checking oil FORD MUSTANG 1969 Volume One Chassis

03-08-07
Ford Design Integral Power Steering Gear

03-08-07

Press Ram
Tool-

T65P.3524-A1

G1362-A

FIG.
17—Installing
Oil Seal in

Valve Housing

11.
Place the dust seal in the hous-

ing with the dished side (rubber side)

facing out. Drive the dust seal into

place with the tool shown in Fig. 11.

the seal must be located behind the

undercut in the input shaft when it is

installed.

Worm and Valve

1.
Remove the snap ring from the

end of the actuator.

2.
Slide the control valve spool

(Fig. 6) off the actuator.

3.
Install the valve spool evenly and

slowly with a slight oscillating motion

into the flanged end of valve housing

with the Valve identification groove

between the valve spool lands out-

ward, checking for freedom of valve

movement within the housing working

area. The valve spool should enter the

housing bore freely and fall by its own

weight.

4.
If the valve spool is not free,

check for burrs at the outward edges

of the working lands in the housing

and remove with a hard stone.

5.
Check the valve for burrs and if

burrs are found, stone the valve in a

radial direction only. Check for free-

dom of the valve again.

6. Remove the valve spool from the

housing.

7.
Slide the spool onto the actuator

making, sure that the groove in the

spool annulus is toward the worm.

8. Install the snap ring to retain the

spool.

9. Check the clearance between the

spool and the snap ring. The clearance

should be between 0.002-0.005 inch. If

the clearance is not within these lim-

its,
select a snap ring that will allow a

clearance of 0.003 inch.
STEERING GEAR HOUSING

J

UPPER SEAL

I LOWER SEAL

SNAP RING

SPACER WASHER

FIG. 12—Steering Gear Housing Disassembled

Tool - T59L - 100-B

Tool T57L-500 - A

G1551-A

FIG. 13—Removing Lower Seal

Piston and Ball Nut

1.
Remove the teflon ring and the

O-ring (Fig. 7) from the piston and

ball nut.

2.
Dip a new O-ring in gear lubri-

cant and install it on the piston and

ball nut.

3.
Install a new teflon ring on the

piston and ball nut being careful not

to stretch it any more than necessary.

Steering Gear Housing

1.
Remove the snap ring and the

spacer washer (Fig. 12) from the

lower end of the steering gear housing.

2.
Remove the lower seal from the

housing as shown in Fig. 13. Lift the

spacer washer from the housing.

3.
Remove the upper seal in the

same manner as the lower seal.

4.
Dip both sector shaft seals in

gear lubricant.
SHORT END

AWAY

FROM SEAL
G1550-A

Press Rom

G1374-A

FIG. 14—Installing Sector Shaft

Inner Seal

5. Apply Lubricant to the sector

shaft seal bore of the housing and

position the sector shaft inner seal

into the housing with the lip facing in-

ward. Press the seal into place with

the tool shown in Fig. 14. Place a spa-

cer washer (0.090 inch) on top of the

seal and apply more Lubricant to the

housing bore.

6. Place the outer seal in the hous-

ing with the lip facing inward and

press it into place as shown in Fig. 15.

Then, place a 0.090 inch spacer wash-

er on top of the seal.

7.
Position the snap ring in the

housing. Press the snap ring into the

housing with the tool shown in Fig. 15

to properly locate the seals and en-

gage the snap ring in the groove.

STEERING GEAR

ASSEMBLY

Do not clean, wash, or soak seals in

cleaning solvent.procarmanuals.com

03-13-08
Specifications
03-13-08

SPECIAL SERVICE TOOLS

Tool No.

T50T-100-A

T59L-100-B

T58L-101-A

T53L-200-A

T62L-201-A

OTC-462

T57L-500-A

T69L-1102-A

Tool 1175-AB

Tool 1175-AH

T56P-1217-A

T60K-1217-A

Tool 1217-J

Tool 1217-K

Tool
1217- L

Tool 1217-M

T65P-3000-A, D

T65P-3000-B, C, E, F

T57P-3006-A

T60K-3005-A

T62F-3006-A

Tool 3044-A

T54P-3044-A

T60K-3044-A

T65P-3044-A

Tool 3068

Tool 3069-AA

Tool
3069-
M

Tool 3290-C

T65P-3524-A

T66P-3553-A, B

T66P-3553-C

T65P-3548-A

T62F-3576-A

T64K-3576-A

T64K-3576-B

T65P-3576-A, B

T65P-3576-C

Tool 3583-J

T65P-3590-F

T67L-3600-A

T65P-3805-A

T63P-5310-A

T64K-5310-A, B

T66P-5310-A, B

T64N-5781-A

T64K-5781-B

Tool 6306-AG

T63L-8620-A

T63L-10300-B

T65P-10300-B

T56L-33610-D

T68L-33610-A

Tool 33623-D

T65P-3A537-A

T65P-3A537-B

T69P-3A674-A

T65P-3A733-A

T65T-3B177-A

T68P-3B586-A

T68P-3B592-A

T68P-3B592-B

T64B-3C716-A

T65P-3C732-A

T65P-3D517-A

T65P-3D525-A

T65P-3D525-B

T65P-3D526-A

T69P-3D608-A

T69P-3D608-B

T65P-3D642-A

T67P-3D739-A
Description

Slide Hammer-Long

Slide Hammer-Short

Puller Attachment

Handle Adapter

Input Shaft Seal Installer

Tie Rod Separator (Owatonna Tool Co.)

Bench Mounted Holding Fixture

Front Wheel Bearing Remover

Grease Seal Remover (Head Only)

Grease Seal Replacer

Front Hub Bearing Cup and Grease Seal Replacer

Front Hub Bearing Cup and Grease Seal Replacer

Front Hub Outer Bearing Cup Replacer

Front Hub Inner Bearing Cup Replacer

Front Hub Outer Bearing Cup Remover

Front Hub Inner Bearing Cup Remover

Adjusting Bars-Caster and Camber

Alignment Spacers

Spindle Ball Joint Remover Press

Spindle Ball Joint Press Adapter Screw

Spindle Ball Joint Press Adapter Screw

Front Suspension Upper Arm Bushing Remover

Front Suspension Upper and Lower Arm Overhaul Kit

Front Suspension Lower Arm Bushing Remover and Replacer

Upper Arm Bushing Overhaul Kit

Front Suspension Upper Arm Bushing Adapter

Front Suspension Lower Arm Bushing Remover

Lower Arm Bushings-Remover and Replacer Kit

Tie Rod Ball Ends and Control Valve Ball Stud Remover

Input Shaft Bearing Remover and Installer

Spanner Wrench

Spacer

Oil Line Connector Seal Installer

Sector Shaft Bushing Remover and Replacer

Sector Shaft Needle Bearings and Seal Remover and Replacer

Sector Shaft Needle Bearings and Seal Remover and Replacer Adapter

Sector Shaft Bushing Remover and Installer

Remover and Installer Adapter

Control Valve Bearing and Seal Remover and Replacer

Steering Pitman Arm Remover

Steering Wheel Remover

Ring Compressor-Rack Piston

Front Coil Spring Remover and Replacer

Adapters

Adapters

Rear Spring Front Bushing Remover and Installer

Rear Spring Bushing Adapter

Crankshaft Damper Remover and Power Steering Pump Sprocket Replacer

Bent Tension Gauge

Pulley Remover

Alternator Pulley Replacer

Pressure Testing Gauge Assembly

Bypass and Orifice Gauge

Pump Oil Seal Pilot

Bearing Preload Spanner Wrench

Adjuster Plug Seal Protector

Fixture Adapter Plate

Power Steering Pump Pulley Remover

Front Suspension Bushings Remover and Replacer

Pump Housing Hole Plugging Tool

Pump Shaft Seal Replacer

Pump Shaft Seal Protector

Insulator Remover and Replacer Socket

Lock Spring Installing Hook

Rack Piston Arbor

Adjuster Plug Bearing Remover and Installer

Thrust Bearing Retainer Installer Adapter

Adjuster Plug Seal Installer

Pin Straightness Checking Block

Pin Guide Support

Sector Shaft Seal Installer

Pivot Pin Removerprocarmanuals.com

04-01-07
General Axle Service

04-01-07

Tool-4201-
C

Tool-6565 USED WITH BRACKET

FROM Too/^*207-C

FLANGE

E1743-A
procedure under Backlash and Differ-

ential Bearing Preload Adjustments.

If the tooth pattern indicates a change

in shim thickness, follow the proce-

dure under Pinion Location.

REMOVABLE CARRIER

TYPE AXLE

The shim location for the removable

carrier type axle is between the pinion

retainer and the carrier (Fig. 13).

When adjusting this type carrier re-

ducing shim thickness will move the

pinion toward the ring gear; increas-

ing shim thickness will move the pi-

nion away from the ring gear (Fig.

13).

FIG. 11—Checking Companion Flange Lateral Runout—

Thunderbird and Continental Mark III
INTEGRAL CARRIER

TYPE AXLE

8. If the runout is still excessive, re-

place the companion flange and check

the runout. If necessary, rotate the

new flange on the pinion shaft until an

acceptable runout is obtained.

If excessive runout is still evident

after replacement of the companion

flange, it will be necessary to replace

the ring and pinion gear, and repeat

the above checks until runout is within

specifications.

9. Install the driveshaft assembly

(Group 5).

PINION LOCATION

ADJUSTMENT

BACKLASH

ADJUSTMENT,

LEFT

ADJUSTING

NUT

E1476-A

FIG. 12—Pinion and Ring Gear

Tooth Contact Adjustment
—

Integral Carrier Type Axles
PINION AND RING GEAR

TOOTH CONTACT

ADJUSTMENT

Two separate adjustments affect pin-

ion and ring gear tooth contact.

They are pinion location and backlash

(Figs.
12 and 13).

Individual differences in matching

the differential housing and the gear

set require the use of shims to locate

the pinion for correct contact with the

ring gear.

When adjusting either type axle,

shim thickness should be increased or

reduced only as indicated by the tooth

pattern check described in the fore-

going Section 1.

If the tooth pattern check indicates

a change in backlash only, follow the

PINION

LOCATION

ADJUSTMENT

SHIMS

LEFT

ADJUSTING

NUT
RIGHT

ADJUSTING

BACKLASH NUT

ADJUSTMENT El 409-A

FIG. 13—Pinion and Ring Gear

Tooth Contact Adjustment—

Removable Carrier Axles
The shim location for the integral

carrier type axle, is between the pi-

nion gear and the pinion rear bearing

cone (Fig. 12). When adjusting this

type axle, increasing shim thickness

moves the pinion toward the ring

gear; reducing shim thickness moves

the pinion away from the ring gear

(Fig. 12).

BACKLASH AND DIFFERENTIAL

BEARING PRELOAD

ADJUSTMENTS (ALL AXLES)

On a Light-Duty (WER) Axle, it is

necessary to remove the rear axle

shafts prior to performing the adjust-

ment procedures. Refer to Rear Axle

Shaft Wheel Bearing and Oil Seal Re-

placement—Light-Duty (WER), Axle,

Part 4-4, Section 2.

To secure a more uniform control

of differential side bearing preload in

service repairs, a dial indicator set-up

such as shown in Fig. 12 is used.

In both types of axle (Fig. 11 and

12),
the ring gear is moved away from

or toward the pinion as described in

the following procedure.

1.
Remove the adjusting nut locks,

loosen the differential bearing cap

bolts,
then torque the bolts to 15 ft-lbs

on integral carrier type axle; 20 ft-lbs

on removable carrier type axles before

making adjustments.

2.
The left adjusting nut is on the

ring gear side of the carrier. The right

nut is on the pinion side. Loosen the

right nut until it is away from the cup.

Tighten the left nut until the ring gear

is just forced into the pinion with

0.000 backlash then rotate the pinion

several revolutions to be sure no bind-

ing is evident. (Recheck the right nutprocarmanuals.com

04-01-09
General Axle Service

04-01-09

CLEANING AND INSPECTION

INSPECTION BEFORE

DISASSEMBLY OF CARRIER

(ALL AXLES)

The differential case or carrier

should be inspected before any parts

are removed from it. These inspec-

tions can help to find the cause of the

trouble and to determine the correc-

tions needed.

Mount the carrier in the holding

fixture shown in Fig. 15. Wipe the lu-

bricant from the internal working

parts,
and visually inspect the parts

for wear or damage.

Tool-T57L-500-A

FIG. 15
— Bench
Fixture for

Carrier Overhaul—Typical

Rotate the gears to see if there is

any roughness which would indicate

damaged bearings or chipped gears.

Check the gear teeth for scoring or

signs of abnormal wear.

Set up a dial indicator (Fig. 16) and

check the backlash at several points

around the ring gear. Backlash should

be within specifications.
If no obvious defect is noted, check

the gear tooth contact.

To check the gear tooth contact,

paint the gear teeth with the special

compound furnished with each service

ring gear and pinion. A mixture that

is too wet will run and smear. Too dry

a mixture cannot be pressed out from

between the teeth.

As shown in Fig. 17, rotate the ring

gear (use a box wrench on the ring

gear attaching bolts for a lever) five

complete revolutions in both directions

or until a clear tooth contact pattern

is obtained.
DIFFERENTIAL BEARING

CAP BOLTS

E 1776-A

FIG. 76-Backlash Check-

Typical
E
1001 - C

FIG.
7
7—Checking Gear Tooth

Contact—Typical

Certain types of gear tooth contact

patterns on the ring gear indicate in-

correct adjustment. Noise caused by

incorrect adjustment can often be cor-

rected by readjusting the gears. Ac-

ceptable patterns and the necessary

corrections are explained under Tooth

Contact Pattern Check in Section I.

Gear tooth runout can sometimes

be detected by an erratic pattern on

the teeth. However, a dial indicator

should be used to measure the runout

of the back face of the ring gear as

shown in Fig. 18. If this runout ex-

ceeds specifications, disassemble the

carrier and replace necessary parts as

indicated in Part 4-2, Section 4 and

Part 4-3, Section 4.
1699-A

FIG. 18 -Checking Ring Gear

Runout—Typical

Loosen the differential bearing cap

bolts,
and then torque them to 25 ft-

lbs.
Remove the adjusting nut locks.

Carefully loosen one of the adjusting

nuts to determine if any differential

bearing preload remains. If any pre-

load remains, the differential bearings

may be re-used, provided they are not

pitted or damaged.

INSPECTION AFTER

DISASSEMBLY OF CARRIER

(ALL AXLES)

Thoroughly clean all parts. Syn-

thetic seals must not he cleaned, soak-

ed or washed in cleaning solvents.

Always use clean solvent when clean-

ing hearings. Oil the bearings im-

mediately after cleaning to prevent rust-

ing. Inspect the parts for defects.

Clean the inside of the carrier before

rebuilding it. When a scored gear set

is replaced, the axle housing should he

washed thoroughly and steam cleaned.

This can onl\ be done effectively if the

axle shafts and shaft seals are re-

moved from the housing. Inspect indi-

vidual parts as outlined below.

GEARS

Examine the pinion and ring gear

teeth for scoring or excessive wear.

Extreme care must he taken not to

damage the pilot hearing surface of

the pinion.procarmanuals.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

04-03-04
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

04-04-07
Rear Axle — Ford Light-Duty (WER)
04-04-07

RUNOUT CHECK

E 1573-A

FIG. 70—Checking Backlash and Runout—Light-Duty (WER) Axle

All service operations on the differ-

ential case assembly can be performed

with the axle housing in the vehicle.

1.
Raise the vehicle on a hoist.

2.
Position the drain pan under the

axle housing. Loosen the housing

cover attaching bolts. Drain the lubri-

cant from the housing.

3.
Make scribe marks on the drive

shaft end yoke and the rear axle shaft

companion flange to insure proper po-

sition of the drive shaft at assembly.

Disconnect the driveshaft from the

rear axle companion flange. Be care-

ful to avoid dropping the loose univer-

sal joint bearing cups. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their origi-

nal position in relation to the flange

when they are reassembled. Remove

the drive shaft from the transmission

extension housing. Install an oil seal

replacer tool in the transmission ex-

tension housing to prevent transmis-

sion leakage. Refer to the transmis-

sion group for the appropriate tool.

4.
Raise the vehicle and place

jack-type stands under the rear frame

crossmember. Lower the vehicle on a

hoist and allow the axle to lower as

far as possible.

5.
Remove the axle housing cover

and gasket. Discard the gasket.

6. Perform the Inspection Before

Disassembly of Carrier procedure.

Refer to Part 4-1, Section 3 of this

Shop Manual.

7.
Remove the attaching (Tinner-

man) nuts that secure the rear brake

drums to the axle shaft flanges, and

then remove the drums.

8. Working through the differential

case opening, remove the pinion shaft

lock bolt and pinion shaft (Fig. 2).

9. Push the axle shafts inward

toward the center of the axle housing.

Remove the C-locks (Fig. 3) from the

inner ends of the rear axles. Remove

the axle shafts from the housing. Ex-

treme care must be used to avoid con-

tacting the axle shaft seal lip with any
portion of the axle shaft except the

seal journal.

10.
Remove the bearings and oil

seals from the axle housing as shown

in Fig. 4.

11.
Remove the pinion side gears

and the side gear thrust washers.

12.
Remove both side bearing ad-

justing nut locks (bolts).

13.
Install a dial indicator (Fig. 10),

and check and record the backlash

and ring gear runout.

14.
Mark one differential bearing

cap and the case to help in positioning

the parts properly during assembly.

15.
Remove the bearing cap retain-

ing bolts. Remove the bearing caps,

cups,
adjusting nuts and case assem-

bly.

16.
Hold the drive pinion flange

and remove the pinion nut (Fig. 11).

Discard the nut.

17.
Remove the pinion flange (Fig.

12).

18.
Drive the pinion out of the

front bearing cone and remove it from

the carrier housing. Remove and dis-

card the bearing spacer.

19.
With a hammer and drift re-

move the pinion shaft oil seal out

through the front of the carrier hous-

ing.

20.
Remove the pinion rear bearing

from the drive pinion shaft (Fig. 13).

21.
Measure the shim which is

found under the bearing cone with a

Tool-T57L-485T-A

or 4851-K

El 906A
Tool
-
T6SL-485UA
\

E 1574-A

FIG. 12—Drive Pinion Flange

Removal

1575-A

FIG. 13—Pinion Rear Bearing

Removal

00/
- T57L-4220-A

FIG. 11—Typical Drive Pinion

Shaft Nut Removal
E 1576-A

FIG. 14—Differential Bearing

Removal

micrometer. Record the thickness of

the shim.

DISASSEMBLY OF

DIFFERENTIAL CASE

1.
If the 2 differential side bearings

are to be removed from the differen-

tial case, use the tool shown in Fig.

14.procarmanuals.com

04-04-09
Rear Axle — Ford Light-Duty (WER)
04-04-09

case several revolutions in each direc-

tion while the bearings are loaded to

seat the bearings in their cups. This

step is important.

5. Again loosen the right nut to re-

lease the preload. Check to see that

the left nut contacts the bearing cup.

Using the dial indicator set-up shown

in Fig. 13, Part 4-1, adjust the preload

to 0.008 to 0.012 case spread for new

bearings or 0.005 to 0.008 for the

original bearings, if re-used.

6. Check the runout of the differen-

tial case flange with a dial indicator.

If the runout does not now exceed

specifications, install a new ring gear,

if the runout still exceeds specifica-

tions,
the ring gear is true and the

trouble is due to either a defective

casting or worn bearings.

7.
Remove the differential case

from the carrier and remove the side

bearings from the case.

8. Install new bearings on the case

hubs,
and again install the differential

assembly in the carrier without the

ring gear.

9. Check the case runout again with

the new bearings. If the runout is now

within limits, the old bearings were

excessively worn. Use the new bear-

ings for assembly. If the runout is still

excessive, the case is defective and

should be replaced.

ASSEMBLY OF AXLE

Refer to Part 4-1 of this Shop

Manual for Cleaning and Inspection

procedures before starting assembly

operations.

ASSEMBLY OF

DIFFERENTIAL CASE

1.
Place the ring gear on the differ-

ential case. Install the retaining bolts

and torque them to specification.

2.
If the differential bearings were

removed, press them on as shown in

Fig. 17.

3.
Insert the pinion gear shaft lock

bolt into the case (loosely).

INSTALLATION OF DRIVE

PINION AND

DIFFERENTIAL CASE

1.
Place the shim(s) and pinion rear

bearing cone on the pinion shaft.

Press the bearing and shim(s) firmly

against the pinion shaft shoulder (Fig.

18).

2.
Place a new pinion bearing pre-

load (collapsible) spacer on the pinion

shaft.
REAR BEARING

CONE AND

ROLLER
Press Ram

FIG. 18—Drive Pinion Bearing

Installation

3.
Lubricate the pinion rear bearing

with axle lubricant.

4.
Lubricate the pinion front bear-

ing with axle lubricant. Lubricate the

pinion front bearing cone and place it

in the carrier housing.

5.
Install a new oil seal in the car-

rier casting (Fig. 19).

6. Insert the drive pinion shaft (U-

joint) flange into the pinion 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.
Apply a small amount of lubri-

cant to the washer side of the flange

nut and start the nut. Use a new nut.

Hold the flange with the tool shown in

Fig. 12 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 bearing preload play

checked often, so that the pinion bear-

ing preload does not exceed the speci-

fied limits.

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
/
Tool
-
T58L-4676-A

/ E
1581-A

FIG. 19—Installing Pinion Seal

E 1582-A

FIG. 20—Checking Pinion Bearing

Preload

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.

8. As soon as there is preload on

the bearings, turn the pinion shaft in

both directions several times to seat

the bearing rollers.

9. Adjust the bearing preload to

specification. Measure the preload

with the tool shown in Fig. 20.

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.

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. 49, Part 4-2.

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), assembleprocarmanuals.com

04-05-04
Specifications

04-05-04

ATTACHING TORQUE SPECIFICATIONS -(By Axle Ring Gear Diameter)

Description

Differential Bearing Cap Bolt- 7 1/4"

8"

All Others

Differential Bearing Adjusting

Nut Lock Bolts

Carrier
to
Housing Stud Nuts-

8", 8 3/4", 9" 8 3/8"

Pinion Retainer
to
Carrier Bolts-

8", 8 3/4", 9" 9 3/8"

Ring Gear Attaching Bolts-

7 1/4"

All Others

Differential Pinion Shaft

Lock Pin
•
8 1/2" Only
Torque Lbs.
Ft.

40-55

55-70

70-85

12-25

25-40

30-45

40-55

65-80

15-22
Description

Rear Cover Screw and Washer

Assemblies
-8
1/4" &
8
1/2

Only

Oil Filler Plug

Rear Axle Shaft Bearing Retainer

Bolt Nuts:

Falcon,
Fairlane, Montego,

Mustang and Cougar (All)

Ford & Meteor (Exc.
8 1/2" R.G.)

Mercury,
T
Bird

Lincoln Continental (All)

Brake Backing Plate Bolt Nuts-

Ford & Meteor
8
1/2" Only
Torque Lbs.
Ft.

25-35

25-50

20-40

50-75

30-55

20-40

LUBRICANT
CAPACITIES
AND CHECKING PROCEDURES®

Vehicle

Falcon,
Mustang

Cougar, Fairlane, Falcon

Montego, Mustang

Ford,
Meteor

Ford,
Meteor

Cougar, Fairlane, Falcon, Ford,

Mercury, Meteor, Montego, Mustang

Lincoln,
Thunderbird
Engine

(C.I.D.)

170,
200

250,
302

240,
302

240,
302

351,
390,

428,
429

429,
460
Axle

Ratio

All

All

2.80:1,
3.10:1

All Except

2.80:1,
3.10:1

All

All
U.S. Measure

Capacity® (Pints)

2.5

4.0

4.0

5.0

5.0

5.0©
Imperial

Capacity
CD
(Pints)

2

31/5

3 1/5

4.0

4.0

4.0©

©All limited slip and Traction-Lok axles use ESW-M2C-104-A lubricant (C6AZ-19580-C).

All conventional axles use ESW-M2C-105-A lubricant (C6AZ-19580-B).

©Approximate refill capacity-Actual lubricant capacities are determined
by
filling
to
bottom
of
filler hole.

©To check these axles, the plug should be backed
out
slowly.
If
seepage occurs around the threads, the plug should
be
turned back
in

immediately to avoid any drainage. This indicates that the specified amount
of
lubricant
is
present
in
the axle.

SPECIAL TOOLS

FORD,
MERCURY, METEOR

Ford Tool No.

T66L-4204-L

T57L-500-A

T50T-100-A

TOOL-4235-C

T00L-4621-A

TOOL-1225-D

T00L42344

TOOL-1177

TOOL-U75-AB

T57L4220-A

T00L4221-AE

T00L-4221-AF

T66P-4220-P

TOOL-4851-K
Former No.

42211 or

42211-A

6005-M

6005-MS

B-160

4235C

—

—

4234-A

4245-B

1175-AB

—

4221-AF

T57L-4851-A

4851-K
Description

Limited-Slip Differential Check

Bench Fixture

Impact Hammer

Axle Shaft Remover

Drive Pinion Bearing and

Rear Wheel Bear Replacer

Rear Wheel Bearing Remover

Rear Wheel Bearing Installer

Rear Wheel Bearing Oil Seal Installer

Rear Wheel Bearing Oil Seal Remover

Differential Bearing Remover

Differential Bearing Remover

U-Joint
Flange Holder
Ford Tool No.

T53T4851-A

T00L4858-D

T57L4614-A

T00L4621-K

T53L-200-A

T57L-4625-A or

T00L4625-K

T57L4616-A or

T00L4615-D

T58L-101-A

T55P4616-A2

T57L4621-B or

T00L4621-L

T58L4676-A

T00L4858-E
Former No.

4851-A, D

—

4614

4621-K

—

4625-K

—

—

—

—

4676-F

4858-E
Description

U-Joint
Flange Remover

U-Joint
Flange Remover

Drive Pinion Retainer Support

Pinion Rear Bearing Cone Remover

Handle Adapter

Pinion Pilot Bearing Remover and

Installer

Pinion Front Bearing Cup Remover

and Replacer

Puller Attachment—For Bearing

Cup Removal

Pinion Rear Bearing Cup Remover

and Replacer

Pinion Rear Bearing Cone Installer

Drive Pinion Oil Seal Replacer

U-Joint
Flange and Pinion Bearing

Replacerprocarmanuals.com

07-01-04
General Transmission Service

07-01-04

taching bolts to the proper torque. If

necessary, replace the gasket.

Check the fluid filler tube connec-

tion at the transmission case or pan.

If leakage is found here, install a new

O-ring or tighten the fitting to the

specified torque.

Check the fluid lines and fittings

between the transmission and the

cooler in the radiator tank for loose-

ness,
wear, or damage. If leakage can-

not be stopped by tightening a fitting,

replace the damaged parts.

Check the engine coolant in the ra-

diator. If transmission fluid is present

in the coolant, the cooler in the radia-

tor is probably leaking.

The cooler can be further checked

for leaks by disconnecting the lines

from the cooler fittings and applying

50-75 psi air pressure to the fittings.

Remove the radiator cap to relieve the

pressure build at the exterior of the oil

cooler tank. If the cooler is leaking

and will not hold this pressure the

cooler must be replaced. Cooler re-

placement is described in the Cooling

System Section of Group 11.

If leakage is found at either the

downshift control lever shaft or the

manual lever shaft, replace either or

both seals.

Inspect the pipe plug on the left

side of the transmission case at the

front. If the plug shows leakage, tor-

que the plug to specifications. If tight-

ening does not stop the leaks, replace

the plug. On a C6 transmission, a TV

pressure plug is also provided on the

right rear side of the case.

When converter drain plugs leak,

remove drain plugs with a six-point

wrench. Coat the threads with FoMo-

Co Perfect Seal Sealing Compound or

its equivalent, and install the plugs.

Torque the drain plugs to specifica-

tion. Fluid leakage from the converter

housing may be caused by engine oil

leaking past the rear main bearing or

from oil gallery plugs, or power steer-

ing oil leakage from steering system.

Be sure to determine the exact cause

of the leak before repair procedures

are started.

Oil-soluble aniline or fluorescent dyes

premixed at the rate of 1/2 teaspoon

of dye powder to 1/2 pint of transmis-

sion fluid have proved helpful in locat-

ing the source of the fluid leakage.

Such dyes may be used to determine

whether an engine oil or transmission

fluid leak is present or if the fluid in

the oil cooler leaks into the engine

coolant system. A black light, how-

ever, must be used with the fluorescent

dye solution.
DISHED OR

FLAT WASHER

" O.D.,
a" STEEL PLATE

5/8"X \W,

DRILL TO SUIT
HEX. HEAD SCREW

3/8"-24 X Vl

HEX. NUT W—
24

WELD

TOGETHER

WING
NUT

>/2"_13
THREAD

CHAIN,
10"
LONG
RUBBER PLUG

1
Vi" DIA. X 2"

LONG Vl"

HOLE THRU

APPROXIMATELY

40 DUROMETER
FLAT WASHER

Vs" O.D.

PLUG

VALVE
STANDARD BOLT

W-13
X 4Vl"

LONG SQUARE

THREAD
END

REMOVE HEAD

AND WELD
TO

WASHER

STANDARD 1/8" FITTING-87971-S FOR

RETAPPED DRAIN PLUG THREADS-USE

1/4" OVERSIZE FITTING-87973-S

D 1067-B
WELD TOGETHER

SECURELY—MUST

NOT LEAK

FIG. 2—Converter Leak Checking Tool

CONVERTER LEAKAGE

CHECK

If there are indications that the

welds on the torque converter are

leaking, the converter will have to be

removed and the following check

made before the unit is replaced.

A leak checking tool (Fig. 2) can be

made from standard parts. The tool

can be used to check all converters.

1.
Install the plug in the converter

(Fig. 3) and expand it by tightening

the wing nut. Attach the safety chains.

2.
Install the air valve in one of the

drain plug holes.

3.
Introduce air pressure into the

converter. Check the pressure with a

tire gauge and adjust it to 20 psi.

4.
Place the converter in a tank of

water. Observe the weld areas for

bubbles. If no bubbles are observed, it

may be assumed that the welds are

not leaking.

ENGINE IDLE SPEED CHECK

Check and, if necessary, adjust the

engine idle speed, using the procedure

given in Group 10.

If the idle speed is too low, the en-

gine will run roughly. An idle speed

that is too high will cause the vehicle

to creep, have harsh engagements and

harsh closed-throttle downshifts.
ANTI-STALL DASHPOT

CLEARANCE CHECK

After the engine idle speed has been

properly adjusted, check the anti-stall

dashpot clearance. Follow the proce-

dure given in Group 10 for checking

and adjusting this clearance.

MANUAL LINKAGE CHECKS

Correct manual linkage adjustment

is necessary to position the manual

valve for proper fluid pressure direc-

tion to the different transmission com-

ponents. Improperly adjusted manual

Tire Pressure Gauge

D1921-A

FIG. 3—Converter Leak Checking

Tool Installationprocarmanuals.com