as outlined under

Drive Pinion Oil Seal Replacement.

Synthetic seals must not be cleaned,

soaked or washed in cleaning solvent.

INSTALLATION OF A NEW

UNIVERSAL JOINT FLANGE

COLLAPSIBLE SPACER

1.
Raise the vehicle and install

safety 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. Record the torque re-

quired to maintain rotation of the pin-

ion shaft through several revolutions.

4.
While holding the flange with the

tool shown in Fig. 23 or Fig. 24, re-

move the integral 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 solvent.

6. Using the tool shown in Fig. 23

or Fig. 24, 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 a

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. 46.

9. Install a new integral nut and

washer 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. 23 or Fig. 24 while the

nut is being tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, and take

frequent preload readings until the

preload is at the original recorded

reading established in step 3.

12.
After original preload has been

reached, tighten the pinion nut slowly,

until an additional preload of 8 to 14

in-lb over the original reading is

reached. (The preload should not ex-

ceed 8 to 14 in-lb over the original

reading, or bearing failure 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 power 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.

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.

SOLID SPACER

1.
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 leak-

age.
Refer to the transmission group

for the appropriate tool.

2.
While holding the flange with the

tool shown in Fig. 23 or Fig. 24, re-

move the integral pinion nut and

washer.

3.
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.

4.
Using the tool shown in Fig. 23

or Fig. 24, remove the U-joint flange.

5.
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, then wipe clean.

Apply a small amount of lubricant to

U-joint splines.

6. Install the U-joint flange using

the tool shown in Fig. 46.

7.
Install integral attaching nut and

washer on the pinion shaft.

8. Tighten the pinion attaching nut,

rotating the pinion several times to

seat the bearing, then torque the pin-

ion attaching nut to 180-220 ft-lbs.

Hold the flange with the tool shown in

Fig. 23 or Fig. 24 while the nut is

being tightened.

9. Remove the oil seal replacer tool

from the transmission extension hous-

ing. Install the front end of the drive

shaft on the transmission output shaft.

10.
Connect the rear end of the

drive shaft to the axle U-joint flange.

11.
Check the lubricant level, and

add whatever amount of specified lu-

bricant is necessary to reach the lower

edge of the filler plug hole. Make sure

the axle is in running position when

the level is checked.

DRIVE SHAFT PINION ANGLE

ADJUSTMENT

Refer to Group 3, Part 3-2 for this

procedure.procarmanuals.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

04-02-13

Rear Axle
—
Removable Carrier Type
04-02-13

lower insulators. Torque
the
spring

clip nuts
to
specification.

2.
Place
the
brake backing plates
in

their normal position
on the
axle

housing.

3.
Install
new
axle shaft
oil
seals

with
the
tool shown
in Fig. 10.
Soak

the
new
seals
in
light weight engine
oil

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

ing them. Installation without
use of

the proper tool will distort
the
seal

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

hardening type
of
sealer such
as Per-

matex
No. 2 or its
equivalent.

4.
Install
the
axle shafts, brake

drums
and
wheels
as
outlined
in Sec-

tion
2.

5.
Attach
the
hydraulic brake line

T fitting
to the
axle housing,
and se-

cure
the
hydraulic brake line
in its re-

tainer
on the
axle housing.

6. Install vent tube
to
brake tube

junction
and
install vent hose
to
vent
tube.

7.
Raise
the
axle housing
and con-

nect
the
shock absorbers.

8. Connect
the
rear
end of the
drive

shaft
to the
axle U-joint flange, align-

ing
the
scribe marks made
on the

drive shaft
end
yoke
and the
axle
U-

joint flange.

9. Fill
the
axle with
the
proper

grade
and
amount
of
lubricant.

10.
Road test
the
vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY
OF

DIFFERENTIAL CARRIER

CONVENTIONAL

DIFFERENTIAL

A disassembled view
of the
rear

axle assembly
is
shown
in Fig. 17.

After mounting
the
carrier
in a

holding fixture, disassemble
the car-

rier
as
outlined
in the
following proce-

dures:

1.
Mark
one
differential bearing

cap
and the
mating bearing support

with punch marks
to
help position
the

parts properly during assembly
of the

carrier. Also, mark
one of the
bearing

adjusting nuts
and the
carrier with

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

ing assembly.

2.
Remove
the
adjusting
nut
locks,

bearing caps,
and
adjusting nuts. Then

lift
the
differential case assembly
out

of
the
carrier.

(Remove
the
bearing caps
by tap-

ping
the
caps lightly with
a
soft
mal-

let).

3.
Remove
the
differential bearings

with
the
tools shown
in Fig. 18.

4.
Mark
the
differential case, cover,

and ring gear
for
assembly
in the
orig-

inal position.

5.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the gear from
the
case
or tap it off

with
a
soft-faced hammer.

6. With
a
drift, drive
out the
differ-

AXLE HOUSING-4010

DIFFERENTIAL

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

and separate
the
2-piece differential

case.

7.
Drive
out the
pinion shaft with
a

brass drift
(Fig. 20).

8. Remove
the
gears
and
thrust

washers
(Fig. 48).

LIMITED-SLIP DIFFERENTIAL

1.
Remove
the
differential case

from
the
carrier
and
remove
the
bear-

ings from
the
differential case
in the

same manner
as the
conventional
dif-

ferential case.

2.
Place
the
differential case
in a

hydraulic press,
and
apply about
one

ton pressure across
the
case bearing

hubs while removing
the
ring gear
at-

FLAT WASHER (LIMITED SLIP ONLY)

DRIVE GEAR ATTACHING BOLT

DIFFERENTIAL CASE COVER -4206

DIFFERENTIAL PINION GEAR-4215

THRUST WASHER-4230

ADJUSTING NUT-4067

CARRIER HOUSING-4025

DRIVE PINION-4610
PINION BEARING

SPACER-4662

PINION FRONT

BEARING-4621

RING GEAR

PILOT BEARING-4A242

FIG. 17—Rear Axle Disassembled—Typical
PILOT BEARING

RETAINER-4627

PINION REAR

BEARING CUP-4616
DEFLECTOR-4859

PINION RETAINER-4668

SEAL-4676
FLANGE_4858
E1750-Aprocarmanuals.com

04-03-04
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