1969 FORD MUSTANG oil type

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

04-02-01

Rear Axle
—
Removable Carrier Type

04-02-01

PART
4-2
Rear Axle—Removable Carrier Type

COMPONENT INDEX

AXLE HOUSING (Coil Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE HOUSING (Leaf Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

CONVENTIONAL DIFFERENTIAL

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND RING

GEAR

Adjustment

Cleaning and Inspection

Removal and Installation

DIFFERENTIAL CARRIER

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

LIMITED SLIP DIFFERENTIAL

Cleaning and Inspection

Description

Disassembly and Overhaul

Removal and Installation

PILOT BEARING

Cleaning and Inspection

Removal and Installation

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING

Cleaning and Inspection

Removal and Installation

PINION BEARING RETAINER

Cleaning and Inspection

Removal and Installation

PINION SPACER (Collapsible)

Removal and Installation

PINION OIL SEAL

Removal and Installation
MODEL APPLICATION
All
Models

01-10

02-04

01-10

02-13

02-08

02-19

01-10

02-19

01-10

02-13

02-08

01-10

02-03

02-13

02-13

01-10

02-15

01-10

02-15

01-10

02-15

01-10

02-15

02-04
J

01-09

02-08

N/A

N/A

02-17
Mercury
01-09

02-08

N/A

N/A

N/A
Meteor
01-09

02-08

N/A

N/A

02-17
Cougar
N/A

N/A

01-09

02-11

02-17
Fairlane
N/A

N/A

01-09

02-11

02-17
Falcon
N/A

N/A

01-09

02-11

02-17
Montego
N/A

N/A

01-09

02-11

02-17
Mustang
N/A

N/A

01-09

02-11

02-17
Lincoln-
Continental
N/A

N/A

01-09

02-11

N/A
Thunderbird
01-09

02-08

N/A

N/A

N/A
Continental-
Mark
III
01-09

02-08

N/A

N/A

N/A

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

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

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

IN-VEHICLE ADJUSTMENTS AND REPAIRS

REAR AXLE SHAFT, WHEEL

BEARING AND OIL SEAL

REPLACEMENT

The rear axle shafts, wheel bear-

ings,
and oil seal can be replaced

without removing the differential as-

sembly from the axle housing.

REMOVAL OF

AXLE SHAFT

Synthetic wheel bearing seals are

used in production only. Removal and

insertion of rear axle shafts must be

performed with caution. The entire

length of the shaft (including spline)

up to the seal journal must pass

through the seal without cutting of the

seal element during axle removal or

installation will result in early seal fai-

lure.
Leather seals only will be used as

service replacement for synthetic

wheel bearing seals.

1.
Remove the wheel cover, wheel

and tire from the brake drum.

2.
Remove the nuts that secure the

brake drum to the axle shaft flange,

then remove the drum from flange.

3.
Working through the hole pro-

vided in each axle shaft flange, re-

move the nuts that secure the wheel

bearing retainer plate. Then pull the

axle shaft assembly out of the axle

housing (Fig. 4). The brake backing

plate must not be dislodged. Install

one nut to hold the plate in place after

the axle shaft is removed.

Too/-4235-C

E1032-D

FIG. 4—Removing Axle Shaft

REMOVAL OF REAR

WHEEL BEARING AND

SEAL

Synthetic seals must not be cleaned,

soaked or washed in cleaning solvents.

Removal of the wheel bearings from

the axle shaft makes them unfit for

further use.

1.
On all models except Ford, Mer-

cury or Meteor, if the rear wheel

bearing is to be replaced, loosen the

inner retainer ring by nicking it deeply

with a cold chisel in several places

(Fig. 5). It will then slide off easily.
E 1731-A

FIG. 5—Removing Rear Wheel

Bearing Retainer Ring

On Ford, Mercury and Meteor mo-

dels,
it is necessary to first drill a 1/4

inch hole not more than 5/16 inch

deep in the retainer ring surface bef-

ore using the cold chisel.

2.
Remove the bearing from the

axle shaft with the tool shown in Fig.

6 or Fig. 7.

3.
Whenever a rear axle shaft is re-

placed, the oil seal must be replaced.

Remove the seal with Tool 1175-AB

and a slide hammer (Fig. 8). If new

leather-type wheel bearing service

seals are to be installed, soak new oil

seals in SAE 10 oil for 1/2 hour

before installing.

INSTALLATION OF REAR

WHEEL BEARING AND

SEAL

1.
Inspect the machined surface of

the axle shaft and the axle housing for

rough spots or other irregularities

which would affect the sealing action

of the oil seal. Check the axle shaft

splines for burrs, wear or twist. Care-

fully remove any burrs or rough spots.

Replace worn or damaged parts.

2.
Lightly coat wheel bearing bores

with axle lubricant.

3.
Place the retainer plate on the

axle shaft, and press the new wheel

bearing on the shaft with the tool

shown in Fig. 6 or Fig. 9. Do not at-

tempt to press on both the bearing

and the inner retainer ring at the same

time.

4.
Using the bearing installation

tool (Tool 4621-A or 4234-4), press

the bearing inner retainer ring on the

shaft until the retainer seats firmly

against the bearing. On Ford, Mercu-

ry, or Meteor models, before assem-

bling the retainer onto the axle shaft,

the shaft journal and the inside di-
ameter of the retainer should be wiped

clean with a dry cloth. These parts

must not be degreased or lubricated.

5. Rear wheel oil seals with synthe-

tic sealing elements have been incor-

porated in production only. However,

leather seals only will be used as re-

placements for the synthetic sealing

elements. Install the new oil seal with

the tools shown in Figs. 10 and 12. Be

sure the new seal has been soaked in

SAE 10 oil for 1/2 hour before in-

stalling it. Wipe a small amount of oil

resistant sealer on the outer edge of

the seal before it is installed. Do not

put sealer on the sealing lip.

INSTALLATION OF

AXLE SHAFT

1.
Carefully slide the axle shaft into

the housing so that the rough forging

of the shaft will not damage the oil

seal. Start the axle splines into the

side gear, and push the shaft in until

the bearing bottoms in the housing.

2.
Install the bearing retainer plate

and the nuts that secure it. Torque the

nuts to specifications.

3.
Install the brake drum and the

drum attaching (Tinnerman) nuts.

4.
Install the wheel and tire on the

drum. Install the wheel cover.

DRIVE PINION OIL SEAL

REPLACEMENT

COLLAPSIBLE SPACER

Synthetic seals must not be cleaned,

soaked or washed in cleaning solvent.

The drive pinion oil seal can be re-

placed without removing the differen-

tial carrier assembly from the axle

housing.

1.
Raise the vehicle and install

safety stands. Remove both rear wheels

and brake drums.

2.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly (Fig. 11). Dis-

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission fluidprocarmanuals.com

04-02-06

Rear Axle — Removable Carrier Type

04-02-06

FIG. 7—Removing Wheel Bearing

leakage. Refer to the transmission

group for the appropriate tool.

3.
Install an in-lb torque wrench on

the pinion nut. Record the torque re-

quired to maintain rotation of the pi-

nion shaft through several revolutions.

4.
Scribe the pinion shaft and the

U-joint flange inner surface for as-

sembly realignment. While holding the

flange with the tool shown in Fig. 22

or Fig. 23, remove the integral pinion

nut and washer.

5.
Clean the pinion bearing retainer

around the oil seal. PlaSe a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

6. Using the tool shown in Fig. 24

or Fig. 25, remove the U-joint flange.

7.
Using the tool shown in Fig. 26

remove the drive pinion oil seal.

8. Clean the oil seal seat.

9. Install the new seal in the retain-

er, using the applicable tool shown in

Fig. 47.

10.
Check splines on the pinion

shaft to be sure they are free of burrs.

If burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion. Wipe the pinion

shaft clean.

11.
Apply a small amount of lubri-

cant to U-joint splines.

Align scribe marks on U-joint

flange and pinion shaft.

12.
Install the U-joint flange using

the tool shown in Fig. 46.
SCRIBE MARKS

AXLE SHAFT

FLANGE

Tool

4621-A

E1921A

FIG. 9—Installing Wheel Bearing

13.
Install a new integral nut and

washer on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut).

14.
Hold the flange with the tool

shown in Fig. 24 or Fig. 25 while

tightening nut.

15.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, and take

frequent preload readings until the

preload is at the original recorded

reading established in step 3.

16.
After original preload has been

reached, tighten the pinion nut slowly,

until an additional preload of 8 to 14

in-lb over the original reading is

reached. The preload should not ex-

ceed 8 to 14 in-lb over the original

reading, or bearing failure may result.

Under no circumstances should the pi-

nion 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.

17.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission output

shaft.

18.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

Tool-1177

or 4245-B

E1359-A
U-BOLT-4529 2 REQ'D.
5/l<>-24

4 REQ'D.

12-15
LB.
FT.

IE 1783-A

FIG. 8—
Removing
Rear Wheel

Bearing Oil Seal
FIG. 70—Installing Rear Wheel

Bearing Oil Seal
FIG. 11
— Drive
Shaft-To-Axle

U-Joint Connection

drive shaft end yoke and the axle U-

joint flange (Fig. 11).

19.
Check the lubricant level Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole.

SOLID SPACER

The drive pinion oil seal can be re-

placed without removing the differen-

tial carrier assembly from the axle

housing.

1.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly (Fig. 11). Dis-

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

2.
Make punch marks on the end

of the pinion shaft and the U-joint

flange inner surface for realignment.

While holding the flange with the tool

shown in Fig. 22 or Fig. 23, remove

the integral pinion nut and washer.

3.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

4.
Using the tool shown in Fig. 24

or Fig. 23, remove the U-joint flange.

5.
Using the tool shown in Fig. 26

remove the drive pinion oil seal.

6. Clean the oil seal seat.

7.
Install the new seal in the retain-

er, using the applicable tool shown in

Fig. 47.

8. Check splines on the pinion shaft

to be sure they are free of burrs. Ifprocarmanuals.com

04-02-07
Rear Axle — Removable Carrier Type

04-02-07

burrs are evident, remove them with a

fine crocus cloth, working in a rota-

tional motion, then wipe clean. Apply

a small quantity of lubricant to U-

joint splines.

9. Install the U-joint flange using

the tool shown in Fig. 46.

10.
Install a new integral attaching

nut and washer on the pinion shaft.

11.
Tighten the pinion attaching

nut, rotating the pinion several times

to seat the bearing, then torque the pin-

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

flange with the tool shown in Fig. 22

or Fig. 23 while the nut is being tight-

ened.

12.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission output

shaft.

13.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange.

14.
Check the lubricant level, and

add whatever amount of specified lu-

bricant is necessary to reach the lower

edge of the filler plug hole. Make sure

the axle is in running position when

the level is checked

ORIGINAL U-JOINT FLANGE

(IN VEHICLE REPLACEMENT)

Use procedure as outlined under

Drive Pinion Oil Seal Replacement.

Synthetic seals must not be cleaned,

soaked or washed in cleaning solvent.

INSTALLATION OF A NEW

UNIVERSAL JOINT FLANGE

COLLAPSIBLE SPACER

1.
Raise the vehicle and install

safety stands. Remove both rear wheels

and brake drums.

2.
Disconnect the drive shaft from

the axle U-joint flange. Be careful to

avoid dropping the loose universal

joint bearing cups. Hold the cups on

the spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission fluid

leakage. Refer to the transmission

group for the appropriate tool.
3.
Install an in-lb torque wrench on

the pinion nut. Record the torque re-

quired to maintain rotation of the pin-

ion shaft through several revolutions.

4.
While holding the flange with the

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

move the integral pinion nut and

washer.

5.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear. Syn-

thetic seals must not be cleaned,

soaked or washed in cleaning solvent.

6. Using the tool shown in Fig. 23

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

7.
Check splines on the pinion shaft

to be sure they are free of burrs. If

burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion, then wipe clean.

Apply a small amount of lubricant

to U-joint splines.

8. Install the U-joint flange using

the tool shown in Fig. 46.

9. Install a new integral nut and

washer on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 23 or Fig. 24 while the

nut is being tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, and take

frequent preload readings until the

preload is at the original recorded

reading established in step 3.

12.
After original preload has been

reached, tighten the pinion nut slowly,

until an additional preload of 8 to 14

in-lb over the original reading is

reached. (The preload should not ex-

ceed 8 to 14 in-lb over the original

reading, or bearing failure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. In

addition, the U-joint flange must

never be hammered on, or power tools

used.

13.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange.

15.
Check the lubricant level. Make

sure the axle is in running position.
Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole.

SOLID SPACER

1.
Disconnect the drive shaft from

the axle U-joint flange. Be careful to

avoid dropping the loose universal

joint bearing cups. Hold the cups on

the spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

2.
While holding the flange with the

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

move the integral pinion nut and

washer.

3.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

4.
Using the tool shown in Fig. 23

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

5.
Check splines on the pinion shaft

to be sure they are free of burrs. If

burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion, then wipe clean.

Apply a small amount of lubricant to

U-joint splines.

6. Install the U-joint flange using

the tool shown in Fig. 46.

7.
Install integral attaching nut and

washer on the pinion shaft.

8. Tighten the pinion attaching nut,

rotating the pinion several times to

seat the bearing, then torque the pin-

ion attaching nut to 180-220 ft-lbs.

Hold the flange with the tool shown in

Fig. 23 or Fig. 24 while the nut is

being tightened.

9. Remove the oil seal replacer tool

from the transmission extension hous-

ing. Install the front end of the drive

shaft on the transmission output shaft.

10.
Connect the rear end of the

drive shaft to the axle U-joint flange.

11.
Check the lubricant level, and

add whatever amount of specified lu-

bricant is necessary to reach the lower

edge of the filler plug hole. Make sure

the axle is in running position when

the level is checked.

DRIVE SHAFT PINION ANGLE

ADJUSTMENT

Refer to Group 3, Part 3-2 for this

procedure.procarmanuals.com

04-02-08
Rear Axle — Removable Carrier Type

04-02-08

REMOVAL AND INSTALLATION

CARRIER ASSEMBLY

REMOVAL

1.
Raise the vehicle on a hoist and

remove the two rear wheels and tires.

2.
Remove the two brake drums (3

Tinnerman nuts at each drum) from

the axle shaft flange studs. If diffi-

culty is experienced in removing the

drums, remove the brake adjuster

knockout slug or rubber plug (if so

equipped) and back off the brake

shoes.

3.
Working through the hole pro-

vided in each axle shaft flange, re-

move the nuts that secure the rear

wheel bearing retainer plate. Pull each

axle shaft assembly out of the axle

housing using axle shaft remover,

Tool 4235-C. (Fig. 4). Care must be

exercised to prevent damage to the

production-type synthetic oil seal, if so

equipped. Any roughing or cutting of

the seal element during removal or in-

stallation can result in early seal fail-

ure.
Install a nut on one of the brake

backing plate attaching bolts to hold

the plate to the axle housing after the

shaft has been removed. Whenever a

rear axle shaft is replaced, the wheel

bearing oil seals must be replaced.

Remove the seals with tool 1175AB.

4.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position at as-

sembly. Disconnect the drive shaft at

the rear axle U-joint. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their orig-

inal position relative to the flange

when they are assembled. Remove the

drive shaft from the transmission ex-

tension housing. Install an oil seal re-

placer tool in the housing to prevent

transmission leakage. Refer to the

transmission group for the appropriate

tool.

5.
Clean area around carrier to

housing surfaced with a wire brush and

wipe clean, to prevent dirt entry into

the housing. Place a drain pan under

the carrier and housing, remove the

carrier attaching nuts, and drain the

axle.
Remove the carrier assembly

from the axle housing.

INSTALLATION

Synthetic production-type wheel

bearing seals must not be cleaned,

soaked or washed in cleaning solvent.

1.
Clean the axle housing and

shafts using kerosene and swabs. To

avoid contamination of the grease in
the sealed ball bearings, do not allow

any quantity of solvent directly on the

wheel bearings. Clean the mating sur-

faces of the axle housing and carrier.

2.
Position the differential carrier

on the studs in the axle housing using

a new gasket between carrier and

housing. Install the carrier-to-housing

attaching nuts, and torque them to

specifications.

3.
Remove the oil seal replacer tool

from the transmission extension hous-

ing. Position the drive shaft so that

the front U-joint slip yoke splines to

the transmission output shaft.

4.
Connect the drive shaft to the

axle U-joint flange, aligning the scribe

marks made on the drive shaft end

yoke and the axle U-joint flange dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

5.
If the synthetic, production-type

wheel bearing seals were replaced with

service-type leather seals, soak the

new rear wheel bearing oil seals in

SAE 10 oil for 1/2 hour before instal-

lation. Wipe a small amount of an oil

resistant sealer on the outer edge of

each seal before it is installed. Do not

put any of the sealer on the sealing

lip.
Install the oil seals in the ends of

the rear axle housing with one of the

tools shown in Figs. 10 and 12.

Tool

T65F-1177.A

E 1571-A

FIG. 12—Rear Axle Shaft Bearing

Seal Installation

6. Install the two axle shaft assem-

blies in the axle housing. Care must

be exercised to prevent damage to the

oil seals. The shorter shaft goes into

the left side of the housing.

Carefully slide the axle shaft into

the housing so that the rough forging

of the shaft will not damage the oil

seal. Start the axle splines into the

differential side gear, and push the

shaft in until the bearing bottoms in

the housing.
7.
Install the bearing retainers on

the attaching bolts on the axle housing

flanges. Install the nuts on the bolts

and torque to specifications.

8. If the rear brake shoes were

backed off, adjust the brakes as out-

lined in Part 2-1 and install rubber

plugs in the adjuster slots.

9. Install the two rear brake drums

and the drum Tinnerman nuts.

10.
Install the rear wheels and tires.

11.
Fill the rear axle with specified

lubricant.

AXLE HOUSING (COIL

SPRING SUSPENSION)

REMOVAL

1.
Remove the carrier assembly

from the axle housing as outlined in

Differential Carrier Removal and In-

stallation.

2.
Position safety stands under the

frame rear members, and support the

axle housing with either a floor jack

or hoist.

3.
Disengage the brake line from

the clips that retain the line to the

axle housing.

4.
Disconnect the vent tube from

the rear axle housing.

5.
Remove the brake backing plate

assemblies from the axle housing, and

support them with wire. Do not dis-

connect the brake line.

6. Disconnect the lower studs of the

two rear shock absorbers from the

mounting brackets on the axle housing

(Fig. 13 and 14).

7.
Remove the attaching nut and

washer, and disconnect the track bar

from the mounting stud on the axle

housing bracket.

8. Lower the axle housing until the

coil springs are released. Lift out the

coil springs and insulators.

9. Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

10.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and the two eccentric washers (Fig.

13 and 14).

11.
Lower the axle housing and re-

move it from under the vehicle.

INSTALLATION

1.
Transfer the track bar mounting

stud from the old to the new housing.procarmanuals.com

04-02-11
Rear Axle — Removable Carrier Type

04-02-11

If the axle housing is new, install a

new vent. The hose attaching portion

must face toward the front of the ve-

hicle.

2.
If leather-type wheel bearing ser-

vice seals are to be installed, soak the

new rear wheel bearing oil seals in

SAE 10 oil for 1/2 hour before instal-

lation. Wipe a small amount of an oil

resistant sealer on the outer edge of

each seal before it is installed. Do not

put any of the sealer on the sealing

lip.
Install the oil seals in the ends of

the axle housing with one of the tools

shown in Fig. 10 and 12.

3.
Position the replacement axle

housing under the vehicle, and raise

the axle with a hoist or floor jack.

Connect the suspension lower arms to

their mounting brackets on the axle

housing with pivot bolts and nuts. Do

not tighten the bolts and nuts at this

point.

4.
Position the suspension upper

arm in its mounting bracket on the

axle housing, and install the adjusting

bolt, eccentric washers, lock washer

and nut. Leave the bolt and nut loose

at this point.

5.
Position the brake lines to the

axle housing, and secure with the re-

taining clips.

6. Install the brake backing plates

on the axle housing flanges.

7.
Connect the track bar to the

mounting stud, install the washer and

attaching nut, and torque to specifica-

tions.

8. Position the rear coil springs and

insulators in the pockets provided.

9. Connect the lower studs of the

two rear shock absorbers to the

mounting brackets on the axle hous-

ing. Install the attaching nuts, and

torque to specifications.

10.
Connect the vent tube to the

vent on the housing. If axle housing is

new, install a new vent.

11.
Clean the mating surfaces of

the axle housing and differential car-

rier. Position the carrier on the

mounting studs on the housing using a

new gasket between carrier and hous-

ing. Install the copper washers and the

carrier-to-housing attaching nuts, and

torque to specifications.

12.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, and

then raise the axle assembly to con-

trolled curb height (Fig. 15). Hold the

axle at controlled curb height by plac-

ing blocks or pieces of steel pipe be-

tween the axle housing and the bumper

rear screw on the side rail. (See speci-

fications for dimensions.)
FRAME

TIGHTEN ARM

ATTACHING BOLTS

AT 5-45/64 INCH

HEIGHT POSITION
5-45/64 INCH

HEIGHT FOR

INSTALLATION

OF ARMS

E 1600-B

FIG. 75 -Axle Normal Curb

Height and Controlled Height

for Arm Installation

13.
With the axle at controlled curb

height, torque the suspension upper

and lower arm front pivot bolts and

nuts to specifications. Torque the

lower arm-to-axle housing pivot bolts

and nuts to specifications.

14.
Remove the oil seal replacer

tool from the transmission extension

housing. Position the drive shaft so

that the front U-joint slip yoke splines

to the transmission output shaft.

15.
Connect the drive shaft to the

U-joint flange, aligning the scribe

marks made on the drive shaft end

yoke and the axle U-joint flange dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

16.
Carefully slide the two axle

shaft assemblies in the axle housing.

The shorter shaft goes into the left

side of the housing. Use care in slid-

ing the axle shafts into the housing so

that the rough forging of the shaft will

not damage the oil seal. Start the axle

splines into the differential side gear,

and push the shaft in until the rear

wheel bearing bottoms in the housing.

17.
Install the rear wheel bearing

retainers on the attaching bolts on the

axle housing flanges. Install the nuts

on the bolts and torque to specifica-

tions.

18.
If the rear brake shoes were

backed off, adjust the brakes as out-

lined in Part 2-1, and install rubber

plugs in the adjuster slots.

19.
Install the two rear brake

drums and the drum attaching (Tin-

nerman) nuts.

20.
Install the rear wheels and tires.

21.
Fill the rear axle to the bottom

of the filler plug hole located in either

the carrier casting or housing cover

with specified lubricant. Be sure that

the axle is in operating position.

22.
Road test the vehicle to be sure

that pinion and driveshaft angles are
correct. Any shudder during heavy ac-

celeration, or deceleration may require

a pinion and driveshaft angle re-

adjustment as detailed in Driveshaft

and Pinion Angle Adjustment, Group

3,
Part 3-2.

AXLE HOUSING (LEAF

SPRING SUSPENSION)

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly. Disconnect

the drive shaft at the drive pinion

flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in

Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-

fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tool shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with

mechanic's wire. The hydraulic brake

lines and the parking brake cables are

still attached to the brake backing

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 16).

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operation*.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install theprocarmanuals.com

04-02-13

Rear Axle
—
Removable Carrier Type
04-02-13

lower insulators. Torque
the
spring

clip nuts
to
specification.

2.
Place
the
brake backing plates
in

their normal position
on the
axle

housing.

3.
Install
new
axle shaft
oil
seals

with
the
tool shown
in Fig. 10.
Soak

the
new
seals
in
light weight engine
oil

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

ing them. Installation without
use of

the proper tool will distort
the
seal

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

hardening type
of
sealer such
as Per-

matex
No. 2 or its
equivalent.

4.
Install
the
axle shafts, brake

drums
and
wheels
as
outlined
in Sec-

tion
2.

5.
Attach
the
hydraulic brake line

T fitting
to the
axle housing,
and se-

cure
the
hydraulic brake line
in its re-

tainer
on the
axle housing.

6. Install vent tube
to
brake tube

junction
and
install vent hose
to
vent
tube.

7.
Raise
the
axle housing
and con-

nect
the
shock absorbers.

8. Connect
the
rear
end of the
drive

shaft
to the
axle U-joint flange, align-

ing
the
scribe marks made
on the

drive shaft
end
yoke
and the
axle
U-

joint flange.

9. Fill
the
axle with
the
proper

grade
and
amount
of
lubricant.

10.
Road test
the
vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY
OF

DIFFERENTIAL CARRIER

CONVENTIONAL

DIFFERENTIAL

A disassembled view
of the
rear

axle assembly
is
shown
in Fig. 17.

After mounting
the
carrier
in a

holding fixture, disassemble
the car-

rier
as
outlined
in the
following proce-

dures:

1.
Mark
one
differential bearing

cap
and the
mating bearing support

with punch marks
to
help position
the

parts properly during assembly
of the

carrier. Also, mark
one of the
bearing

adjusting nuts
and the
carrier with

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

ing assembly.

2.
Remove
the
adjusting
nut
locks,

bearing caps,
and
adjusting nuts. Then

lift
the
differential case assembly
out

of
the
carrier.

(Remove
the
bearing caps
by tap-

ping
the
caps lightly with
a
soft
mal-

let).

3.
Remove
the
differential bearings

with
the
tools shown
in Fig. 18.

4.
Mark
the
differential case, cover,

and ring gear
for
assembly
in the
orig-

inal position.

5.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the gear from
the
case
or tap it off

with
a
soft-faced hammer.

6. With
a
drift, drive
out the
differ-

AXLE HOUSING-4010

DIFFERENTIAL

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

and separate
the
2-piece differential

case.

7.
Drive
out the
pinion shaft with
a

brass drift
(Fig. 20).

8. Remove
the
gears
and
thrust

washers
(Fig. 48).

LIMITED-SLIP DIFFERENTIAL

1.
Remove
the
differential case

from
the
carrier
and
remove
the
bear-

ings from
the
differential case
in the

same manner
as the
conventional
dif-

ferential case.

2.
Place
the
differential case
in a

hydraulic press,
and
apply about
one

ton pressure across
the
case bearing

hubs while removing
the
ring gear
at-

FLAT WASHER (LIMITED SLIP ONLY)

DRIVE GEAR ATTACHING BOLT

DIFFERENTIAL CASE COVER -4206

DIFFERENTIAL PINION GEAR-4215

THRUST WASHER-4230

ADJUSTING NUT-4067

CARRIER HOUSING-4025

DRIVE PINION-4610
PINION BEARING

SPACER-4662

PINION FRONT

BEARING-4621

RING GEAR

PILOT BEARING-4A242

FIG. 17—Rear Axle Disassembled—Typical
PILOT BEARING

RETAINER-4627

PINION REAR

BEARING CUP-4616
DEFLECTOR-4859

PINION RETAINER-4668

SEAL-4676
FLANGE_4858
E1750-Aprocarmanuals.com