light FORD MUSTANG 1969 Volume One Chassis

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

E 1195-C

FIG. 41—Removing
or
Installing

Pinion
and
Retainer Assembly

10.
Hold
the
flange with
the
tool

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

(Mercury),
and
torque
the
pinion shaft

nut
to 175
ft-lbs.
Do not
exceed
175

ft-Ibs
at
this time.

11.
Check
the
pinion bearing
pre-

load
as
shown
in Fig. 42.
Correct

pre-load will
be
obtained when
the

torque required
to
rotate
the
pinion
in

the retainer
is as
specified
in
Part
4-3.

If
the
torque required
to
rotate
the pin-

ion
is
less than specified, tighten
the

pinion shaft
nut a
little
at a
time until

Inch-Pound

Torque Wrench

E1899A

FIG. 42—Checking Pinion Bearing

Preload
the proper preload
is
established.
Do

not overtighten
the nut. If
excessive

preload
is
obtained
as a
result
of
over-

tightening, replace
the
collapsible

bearing spacer.

Do
not
back
off the
pinion shaft
nut

to establish pinion bearing preload.
If

the torque
on the
pinion shaft
nut is

less than
175
ft-lbs after bearing
pre-

load
is
established,
a new
collapsible

spacer must
be
used.

SOLID PINION BEARING

SPACER INSTALLATION

The spacer
is
serviced
in 20
sizes

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

ecting
the
size spacer required
for ob-

taining correct preload
is
included
in

the following assembly procedure.

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

pinion shaft
as
shown
in
Figs.
38 or

39.

2.
Select
a new
solid spacer
of a

larger size (0.485 inch thick),
and
slide

it over
the
pinion shaft against
the

rear bearing.

The pinion bearing preload
can be

accurately measured only when
the

pinion shaft
nut is
torqued
to 180-

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

quired
was
used,
the
specified
180-

220 ft-lbs torque would damage
the

bearings.
For
this reason,
the
largest

spacer should
be
tried first. Then,
if

the bearings
are too
loose,
the
size
of

the spacer
can be
decreased until
the

correct preload
is
obtained.

3.
Position
the
bearing retainer
and

cup assembly
on the
pinion shaft
and

install
the
front bearing cone
and rol-

ler. Press
the
front bearing cone
and

roller assembly into position,
as

shown
in Fig. 38.

4.
Mount
the
retainer
in a
holding

fixture
as
shown
in Fig. 23, and
place

the slinger over
the
pinion shaft
and

against
the
front bearing.

5.
Install
the
U-joint flange with

the tool shown
in Fig. 46.

6. Hold
the
flange with
the
tool

shown
in Fig. 23 or 24, and
install
the

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

ft-lbs.
While tightening
the nut,
rotate

the bearing retainer
to
determine
the

existance
of any
bearing preload

which will
be
indicated
by a
slight

drag
in the
rotation
of the
retainer.

DETERMINING SPACER

SIZE FROM

PRELOAD READING

1.
If
bearing drag indicates
a pre-

load condition exists, apply
an
in-lb

torque wrench
to the
pinion
nut as

shown
in Fig. 42 and
read
the
torque

required
to
turn
the
shaft. Effort

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

2.
If
preload
is the
correct valve,

proceed with assembly procedure

given
in
Final Assembly
of
Pinion
and

Retainer, which follows.

2.
If
preload exists,
but is
below

specification, select
the
correct spacer

from
Fig. 43 and
install, completing

assembly
as
shown
in
Final Assembly

of Pinion
and
Retainer.

DETERMINING SPACER

SIZE FROM
END

PLAY READING

1.
If no
perceptible preload
is
felt

when rotating
the
pinion shaft, install

a dial indicator
as
shown
in Fig. 44,

so that
the
indicator point
is
resting

on
the end of the
pinion gear shaft

(companion flange
end).

2.
Use
both hands
to
squeeze
the

pinion shaft
and the
bearing retainer

together
(Fig. 45).
Record
the
endplay

reading shown
on the
dial indicator.

3.
Disassemble
the
pinion shaft
and

retainer
and
install
the
correct spacer

as shown
in Fig. 43.

4.
Proceed with assembly
of the pin-

ion shaft
and
retainer
as
directed
in

Final Assembly
of
Pinion
and
Retain-

er.

FINAL ASSEMBLY
OF

PINION
AND
RETAINER

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

AS
END
PLAY

READS

(10/1000 inch)

USE THIS

SPACER
0

0.481
1

0.480
2

0.479
3

0.478
4

0.476

If there
is no end
play
and
preload
on the
bearings

IF PRELOAD READS

(in-lbs.)

USE THIS SPACER
2-11

0.482
12-20

0.483
5

0.476
6

0.474
7

0.474
8

0.472
9

0.472
10

0.470
11

0.470
12

0.468
13

0.468
14

0.466
15

0.465

exists:

21-30

0.484
31-45

0.485

FIG. 43— Solid Spacer Selectionprocarmanuals.com

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

POINTER RESTING ON

PINION NUT

E 1505-B

FIG.
44
— End Play Indicator

Installation

pinion shaft as shown in Figs. 37 and

38.

2.
Slide the correct spacer over the

pinion shaft against the rear bearing.

3.
Position the bearing retainer and

cup assembly on the pinion shaft and

install the front bearing cone and rol-

ler. Press the front cone and roller

into position, as shown in Fig. 46.

4.
Lubricate a new O-ring with axle

lubricant and install it in the groove

provided in the pinion retainer. Be

careful not to twist the O-ring. Install

it by snapping it into place.

5.
Place the proper shim on the

carrier housing and install the pinion

and retainer assembly, being careful

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

6. Install the pinion retainer bolts.

Torque the bolts to specification.

7.
Place the slinger over the pinion

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

E 1197-D

FIG. 46—Installing
U-Joint
Flange

8. Install a seal in the bearing re-

tainer, (Fig. 47).

9. Start a new integral nut and

washer on the pinion shaft.

10.
Hold the companion flange with

the tool shown in Fig. 20 or 22 and

torque the pinion nut to specifications

(200 ft-lbs).

11.
With a new seal installed pin-

ion bearing preload should now read

17 to 32 in-lbs for new pinion bearings

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

ginal bearings and a new seal.

ASSEMBLY AND

INSTALLATION OF

DIFFERENTIAL CASE

Conventional

Differential Case

1.
Place a side gear and thrust

washer in the differential case bore

E 1506-B

E 1629-A

FIG. 45— Checking Pinion End

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

parts liberally with axle lubricant dur-

ing assembly.

2.
With a soft-faced hammer, drive

the differential pinion shaft into the

case only far enough to retain a pin-

ion thrust washer and pinion gear.

3.
Place the second pinion and

thrust washer in position, and drive

the pinion shaft into place. Carefully

line up the pinion shaft lock pin holes.

4.
Place the second side gear and

thrust washer in position (Fig. 48),

and install the cover on the differen-

tial case. Install the pinion shaft lock

pin. A pinion or axle shaft spline can

be inserted in the side gear spline to

check for free rotation of the differen-

tial gears.

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

inches long through the differential

case flange, and thread them three or

four turns into the ring gear as a

guide in aligning the ring gear bolt

holes.
Press or tap the ring gear into

position.

6. Install and tighten the ring gear

bolts and washers evenly, and torque

them alternately across the gear to

specification.

7.
If the differential bearings have

been removed, press them on as

shown in Figs. 49 and 50.

8. Wipe a thin coating of lubricant

on the bearing bores so that the dif-

ferential bearing cups will move easily.

9. Place the cups on the bearings.

If the gear set is of the non-hunting or

partial non-hunting type, assemble the

differential case and ring gear assem-

bly in the carrier so that the marked

tooth on the pinion indexes between

the marked teeth on the ring gear as

shown in Fig. 51.

In almost every case of improper

assembly (gears assembled out of

time),
the noise level and probability

of failure will be higher than they

would be with properly assembled

gears.

When installing the hunting type

gear set (no timing marks), assemble

the differential case and ring gear as-

sembly in the carrier without regard

to the matching of any particular gear

teeth.

10.
Slide the assembly along the

bores until a slight amount of back-

lash is felt between the gear teeth.

11.
Set the adjusting nuts in the

bores so that they just contact the

bearing cups. The nuts should be en-

gaged about the same number of

threads on each side.

12.
Carefully position the bearing

caps on the carrier. Match the marks

made when the caps were removed.procarmanuals.com

04-03-01

Rear Axles — Integral Carrier Type

04-03-01

PART 4-3 Rear Axles-Integral Carrier Type

(Except Ford Light Duty
WER
Axle)

COMPONENT INDEX

AXLE HOUSING

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

CONVENTIONAL DIFFERENTIAL CASE

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND RING

GEAR

Cleaning and Inspection

Removal and Installation

LIMITED SLIP DIFFERENTIAL CASE

Disassembly and Overhaul

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING CUPS

Cleaning and Inspection

Removal and Installation

PINION OIL SEAL

Removal and Installation

REAR WHEEL BEARINGS AND SEALS

Cleaning and Inspection

Removal and Installation

U-JOINT FLANGE

Cleaning and Inspection

Removal and Installation
MODEL APPLICATION
All
Models

01-09

01-10

01-10

01-10

01-10

01-10

01-10

01-10
Ford
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mercury
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Cougar
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Fairlane
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Falcon
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Montego
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Mustang
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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

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

DESCRIPTION

The rear axle assembly is an integral-

type housing, hypoid design, with the

centerline of the pinion set below the

centerline of the ring gear (Fig. 1).

The semi-floating axle shafts are re-

tained in the housing by ball bearings

and a bearing retainer at the axle hous-

ing outer ends.

The differential assembly is mount-

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

the housing by removable caps. Dif-

ferential bearing preload and drive

gear backlash is adjusted by nuts lo-

cated behind each differential bearing

cup.

The drive pinion assembly is mount-

ed on two opposed tapered roller

bearings. Pinion bearing preload is

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

tooth contact is adjusted by shims be-

tween the rear bearing cone and

pinion gear.

A cover on the rear of the differen-

tial housing provides access for inspec-

tion and removal and installation of

the differential assembly and drive

pinion.
procarmanuals.com

04-03-04
Rear Axles — Integral Carrier Type

04-03-04

1.
Remove the wheel cover, wheel

and tire from the brake drum.

2.
Remove the Tinnerman nuts that

secure the brake drum to the axle

housing flange, and then remove the

drum from the flange.

3.
Working through the hole pro-

vided in each axle shaft flange, re-

move the nuts that secure the wheel

bearing retainer plate. Then pull the

axle shaft assembly out of the axle

housing (Fig. 2). The brake backing

plate must, not be dislodged. Install

one nut to hold the plate in place after

the axle shaft is removed.

4.
If the rear wheel bearing is to be

replaced, loosen the inner retainer

ring by nicking it deeply with a cold

chisel in several places (Fig. 3). It will

then slide off easily.

5.
Remove the bearing from the

axle shaft with the tool shown in Fig.

4 or 5. If the push-puller operation

shown in Fig. 5 is used, be sure that

the puller arms contact the flat sur-

face of the axle shaft flange rather

than the bolt heads. Also with this

method, be careful not to damage or

burr the oil seal journal as the bearing

breaks loose.

6. Whenever a rear axle shaft is re-

placed the oil seal must be replaced.

Remove the seal with the tools shown

in Fig. 8. Soak new oil seals in SAE

10 oil for 1/2 hour before installing.

7.
Inspect the machined surfaces of

the axle shaft and the axle housing for

rough spots or other irregularities

which would affect the sealing action

of the oil seal. Check the axle shaft

splines for burrs, wear or damage.

Carefully remove any burrs or rough

spots.
Replace worn or damaged

parts.

8. Lightly coat wheel bearing bores

with axle lubricant.

9. Place the retainer plate on the

axle shaft, and press the new wheel

bearing on the shaft with the tool

shown in Fig. 4 or 5. The bearing

should seat firmly against the shaft

shoulder. Do not attempt to press on

both the bearing and the inner retain-

er ring at the same time.

10.
Using the bearing installation

tool, press the bearing inner retainer

ring on the shaft until the retainer

seats firmly against the bearing.

11.
Wipe all lubricant from the in-

side of the axle housing in the area of

the oil seal before installing the new

seal.

12.
Wipe a small amount of oil res-

istant sealer on the outer edge of the

seal before it is installed. Do not put

sealer on the sealing lip.

13.
Rear wheel oil seals with syn-
thetic sealing elements have been in-

corporated in production. However,

only leather seals will be used as re-

placements for the synthetic sealing

element seals. Install the new oil seal

with the tools shown in Fig. 8. Instal-

lation without use of the proper tool

will distort the seal and cause leakage.

Be sure the new seal has been soaked

in SAE 10 oil for 1/2 hour.

14.
Carefully slide the axle shaft

into the housing so that the rough

forging of the shaft will not damage

the oil seal. Start the axle splines into

the side gear, and push the shaft in

until the bearing bottoms in the housing.

15.
Install the bearing retainer plate

on the mounting bolts at the axle

housing, and install the attaching nuts.

Torque the nuts to specifications.

16.
Install the brake drum and the

drum retaining nuts.

17.
Install the wheel and tire on the

drum, and install the wheel cover.

REMOVAL AND REPLACEMENT

OF DRIVE PINION OIL SEAL

Synthetic seals must not be cleaned,

soaked or washed in cleaning solvent.

Replacement of the pinion oil seal

involves removal and installation of

only the pinion shaft nut and the uni-

versal joint flange. However, this op-

eration disturbs the pinion bearing
preload, and this preload must be

carefully reset when assembling.

1.
Raise the vehicle and install safe-

ty stands. Remove the rear wheels and

brake drums.

2.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

3.
Install an in-lb torque wrench on

the pinion nut Fig. 6. Record the tor-

que required to maintain rotation of

the pinion shaft through several revo-

lutions. \

4.
While holding the flange with the

tool shown in Fig. 9, remove the inte-

gral pinion nut and washer.

5.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

KJ
E
I582-A
Tool - 1175-AB

and T50T-100-A

^___ or
J
775-
AE

Torque Wrench

^ mm i e
icot
A

E 1681-A

FIG. 6—Checking Pinion FiG 7_Removing
pjnjon
Sea,

Bearing Preload

,Tool-T58L-101-A or U75-AE

Tool-T50T-100-A

REMOVAL
Tool-60K-1177-B

or 1177-BorC

INSTALLATION E1214-D

FIG. 8—Removing and Installing Axle Shaft Sealprocarmanuals.com

04-03-06

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

04-03-10
Rear Axles
—
Integral Carrier Type

04-03-10

in
the
case. Drive
the
shaft into place

and install
the
lock
pin
(Fig.
21).

6. Place
the
ring gear
on the
differ-

ential case
and
install
the
bolts.
Tor-

que
the
bolts
to
specification.

7.
If the
differential bearings have

been removed, press them
on as

shown (Fig.
24).

INSTALLATION
OF
DRIVE

PINION
AND
DIFFERENTIAL

CASE

1.
Place
the
shim
and
pinion rear

bearing cone
on the
pinion shaft.

Press
the
bearing
and
shim firmly

against
the
pinion shaft shoulder (Fig.

19).

PRESS RAM

Tool T54P-3044-A

Detail
7
2.
Place
a new
pinion bearing
pre-

load spacer
on the
pinion shaft.

3.
Lubricate
the
pinion rear bearing

with axle lubricant.

4.
Lubricate
the
pinion front bear-

ing cone
and
place
it in the
housing.

5.
Install
a new
pinion
oil
seal
in

the carrier casting (Fig.
11).

6. Insert
the
drive pinion shaft

flange into
the
seal
and
hold
it
firmly

against
the
pinion front bearing cone.

From
the
rear
of the
carrier casting,

insert
the
pinion shaft into
the
flange.

7.
Start
a new
pinion shaft
nut.

Hold
the
flange with
the
tool shown
in

Fig.
9 and
tighten
the
pinion shaft

nut.
As the
pinion shaft
nut is
tight-

ened,
the
pinion shaft
is
pulled into

the front bearing cone
and
into
the

flange.

As
the
pinion shaft
is
pulled into

the front bearing cone, pinion shaft

end play
is
reduced. While there
is

still
end
play
in the
pinion shaft,
the

flange
and
cone will
be
felt
to
bottom.

This indicates that
the
bearing cone

and flange have bottomed
on the col-

lapsible spacer.

From this point,
a
much greater

torque must
be
applied
to
turn
the

pinion shaft
nut,
since
the
spacer must

be collapsed. From this point, also,

the
nut
should
be
tightened very slow-

ly
and the
pinion shaft
end
play

checked often,
so
that
the
pinion bear-

ing preload does
not
exceed
the
limits

(Fig.
6).

FIG. 24—Differential Bearing

Installation
If
the
pinion shaft
nut is
tightened

to
the
point that pinion bearing
pre-

load exceeds
the
limits,
the
pinion

shaft must
be
removed
and a
new
col-

lapsible spacer installed.
Do not de-

crease
the
preload
by
loosening
the

pinion shaft
nut.
This will remove
the

compression between
the
pinion front

and rear bearing cones
and the col-

lapsible spacer
and may
permit
the

front bearing cone
to
turn
on the pin-

ion shaft.

&
As
soon
as
there
is
preload
on

the bearings, turn
the
pinion shaft
in

both directions several times
to set the

bearing rollers.

9. Adjust
the
bearing preload
to

specification. Measure
the
preload

with
the
tool shown
in Fig. 6.

10.
Apply
a
thin coating
of
lubri-

cant
on the
bearing bores
so
that
the

differential bearing cups will move

easily.

11.
Place
the
cups
on the
bearings

and
set the
differential case assembly

in
the
carrier casting (Fig.
17).

If
the
gear
set is of the
non-hunting

or partial non-hunting type, assemble

the differential case
and
ring gear
as-

sembly
in the
carrier
so
that
the

marked tooth
on the
pinion indexes

between
the
marked teeth
on the
ring

gear
as
shown
in Fig. 25.

In almost every case
of
improper

assembly (gears assembled
out of

time),
the
noise level
and
probability

of failure will
be
higher than they

would
be
with properly assembled

gears.

When installing
the
hunting type

gear
set (no
timing marks), assemble

the differential case
and
ring gear
as-

sembly
in the
carrier without regard

to
the
matching
of any
particular gear

teeth.

12.
Slide
the
case assembly along

the bores until
a
slight amount
of

backlash
is
felt between
the
gear teeth.

Hold
the
differential case
in
place.

13.
Set the
adjusting nuts
in the

PAINT MARKING INDICATES POSITION
IN
WHICH GEARS WERE LAPPED

E 1335-B

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

E1916A

FIG. 26—Backlash
and
Bearing

Pre-Load Adjustmentprocarmanuals.com

04-04-01

Rear Axle — Ford Light-Duty (WER)
04-04-01

PART 4-4 Rear Ax/e-Ford Light-Duty (WER)

COMPONENT INDEX

AXLE HOUSING

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

DESCRIPTION

DIFFERENTIAL CASE

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND DRIVE

GEAR

Cleaning and Inspection

Removal and Installation

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING CUPS

Cleaning and Inspection

Removal and Installation
MODEL APPLICATION
AN
Models
Ford

01-09

04-04

01-10

04-06

04-01

01-10

04-07

04-06

01-10

04-08

01-10

04-08

01-10

04-08
Mercury
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Meteor
01-09

04-04

01-10

04-06

04-01

01-10

04-07

04-06

01-10

04-08

01-10

04-08

01-10

04-08
Cougar
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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

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

DESCRIPTION

A light-duty, integral-carrier, con-

ventional-type rear axle assembly (Fig.

1) is used in Ford and Meteor passen-

ger vehicles equipped with 240-IV and

302 2V engines and related transmis-

sions.
The axle (model WER) incor-

porates the following features:

The hypoid gear set consists of an

8.50 inch diameter ring gear and an

overhung drive pinion which is sup-

ported by two opposed tapered roller

bearings. A drive pinion pilot bearing

is not used in this axle.

The differential carrier is the non-

removable type, with a stamped bolt-

on cover. The filler hole is tapped in
the front portion of the carrier casting

and uses a
1/2-14
tapered pipe plug

with a 3/8 inch square female drive. A

bumper pad is machined on the pinion

nose portion of the carrier. The rub-

ber bumper is mounted on the vehicle

underbody.

The differential case is a one-piece

design, with openings allowing assem-

bly of the internal components and lu-

bricant flow. The differential pinion

shaft is retained with a threaded bolt

(lock) assembled to the case.

The axle housing assembly consists

of tube assemblies pressed and welded

into the differential casting. The brake
backing plate retainer is welded in-

board of the outer edges of the tubes,

and allows assembly of the backing

plate, independent of the axle shafts.

The roller-type wheel bearings have

no inner race, and contact the bearing

journals of the axle shafts.

The axle shafts do not use an inner

or outer bearing retainer. They are

held in the axle by means of C-locks,

positioned in a slot on the splined end.

These C-locks also fit into a machined

recess in the differential side gears

within the differential case. There is

no retainer bolt access hole in the axle

shaft flange.
procarmanuals.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