1969 FORD MUSTANG tires

03-12-05
Wheels
And
Tires

03-12-05

and sharp edges from valve hole
in

rim.

8. Mount first tire bead exercising

care
not to
pinch
air
container.

9. Start valve through hole
in rim.

Do
not
pull valve housing into place

at this time.

10.
Mount
the
second bead starting

just past
the
valve
so the
last portion

of
the
bead goes over
the rim at the

valve.

11.
Rotate
the
tire back
and
forth

to center
the
valve housing.

12.
Pull
the
valve housing into

place. Make certain that
the
rubber

valve ridge
is
visible around
thi
valve

housing
(Fig.
12).

13.
Tighten
the
core housing lightly

using pliers.

14.
Thread
the
Inflate-Chek adapt-

er onto
the
core housing.
15.
Inflate
the
inner chamber
to

seat
the
tire beads exercising care
not

to exceed
45 psi
pressure. Adjust this

inner chamber
air
pressure
to 15 psi

higher than
the
recommended tire

pressure.

F 1387
- A

FIG. 12—Valve Installation
16.
Remove
the
Inflate-Chek

adapter
and
adjust tire (outer cham-

ber) pressure
to the
recommended

pressure.

17.
Recheck inner chamber pres-

sure.

18.
Install valve
cap.

WHEEL
AND
TIRE

INSTALLATION

1.
Clean
all
dirt from
the hub and

drum.

2.
Position
the
wheel
and
tire
on

the
hub and
drum. Install
the
wheel

hub nuts
and
tighten them alternately

to draw
the
wheel evenly against
the

hub
and
drum.

3.
Lower
the
vehicle
to the
floor,

and torque
the hub
nuts
to
specifica-

tion.

MAJOR REPAIR OPERATIONS

HOISTING INSTRUCTIONS

Damage
to
steering linkage compo-

nents
and
front suspension struts
may

occur
if
care
is
not
exercised when
po-

sitioning
the
hoist adapters
of 2
post

hoists prior
to
lifting
the
vehicle.

If
a 2
post hoist
is
used
to
lift
the

vehicle, place
the
adapters under
the

lower arms
or the
No.
1
crossmember.

Do
not
allow
the
adapters
to
contact

the steering linkage.
If the
adapters

are placed under
the
crossmember,
a

piece
of
wood (2x4x16 inches) should

be placed
on the
hoist channel
be-

tween
the
adapters. This will prevent

the adapters from damaging
the
front

suspension struts.

FRONT WHEEL GREASE

SEAL
AND
BEARING

REPLACEMENT AND/OR

REPACKING

If bearing adjustment will
not
elimi-

nate looseness
or
rough
and
noisy
op-

eration,
the hub and
bearings should

be cleaned, inspected,
and
repacked

with specified wheel grease.
If the

bearing cups
or the
cone
and
roller

assemblies
are
worn
or
damaged, they

should
be
replaced.

DRUM BRAKES

1.
Raise
the
vehicle until
the
wheel

and tire clear
the
floor.

2.
Remove
the
wheel cover
or hub
cap.
Remove
the
grease
cap
from
the

hub.
Remove
the
cotter
pin,
nut
lock,

adjusting
nut, and
flat washer from

the spindjej, Remove
the
outer bearing

cone
and
roller assembly
(Fig.
1).

3.
Pull
the
wheel,
hub, and
drum

assembly
off the
wheel spindle.

4.
Remove
and
discard
the
grease

retainer. Remove
the
inner bearing

Too/-T69L-J102-A

F1476-A

FIG. 13—Removing Front Wheel

Bearing Cup—Except Lincoln

Continental
cone
and
roller assembly from
the hub

with Tool 1175AE.

5.
Clean
the
lubricant
off the
inner

and outer bearing cups with solvent

and inspect
the
cups
for
scratches,

pits,
excessive wear,
and
other
dam-

age.
If
the
cups
are
worn
or
damaged,

remove them with Tool T69L-1102-A

(Fig.
13).

6. Thoroughly clean
the
inner
and

outer bearing cone
and
roller assem-

blies with solvent
and dry
them thor-

oughly.
Do not
spin
the
bearings with

compressed
air.

Inspect
the
cone
and
roller assem-

blies
for
wear
or
damage,
and
replace

them
if
necessary.
The
cone
and
roller

assemblies
and the
bearing cups

should
be
replaced
as a
unit
if
damage

to either
is
encountered.

7. Thoroughly clean
the
spindle
and

the inside
of the hub
with solvent
to

remove
all old
lubricant.

Cover
the
spindle with
a
clean

cloth,
and
brush
all
loose dust
and

dirt from
the
brake assembly.
To
pre-

vent getting dirt
on the
spindle, care-

fully remove
the
cloth from
the

spindle.

8.
If the
inner and/or outer bearing

cup(s) were removed, install
the re-

placement cup(s)
in the hub
with
the

tool shown
in Fig.
14.
Be
sure
to
seat

the cups properly
in the hub.

9. Pack
the
inside
of the hub
with

specified wheel bearing grease.
Add

lubricant
to the hub
only until
the

grease
is
flush with
the
inside diame-

ter
of
both bearing cups
(Fig.
15).procarmanuals.com

03-12-06

Wheels And Tires

03-12-06

Tool-T56P-1217-A

INNER CUP

INSTALLATION
OUTER CUP

INSTALLATION

F1464-A

FIG. ^.Installing Front Wheel

Drum Bearing Cups

LUBR

F1427. A

FIG. 75—Front Wheel Hub

Lubrication

10.
All old grease should be com-

pletely cleaned from the bearings and

surrounding surfaces before repacking

them with new grease (C1AZ-

19590-B). The new lithium base grease

is not compatible with sodium base

grease which may have been present

on the bearing surfaces. Pack the

bearing cone and roller assemblies

with wheel bearing grease. A bearing

packer is desirable for this operation.

If a packer is not available, work as

much lubricant as possible between

the rollers and cages. Lubricate the

cone surfaces with grease.

11.
Place the inner bearing cone

and roller assembly in the inner cup,

Apply a light film of grease to the

lip(s) of the grease retainer and install

the new grease retainer with the rev-

erse end of the tool shown in Fig. 6.
Be sure that the retainer is properly

seated.

12.
Adjust the brake shoes as out-

lined in Group 2.

13.
Install the wheel, hub, and

drum assembly on the wheel spindle.

Keep the hub centered on the spindle

to prevent damage to the grease re-

tainer or the spindle threads.

14.
Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle, then install the ad-

justing nut (Fig. 1).

15.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

16.
Install the hub cap or wheel

cover.

DISC BRAKES

1.
Raise the vehicle until the wheel

and tire clear the floor.

2.
Remove the wheel cover or hub

cap from the wheel.

3.
Remove the wheel and tire from

the hub and rotor.

4.
Remove 2 bolts and washers that

attach the caliper to the spindle. Re-

move the caliper from the rotor and

wire it to the underbody to prevent

damage to the brake hose.

5.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock,

adjusting nut, and flat washer from

the spindle. Remove the outer bearing

cone and roller assembly (Fig. 2).

6. Pull the hub and rotor assembly

off the wheel spindle.

7.
Remove and discard the old

grease retainer and the inner bearing

cone and roller assembly from the

hub.
8. Clean the lubricant off the inner

and outer bearing cups with solvent

and inspect the cups for scratches,

pits,
excessive wear, and other dam-

age.
If the cups are worn or damaged,

remove them with Tool T69L-1102-A

(Fig. 13).

On Lincoln Continental models, re-

move worn or damaged cups with the

tools shown in Fig. 16.

9. Thoroughly clean the inner and

outer bearing cones and rollers with

computer solvent, and dry them

thoroughly. Do not spin the bearings

dry with compressed air.

Inspect the cones and rollers for

wear or damage, and replace them if

necessary. The cone and roller assem-

blies and the bearing cups should be

replaced as a set if damage to either is

encountered.

10.
Thoroughly clean the spindle

and the inside of the hub with solvent

to remove all old lubricant.

Cover the spindle with a clean

cloth, and brush all loose dust and

dirt from the dust shield. To prevent

getting dirt on the spindle carefully re-

move the cloth from the spindle.

11.
If the inner and/or outer bear-

ing cup(s) were removed, install the

replacement cup(s) in the hub with the

tools shown in Fig. 17. Be sure to seat

the cups properly in the hub.

12.
Pack the inside of the hub with

the specified wheel bearing grease.

Add lubricant to the hub only until

the grease is flush with the inside di-

ameter of both bearing cups.

It is important that all old grease

be removed from the wheel bearings

and surrounding surfaces because the

new Lithium base grease C1AZ-

19590-B is not compatible with Sodi-

um base grease which may already be

present on the bearing surfaces.

F 1502-A

FIG. 16—Removing Front Wheel Bearing Cup—Lincoln Continentalprocarmanuals.com

03-12-07
Wheels And Tires

03-12-07

Tool - 7277- K

F 1263-A

FIG. 17—Installing Front Wheel Bearing Cup

13.
Pack the bearing cone and roll-

er assemblies with wheel bearing

grease. A bearing packer is desirable

for this operation. If a packer is not

available, work as much lubricant as

possible between the rollers and cages.

Lubricate the cone surfaces with

grease.

14.
Place the inner bearing cone

and roller assembly in the inner cup.

Apply a light film of grease to the lips

of the grease retainer and install the

new grease retainer with the tool

shown in Fig. 18. Be sure the retainer

is properly seated.

15.
Install the hub and rotor as-

sembly on the wheel spindle. Keep the

hub centered on the spindle to prevent

damage to the grease retainer or the

spindle threads.

16.
Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle, then install the ad-

justing nut.

17.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

18.
Install the caliper to the spindle

and torque the attaching bolts to spe-

cifications as detailed in Group 2.

19.
Install the wheel and tire on the

hub.

20.
Install the hub cap or wheel

cover.

21.
Before driving the vehicle,

pump the brake pedal several times to

obtain normal brake lining to rotor

clearance and restore normal brake

pedal travel.
FRONT HUB AND DRUM

ASSEMBLY REPLACEMENT

When the hub and drum assembly

is replaced, new bearings and a grease

retainer must be installed in the new

assembly. The new grease retainer

should be soaked in light engine oil at

least 30 minutes before installation.

1.
Raise the vehicle until the wheel

and tire clears the floor. Pry off the

hub cap or wheel cover, and remove

the wheel and tire from the hub and

drum assembly.

2.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock

adjusting nut, and flat washer from

the spindle. Remove the outer bearing

cone and roller assembly (Fig. 1).

3.
Pull the hub and drum assembly

off the wheel spindle.

4.
Remuve the grease retainer and

the inner bearing cone and roller as-

sembly from the hub with Tool

1175AE.

5.
Remove the protective coating

from the new hub and drum with car-

buretor degreaser.

6. Pack the inside of the hub with

specified wheel bearing grease. Add

lubricant to the hub only until the

grease is flush with the inside diame-

ter of both bearing cups (Fig. 15).

7.
All old grease should be com-

pletely cleaned from the bearings be-

fore repacking them with new grease.

Pack the bearing cone and roller

assemblies with wheel bearing grease.

A bearing packer is desirable for this

operation. If a packer is not available,

work as much lubricant as possible

between the rollers and cages. Lubri-

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

roller assembly in the inner cup, and

install the new grease retainer with the

reverse end of the tool shown in Fig.

6. Be sure that the retainer is properly

seated.

9. Adjust the brake shoes as out-

lined in Group 2.

10.
Install the new hub and drum

assembly on the wheel spindle. Keep

the hub centered on the spindle to pre-

vent damage to the grease retainer.

11.
Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle; then, install the ad-

justing nut (Fig. 1).

12.
Position the wheel and tire on

the new hub and drum assembly. In-

stall the wheel hub nuts and tighten

them alternately in order to draw the

wheel evenly against the hub and

drum.

13.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

14.
Install the hub cap or wheel

cover.

FRONT HUB AND ROTOR

ASSEMBLY REPLACEMENT

When the hub and rotor assembly is

replaced, new bearings and a grease

retainer must be installed in the new

assembly.

1.
Raise the vehicle until the wheel

and tire clear the floor. Pry off the

hub cap or wheel cover, and remove

the wheel and tire from the hub and

rotor assembly.

2.
Remove 2 bolts and washers that

attach the caliper to the spindle. Re-

move the caliper from the rotor and

wire it to the underbody to prevent

damage to the brake hose.

3.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock,

adjusting nut, and flat washer from

the spindle; then, remove the outer

bearing cone and roller assembly,

(Fig. 2).

4.
Pull the hub and rotor off the

spindle.

5.
Remove the protective coating

from the new hub and rotor with car-

buretor degreaser.

6. Grease and install the inner

bearing cone and roller assembly in

the inner bearing cup. Apply a light

film of grease on the grease retainerprocarmanuals.com

03-12-08

Wheels And Tires

03-12-08

Tool -
7
775 - AH

F1443-A

FIG.
18
— Installing Grease

Retainer
and install the grease retainer.

7.
Install the new hub and rotor as-

sembly to the wheel spindle. Keep the

hub centered on the spindle to prevent

damage to the grease retainer.

8. Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle; then, install the ad-

justing nut.

9. Install the caliper to the spindle

and tighten the attaching bolts to spe-

cifications as detailed in Group 2.

10.
Position the wheel and tire on

the new hub and rotor. Install the

wheel hub nuts and tighten them alter-

nately in order to draw the wheel

evenly against the hub and rotor.

11.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

12.
Install the hub cap or wheel

cover.

13.
Before driving the vehicle,

pump the brake pedal several times to

obtain normal brake lining to rotor

clearance and restore normal brake

pedal travel.
LIFE GUARD

TIRE REPAIRS

REPAIR OF OUTER TIRE

Outside Repairs

All outside repairs are made in the

same manner as on conventional tube-

less tires.

Inside Repairs

1.
Remove the anti-friction treat-

ment on the inside of the tire with

rubber solvent.

2.
Buff the inside area of the tire.

3.
Apply a hot cure patch only.

REPAIR OF AIR

CONTAINER

Air containers are repaired in the

same manner as conventional inner

tubes.

REPAIR OF LIFE GUARD

A damaged life guard that may

pinch the air container should be re-

place. No repairs are required for

small punctures in the life guard.procarmanuals.com

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

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

04-04-04

REMOVAL AND INSTALLATION

AXLE HOUSING

Refer to Fig. 7.

REMOVAL

1.
Raise the vehicle on a hoist.

2.
Remove the wheels and tires

from the brake drums.

3.
Position a drain pan and loosen

the rear axle cover to housing attach-

ing bolts. Drain the housing.

4.
Remove the attaching (Tinner-

man) nuts that secure the brake drums

to the axle shaft flanges, and then re-

move the drums (Fig. 7).

5.
Remove the axle housing cover

bolts,
cover and gasket. Discard the

gasket. Remove the drain pan.

6. Disconnect the drive shaft at the

drive pinion companion flange. Re-

move the drive shaft from the trans-

mission extension housing. Install an

oil seal replacer tool in the transmis-

sion housing to prevent leakage. Refer

to the transmission group for the ap-

propriate tool.

7.
Disconnect the lower end of the

shock absorbers at the mounting

brackets.

8. Disconnect the track bar from

the axle housing stud. If the axle

housing is to be replaced, transfer the

stud to the new housing.

9. Position safety stands under the

rear frame members. Lower the vehi-

cle with the hoist and allow the axle

to lower far enough to relieve rear

spring tension.

10.
Remove the pinion shaft lock

bolt and pinion shaft (Fig. 2), differ-

ential pinion gears and thrust washers.

11.
Push the axle shaft(s) inward

toward the center of the axle housing.

Remove the C-locks from the inner

ends of the axles (Fig. 3). Remove the

axle shafts from the housing. Extreme

care must be used to avoid contacting

the axle shaft seal lip with any portion

of the axle shaft other than the seal

journal.

12.
Disconnect the vent hose from

the rear vent tube and remove all

brake lines from the axle housing re-

taining clips.

13.
Remove the brake backing

plate attaching nuts and the plates

from the axle housing. Suspend the

plates above the axle housing with

mechanics wire. The hydraulic brake

lines and the parking brake cables will

remain attached to the brake backing

plates.
14.
Support the rear axle housine

on a jack.

15.
Remove the right and left rear

springs and insulators.

16.
Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

17.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and two eccentric washers.

18.
Lower the rear axle to the floor

with the jack and remove the axle

from under the vehicle.

19.
Remove the wheel bearings and

oil seals with the tool shown in Fig. 4.

20.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. Refer

to Section 4, Major Repair Operation

for the procedure.

INSTALLATION

1.
Lightly coat the wheel bearing

rollers with axle lubricant. Install

wheel bearings in the axle housing

with the tool shown in Fig. 5. The

bearings should seat firmly against the

shoulder.

2.
Wipe all lubricant from the oil

seal bore before installing the seal. If

axle housing is being replaced, new

seals must be installed.

3.
Inspect the original seal for

nicks,
scuffs or abnormal wear, and

replace if necessary. New seals are

pre-packed with lubricant and do not

require an oil soak.

4.
Install the seal with the tool

shown in Fig. 6. Installation without

the use of the proper tool will distort

the seal and cause leakage.

5. Raise the rear axle into position

under the vehicle with a hoist or floor

jack. Connect the suspension lower

arms to their mounting brackets on

the axle housing with pivot bolts and

nuts.
Do not tighten the mounting

bolts at this point.

6. Position the suspension upper

arm in its mounting bracket on the

axle housing and install the adjusting

bolt, eccentric washers, lock washer

and nut. Do not tighten the mounting

bolt at this point.

7.
Place the rear coil springs and

insulators into position in the pockets

provided.
8. Place the brake backing plates

on the axle housing flanges, install 4

attaching bolts and nuts and torque

them to specifications.

9. Position the brake lines to the

axle housing and secure them with the

retaining clips. If the axle housing is

new, install a new vent. When install-

ing the new axle vent apply a small

amount of Locktite (C5AZ-19554-B)

to prevent oil leakage between vent

and axle housing. Connect the vent

tube to the vent.

10.
Install the pinion side gears and

thrust washer.

11.
Slide the axle shafts into place

in the axle housing. Exercise care that

splines or any portion of the axle

shafts do not damage the oil seals and

that they engage with the splines of

the differential side gears.

12.
Install the axle shaft C-lock O-

ring and C-lock on the inner end of

the shaft and push the shaft outward

so that the shaft lock seats in the

counterbore of the differential side

gear.

13.
Position the pinion differential

gears and thrust washers 180 degrees

apart to the differential side gears.

Revolve the gear assembly until the

holes in the differential case are al-

igned with the pinion gears.

14.
Position the differential pinion

shaft through the case and pinions, al-

igning the hole in the shaft with the

lock bolt hole. Install the lock bolt

and tighten it to specification.

15.
Clean the gasket mounting sur-

face of the rear axle housing and the

cover. Install a new cover gasket,

cover and the attaching bolts. Torque

the bolts to specification.

16.
Raise the rear axle on a hoist

and remove the safety stands.

17.
Connect the track bar to the

mounting stud. Install the washer and

nut. Torque the nut to specification.

18.
Connect the two rear shock ab-

sorbers to the mounting brackets on

the axle housing and torque the at-

taching nuts to specification.

19.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, then

raise the axle assembly to the con-

trolled height (Fig. 8). Hold the axle

at the controlled height by placing

blocks or pieces of steel pipe between

the axle housing and the bumper rear

screw on the side rail.procarmanuals.com

04-04-10
Rear Axle — Ford Light-Duty (WER)

04-04-10

the differential case and ring gear as-

sembly in the carrier without regard

to the matching of any particular gear

teeth.

12.
Slide the case assembly along

the bores until a slight amount of

backlash is felt between the gear teeth.

Hold the differential case in place.

13.
Set the adjusting nuts in the

bores so that they just contact the

bearing cups.

14.
Carefully position the bearing

caps on the carrier casting. Match the

marks made when the caps were re-

moved (Fig. 21).

15.
Install the bearing cap bolts

and lockwashers. As the bolts are

tightened, turn the adjusting nut with

the tool shown in Fig. 21.

16.
If the adjusting nuts do not turn

freely as the cap bolts are tightened,

remove the bearing caps and again in-

spect for damaged threads or incor-

rectly positioned caps. Tightening the

bolts to the specified torque is done to

be sure that the cups and adjusting
.BEARING CAP IDENTIFICATION-j

MARKS
A

T57L-4067-A

E 1583-A

27—Bearing Cap Installation

nuts are seated. Loosen the cap bolts,

and torque them to only 5 ft-)bs be-

fore making adjustments. Refer to

part 4-1, Section 2 of this shop manu-

al for backlash and bearing preload

adjustment procedures.

17.
Clean the marking compound

from the gear teeth.

18.
Install both side bearing adjust-

ing nut locks (bolts) and torque them

to specification.
19.
Install the differential pinion

side gears and thrust washers.

20.
Install the rear wheel bearings

seals,
rear axle shafts, wheels and tires

and the axle carrier cover as outlined

under Part 4-3, Section 2, Rear Axle

Shaft, Wheel Bearing and Oil Seal

Replacement, Steps 10 through 19.

21.
Raise the axle all the way up.

Rdnove the safety support stands.

22.
Connect the track bar to the

mounting stud. Install the washer and

retaining nut, and torque the nut to

specification.

23.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission.output

shaft. Align the scribe marks on the

cups,
flange and drive shaft and con-

nect the rear end of the drive shaft to

the axle U-joint flange. Torque the re-

taining bolts to specification.

24.
Lower the vehicle.procarmanuals.com