1969 FORD MUSTANG wheel

04-05-03
Specifications

04-05-03

SHIM PACK THICKNESS CHART TRACTION-LOK DIFFERENTIAL

Feeler

Gauge

Reading

0.001

0.002

0.003

0.004

0.005

0.006

0.007

0.008

0.009

0.010

0.011

0.012

0.013

0.014

0.015

0.016

0.017

0.018

0.019

0.020

0.021

0.022

0.023

0.024

0.025

0.026

0.027
Remove Shim(s)

From

Nominal

None

0.005

0.010

0.015

0.020

0.025
Total Req'd

Shim Pack

Thickness®

0.050

0.045

0.040

0.035

0.030

0.025
Feeler

Gauge

Reading

0.028

0.029

0.030

0.031

0.032

0.033

0.034

0.035

0.036

0.037

0.038

0.039

0.040

0.041

0.042

0.043

0.044

0.045

0.046

0.047

0.048

0.049

0.050
Remove Shim(s)

From

Nominal

0.030

0.035

0.040

0.045

0.050
Total Req'd

Shim Pack

Thickness ®

0.020

0.015

0.010

0.005

0.000

©Service Shims are available in 0.010" and 0.005" Thicknesses.

ADJUSTMENT TORQUE SPECIFICATION -(BY AXLE RING GEAR DIAMETERS

Description

Minimum torque required to tighten

pinion flange nut to obtain

correct pinion bearing preload

7 1/4" & 8 1/2"

8", 8 3/4" & 9"

9 3/8"

Pinion Bearing Preload-

collapsible spacer)®

Original Bearings 7 1/4"

8", 8 1/2", 8 3/4", 9"

New Bearings 7 1/4"

8", 8 1/2", 8 3/4", 9"

Pinion Bearing Preload-

(Solid Spacer) 9 3/8" Only
Torque

Lbs.
In.

6-12

8-14

17-32

22-32

15-35
. Lbs. Ft.

140®

175®

180-220
Description

Lockers Only • Minimum rotating

Torque required to turn axle

shaft and side gear with one

wheel on ground:

Limited Slip 7 1/4"

All other R. G. Sizes

Traction-Lok-All

Lockers only-Rotating Torques

required during bench check

after assembly:

Original Clutch Plates-

Limited Slip 71/4",

All other R. G. Sizes

Traction-Lok-(All)

New Clutch Plates-

Limited Slip 7 1/4"

All other R. G. Sizes

Traction-Lok-All
Torque

Lbs.
In.
Lbs.
Ft.

50

75

40

50 Min.

75 Min.

40 Min.

100-125

155-195

100-250G

©If pinion bearing preload exceeds specification before this torque is obtained, install a new spacer.

©With Oil Seal.

©Rotating torque may fluctuate up to 40 Lbs. Ft.procarmanuals.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

04-05-05
Specifications

04-05-05

SPECIAL TOOLS

FORD MERCURY, METEOR (Continued)

Ford Tool No.

T57L-4221-A1 or

Tool-4222-K

TOOL 6565-AB

TOOL 6565

TOOLS 4201-C

andD

TOOL-T57L-

4067-A

TOOL-T50T-100-A

T00L-T66L-

12132-B

CJ-6625 (Snap-

On)
Foniisr
NO.

4222-H

6565-AB

6565

4201-C

4067-B

—

—

—
Description

Differential Bearing Installer

Adapter

Dial Indicator

Differential Backlash and Runout

Gauge with Universal Bracket, Dial

Indicator and Bracket

Differential Bearing Adjuster Wrench

Impact Hammer-Long

Adapter

Puller
Ford Tool No.

TOOL-T60K-

7697-B

T00L-T65F-

1177-A

T00L-T65L-

4851-A

TOOL-OTC-951

T00L-T67P-

4616-A

TOOL-T53T-

4621-C
Fomor No.

—

—

—

—

—
Description

Transmission Extension Housing

Bushing Repiacer

Rear Wheel Bearing Oil Seal Repiacer

Flange (Universal Joint) Axle End

Remover

Universal Puller

Pinion Bearing Cups Repiacer

Pinion Bearing Cone Repiacer

COUGAR, FAIRLANE, FALCON,

Ford Tool No.

T50T-100-A

T58L-101-A

T62L-201-A

T56L-400-A

T57L-500-A

T00L-1175-AB

T50T-100-Aand

TOOL-1175-AB

T60K-1177-B

T60K-1225-Aor

T00L-1225-C

TOOL-1225-B

T00L-T54-P-

3044-A

T00L-T57L-

4067-A

T57L-4067-Aor

T60K-4067-A

TOOL-4201-C

andD

T65K-4204A or

T59L-4204-A

T00L-4221-AL

T57L-4221-A

T00L-4222-H

T66L-4235-A
Former No.

B-160

-

4851-A

-

1175-AB

1175-AE

1177-B

4067-B

4221 or

4211-A

4201-C

4067-E

4221-AL

4222-K

4222
MONTEGO, MUSTANG

Description

Impact Hammer

Puller Attachment

Handle Adapter

Puller

Bench Mounted Holding Fixture

Grease Seal Remover (Head Only)

Seal Remover

Rear Wheel Bearing Oil Seal

Axle Shaft Bearing Remover and Repiacer

Axle Shaft Searing Remover

Axle Shaft Bearing Repiacer

Front Suspension Upper and Lower Arm

Overhaul Tool Kit

Differential Bearing Adjuster Nut

Wrench

Limited-Slip Differential Check

Differential Backlash and Runout Gauge

With Universal Bracket, Dial Indicator

and Bracket

Differential Bearing Adjuster Nut

Wrench

Differential Bearing Cone Remover

Pilot (Use with T00L-4221C or

T00L-4851-A)

Differential Bearing Cone Repiacer

Differential Bearing Cone Repiacer

Rear Axle Shaft Assembly Remover

Adapter
Ford Tool No.

T57L-4614-A

T00L-4615-J

T60K-4616-A

T57L-4616-A

T57L-4616-A2

T55P-4616-A2

T00L-4621-K

T62F-4621A

T62F-4625-A

T55P-4676-A

T62F4676A

T53T-4851A

T57L-4851-A

T00L-4858-E

T65K-4204-A

T59L-4204-A

T00L-6565-AB

TOOL-6565
Former No.

4614

4615-J

4615-HF

4625-HR

4615-
E

andP

4615-
E

andF

-

4621-K

4625-AC

land 2

4676-G

4676-
H

4851-A

4858-D

4851-K

4858-
E

—

44211 and

44211-A

6565-AB

6565
Description

Drive Pinion and Drive Pinion Retainer

Assembly Support

Drive Pinion Front Bearing Cup Remover

Pinion Bearing Cup Repiacer

Pinion Front Bearing Cup Remover

Pinion Front Bearing Cup Repiacer

Pinion Rear Bearing Cup Repiacer

Drive Pinion Rear Bearing Cone Remover

Pinion Bearing Cone Repiacer

Drive Pinion Pilot Bearing Remover

and Repiacer

Drive Pinion Oil Seal Repiacer

Drive Pinion Oil Seal Repiacer

Flange (Universal Joint) Axle End

Remover

Universal Joint Flange Holder

Companion Flange and Pinion Bearing

Repiacer

Limited-Slip Differential Torque Check

Adapter

Locking Differential Torque Check

Adapter

Dial Indicator

T68P-4946-A - Traction-Lok Shim Template Toolprocarmanuals.com

04-05-06

Specifications

04-05-06

THUNDERBIRD, CONTINENTAL MARK
III

Ford Tool No.

T50T-100-A

T50T-100-A&

TOOL-1175-AB

T00L-1225-DA

TOOL-4005

TOOL-4020-B

T57L-4067-A

TOOL-4201

TOOL-4201-C

TOOL-4205-B

TOOL-4205-C

T00L-4221-C

T00L-4222-H

T00L-4235-C

T00L-4245-B
Former No.

T50T-100-C

1175-AE

1225-DA

4005

4020-B

_

4201

4201-C

4205-B

4205-C

4221-C

4222-H

4235-C

4245-B
Description

Slide Hammer

Seal Remover

Rear Wheel Bearing Remover

Engine Repair Stand Axle Adapter-

Keyed Shaft

Pinion Depth Gauge-Complete With

Depth Micrometer and Gauge Block

Differential Bearing Adjuster Wrench

Pinion Shaft Drive
Nut

Differential Backlash
&
Runout

Gauge With Univ. Bracket, Dial

Indicator and Bracket

Differential Assembly Bench Holder

Axle Housing Dummy Bearings (1
pr.)

Differential Side Bearing Remover

Differential Bearing Cone Replacer

Axle Shaft
&
Bearing Remover

Wheel Bearing Seal Replacer
Ford Tool No.
Former No. Description

TOOL-4616
4616
Drive Pinion Bearing Cup Replacer

(Front)

T00L-4621-A 4621-A Drive Pinion Bearing and Rear Wheel

Bearing Replacer

T00L-4621-BA 4621-BA Rear Pinion Bearing Remover

TOOL-4628 4628 Pinion Rear Bearing Cup Replacer

T00L-4628-B 4628-B Pinion Bearing Front Cup Remover

T00L-4628-D 4628-D Pinion Rear Bearing Cup Remover

T64N-4676-A 4676 Pinion Shaft Oil Seal Replacer

T68P-4851-A
-
Universal Joint Flange Holder

T64N-4858-A 4858-B Companion Flange
&
Pinion Bearing

Replacer

T00L-4858-G 4858-G Pinion Flange Nut Adjusting Wrench

(Use With T64N-4858-A)

TOOL-4859 4859 Companion Flange Dust
Shield
Replacer

T00L-6565-AB
-
Dial Indicator Adapter

TOOL-6565
-
Dial Indicator

T00L-7657-J 7657-J Extension Housing Bushing
&

Seal Replacer

LINCOLN CONTINENTAL

Ford Tool
No.

T00L-4245-B

TOOL-4616

T00L-4621-A

T00L-4621-BA

TOOL-4628

T00L-4628-B

T64N-4628-B

T00L-4628-D

T64N-4676-A

T00L-4851-K

T64N-4858-A

T00L-4858-G

TOOL-4859

T00L-6565-AB

TOOL 6565

T00L-7657-J
Former
No.

4245-B

4616

4621-A

4621-BA

4628

4628-B

4628-D

4676

T57L-4851-A

4858-B

4858-G

4859

7657-J
Description

Wheel Bearing Seal Replacer

Drive Pinion bearing
Cup

Replacer (Front)

Drive Pinion Bearing
and
Rear

Wheel Bearing Replacer

Rear Pinion Bearing Remover

Pinion Rear Bearing
Cup
Replacer

Pinion Bearing Front
Cup
Remover

Pinion Rear Bearing Cup Remover

Pinion Shaft
Oil
Seal Replacer

Universal Joint Flange Holder

Companion Flange
&
Pinion Bearing

Replacer

Pinion Flange
Nut
Adjusting Wrench

(Use With T64N-4858-A)

Companion Flange Dust Shield

Replacer

Dial Indicator Adapter

Dial Indicator

Extension Housing Bushing
&

Seal Replacer
Ford Tool
No.
Former
No.

T50T-100-A

T50T-100-A&

TOOL-1175-AB

TOOL-1225-DA

TOOL-4000-C

TOOL-4005

TOOL-4020-B

TOOL-4201

TOOL-4201-C

TOOL-4204-A

TOOL-4205-B

TOOL-4205-C

T00L-4209-C

T00L-4221-C

T00L-4222-H

T00L-4235-C
Description

T50T-100-C Slide Hammer

1175-AE

1225-DA

4000-C

4005

4020-B

4201

4201-C

4205-B

4205-C

4209-C

4221-C

4222-H

4235-C
Seal Remover

Rear Wheel Bearing Remover

Differential Housing Spreader

Engine Repair Stand Axle Adapter-

Keyed Shaft

Pinion Depth Gauge-Complete With

Depth Micrometer
and
Gauge

Block

Pinion Shaft Drive
Nut

Differential Backlash
&
Runout

Gauge With Univ. Bracket, Dial

Indicator
and
Bracket

Limited Slip Differential Check

Differential Assembly Bench Holder

Axle Housing Dummy Bearings

(1
pi")

Pinion Tension Scale With

4209-C12 Socket

Differential Side Bearing Remover

Differential Bearing Cone Replacer

Axle Shaft
&
Bearing Removerprocarmanuals.com

05-01-01
05-01-01

Clutch
GROUP

5

PART
5-1
PAGE

Drive Shaft 05-01-01

PART
5-2

General Clutch Service 05-02-01
PART
5-3

Clutch

PART
5-4

Specifications
PAGE

05-03-01

05-04-01

PART
5-1
Drive Shaft

COMPONENT INDEX

DESCRIPTION

DRIVE SHAFT ANGLE CHECK

DRIVE SHAFT BALANCE CHECK

DRIVE SHAFT BALANCING

(Single Universal Joint)

DRIVE SHAFT DISASSEMBLY
AND

OVERHAUL

Single Universal Joint — Ford Design

Double Cardan Joint — Dana Design

Double Cardan Joint — Saginaw Design

DRIVE SHAFT REMOVAL
AND

INSTALLATION

DRIVE SHAFT RUNOUT CHECK
MODEL APPLICATION
All
Models

01-01

01-01

01-01

01-02

01-01
Ford
01-04

01-04

N/A

N/A
Mercury
01-04

01-04

N/A

N/A
Meteor
01-04

01-04

N/A

N/A
Cougar
01-04

01-04

N/A

N/A
Fairlane
01-04

01-04

N/A

N/A
Falcon
01-04

01-04

N/A

N/A
Montego
01-04

01-04

N/A

N/A
Mustang
01-04

01-04

N/A

N/A
Lincoln-
Continental
N/A

N/A

01-04

N/A
Thunderbird
N/A

N/A

N/A

01-05
Continental-
Mark
III
N/A

N/A

N/A

01-05

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.

DRIVE SHAFT TESTS

DRIVE LINE BALANCE CHECK

If detailed parts
of the
drive shaft

are replaced
and
shaft vibration
is en-

countered after installation, disconnect

the shaft
at the
slip yoke. Rotate
the

slip yoke
180
degrees; then, reconnect

the shaft
to the
slip yoke.
If the
vibra-

tion persists, disconnect
the
shaft
at

the rear axle companion flange.
Ro-

tate
the
companion flange
180
degrees

and reconnect
the
shaft
to the
flange.
DRIVE LINE ANGLE CHECK

Vibration
or
"shudder" which
is no-

ticeable either
on
fast acceleration
or

when coasting, using
the
engine
for a

brake,
may be
caused
by the
rear axle

housing being loose
on the
rear

springs
or by
improper pinion angle.

Refer
to
Group
3,
Part
2 for
pinion

angle checking procedures.
If the
rear

axle U-bolts (Fairlane, Montego,

Mustang, Cougar, Falcon models
only)
are
loose, torque
the
nuts
to

specification.

DRIVE SHAFT RUNOUT CHECK

Using
a
dial indicator, check
the

runout
at
each
end and in the
middle

of
the
driveshaft.
The
rear check

should
be
made
on the
small tube
sec-

tion
of the
shaft between
the
balance

weights
and the
yoke welds. Drive-

shaft runout should
not
exceed 0.035

inch
at any one
point.

DESCRIPTION

The drive shaft
is the
means
of

transferring power from
the
engine,

through
the
transmission,
to the dif-
ferential
in the
rear axle,
and
then
to

the rear wheels.
The
drive shaft incor-

porates
two
universal joints
and a
slip
yoke
(Fig. 1) or two
double cardan

universal joints,
one at
each
end of the

shaft (Figs.
2 and 3).
Each double
procarmanuals.com

05-01-04
Drive Shaft

05-01-04

tralizing.
If a
vibration exists,
the

drive shaft should
be
disconnected

from
the
axle, rotated 180 degrees
and

reinstalled.

3.
Install
the
U-blots
and
nuts that

attach
the
U-joint
to the
drive pinion

flange. Torque
the
U-bolt nuts
to

specification.
On
vehicles equipped

with
a
double cardan joint, install
the

rear joint-to-drive pinion flange
at-

taching bolts. Torque
the
bolts
to spe-

cification.

YOKE

C1773-A

FIG. 5—Output Shaft Spline Seal
—

Continental Mark
III
and Thunderbird

IN-VEHICLE REPAIR

USE SUPPORT STAND

AS
A
STEADY REST

E 1685-A

FIG. 6—Marking Driveshaft
CHALK MARK

CLAMPS 18d*FR0M CHALK MARK
*« >

E 1686-A

FIG. 7—Installing Whittek Clamps
E
1687-
A

. 8—Rotating Whittek Clamps

DRIVESHAFT BALANCING

(SINGLE UNIVERSAL JOINT)

If rotating
the
driveshaft
180 de-

grees does
not
eliminate vibration,
the

driveshaft
may be
balanced using
the

following procedure:

1.
Place
the
vehicle
on a
twin post

hoist
so
that
the
rear
of the
vehicle
is

supported
on the
rear axle housing

with
the
wheels free
to
rotate.

2.
With
the
driveshaft rotating
at a

speedometer speed
of
40-50
mph,
carefully bring
a
crayon
or
colored

pencil
up
until
it
just barely contacts

the rearward
end of
driveshaft
(Fig.

6).
The
mark made
by the
crayon
or

pencil will indicate
the
heavy side
of

the shaft. Care should
be
exercised

when working near
the
balance

weights
to
prevent injury
to the
hands.

3.
Install
two
Whittek type hose

clamps
on the
driveshaft
so
that
the

heads
are
located
180
degrees from

the crayon marking
(Fig. 7).
Tighten

the clamps.
4.
Run the
vehicle
up to
65-70
mph

speedometer speed.
If no
vibration
is

felt, lower
the
vehicle
and
road test.
If

unbalance still exists rotate
the
clamp

heads approximately
45
degrees away

from each other
and
test
for
vibration

(Fig.
8).

5.
Continue
to
rotate
the
clamp

heads apart
in
smaller amounts until

vibration
is
eliminated.
To
prevent

overheating,
do not run the
vehicle

on
the
hoist
for an
extended period.

6. Road test
the
vehicle.procarmanuals.com

05-02-01
General Clutch Service

05-02-01

PART
5-2
General Clutch Service

COMPONENT INDEX
MODEL APPLICATION

3

a>
1
o>

il

•U
i
!-

II

CLUTCH DISC

Cleaning and Inspection

02-04
02-04
02-04

02-04
02-04
02-04

02-04
02-04
N/A
N/A

N/A

CHECKING FLYWHEEL HOUSING

ALIGNMENT

02-01
02-01
02-01

02-01
02-01
02-01

02-01
02-01
N/A
N/A

N/A

CORRECTING FLYWHEEL HOUSING

ALIGNMENT

02-03
02-03
02-03

02-03

02-03
02-03

02-03

02-03
N/A
N/A

N/A

PILOT BUSHING

Cleaning and Inspection

02-04
02-04
02-04
02-04

02-04
02-04

02-04

02-04
N/A
N/A

N/A

PRESSURE PLATE AND COVER

Cleaning and Inspection

02-04
02-04
02-04
02-04

02-04
02-04

02-04
02-04
N/A

N/A

N/A

RELEASE BEARING

Cleaning and Inspection

02-04
02-04

02-04
02-04
02-04
02-04

02-04
02-04
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.

l
FLYWHEEL HOUSING ALIGNMENT

Alignment of the flywheel housing

bore and rear face with the engine

should be checked as a possible cause

of any of the following troubles- ex-

cessive transmission gear wear, ..ans-

mission jumping out of gear, especial-

ly third gear, drive line vibration, ex-

cessive pilot bushing wear, noisy re-

lease bearing, or excessive clutch spin

time.

INSPECTION

1. With the clutch release bearing

removed, install the indicator pilot

tool shown in Fig. 1.

2.
Clean the faces of the flywheel

housing bolt bosses, and remove all

burrs, nicks, and paint from the

mounting face of the housing.

3.
Install the dial indicator on the

pilot and adjust the holder so the but-

ton will contact a circumference just

inside of the transmission mounting

holes.

4.
Push the flywheel forward to re-

move crankshaft end play. Set the dial

indicator face to read zero.

5.
Remove the spark plugs to alle-

viate compression.

6. Pull the engine crankshaft

through one revolution. The crank-

shaft must be held in the forward po-

sition while rotating it.

7. Note the indicator reading and

mark the maximum point of runout

on the face of the housing (Fig. 1).
8. Position the dial indicator to

check bore alignment (Fig. 1). The

bore must be clean and free of burrs,

nicks and paint.

9. Pull the crankshaft through one

revolution. Note the indicator reading

and mark the maximum point of run-

out on the face of the housing as

shown in Fig. 1.

10.
Remove the dial indicator from

the crankshaft and the housing.

11.
Select the Dia-L-lgner pilot

(Fig. 2) which will fit snugly in the

bore of the flywheel housing.

12.
Press the pilot into place on the

locator on the back of the dial.
13.
Position the Dia-L-lgner on the

face of the housing (Fig. 3) with the

pilot in the bore.

14.
Rotate the face runout arrow to

the positive face runout mark on the

housing.

15.
Without moving the face runout

arrow, rotate arrow A until it is at the

negative bore reading.

16.
Slide arrow A to register the

amount of bore runout on the .010-

line of the white scale. Use the

scale No. to coincide with the pilot

being used.

17.
Rotate arrow B until it points

CHECKING
FACE
RUN OUT

CHECKING
BORE
RUN OUT

C
1783-
A

FIG.
1—Flywheel
Housing Alignment Checkprocarmanuals.com

05-02-03
General Clutch Service
05-02-03

in the direction of the face runout

arrow and its center line is parallel to

the center line of the face runout

arrow.

18.
Determine the amount of the

face runout on the B arrow scale.

19.
The value of the circular line

beneath the amount of face runout

will be the desired reading. If the

reading is in excess of 0.014 inch the

housing alignment is unacceptable.

20.
Remove the Dia-L-lgner gauge

from the flywheel housing.

21.
Install the spark plugs and con-

nect the wires.

ENGINE IN VEHICLE

Since any change in face alignment

will change bore alignment, it may be

possible to correct bore alignment by

changing face alignment. Face align-

ment can be changed by shimming be-

tween the flywheel housing and en-

gine.
Fig. 4 shows the type of shim

which can be fabricated.

Not more than 0.010 inch thickness

shims may be used between the fly-

wheel housing and engine. If a 0.010-

inch shim will not bring face and bore

alignment within limits, replace the

flywheel housing.

The shim required is one half the

maximum (—) indicator reading, and

should be located at the point of max-

imum minus (—) indicator reading.

If both the bore and face alignment

are out of limits, shim between the

flywheel housing and engine to bring

face alignment within limits. Check

the bore alignment.

If the bore alignment is out of lim-

its and the face alignment is within

limits,
shim the flywheel housing to

the limit of face misalignment and

check the bore alignment. If it is not

within limits, replace the housing.

ENGINE OUT OF VEHICLE

The same procedure to correct

alignment may be used with the en-

gine out of the vehicle or in the vehi-

cle,
up to the point of replacing the

flywheel housing. If the bore align-

ment cannot be brought within limits

by shimming, follow this procedure:

dure:

1.
Remove the flywheel housing

from the engine and remove the dowel

pins.
Install the flywheel housing and

tighten the attaching bolts.

2.
Install the dial indicator (Fig. 1).

Check the face alignment, and shim as
C2068-A

. 3—Dia-L-lgner Gauge Installed

required to bring face alignment with-

in limits.

3.
Position the indicator to check

the bore alignment. If the bore align-

ment is not within limits, reduce the

tension on the flywheel housing at-

taching bolts so that the housing can

be moved by striking it with a lead

hammer or a block of wood and a

steel hammer.

4.
The lateral alignment should be

brought within limits so that an indi-

cator reading is within limits between

the 9 o'clock and the 3 o'clock posi-

tions on the bore circle. When the lat-

eral alignment is within limits the

housing usually can be moved straight

up or down without disturbing the lat-

eral alignment. When alignment is

within limits, torque the housing bolts

and recheck bore alignment.

5.
If the flywheel housing cannot be

moved enough to bring the alignment

within limits, mark the holes restrict-

ing movement, and then remove the

housing and drill the marked bolt

holes 1/32 inch larger.

6. When the flywheel housing bore

alignment is within limits and the at-

taching bolts are at normal torque,
C 178 4-A

FIG. 4— Fabricated Flywheel

Housing Shim

hand ream the dowel pin holes 1/32

inch larger. Use a straight reamer and

ream from the flywheel housing side.

Oversize dowel pins can be made from

drill rod stock.

7.
Remove the flywheel housing

and then install the oversize dowel

pins in the cylinder block. Complete

the assembly in the usual way.

8. Recheck the flywheel housing

with the Dia-L-lgner gauge to make

sure that the housing is within the spe-

cified limits.procarmanuals.com