1969 FORD MUSTANG brake light

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

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

04-02-13

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

04-03-04
Rear Axles — Integral Carrier Type

04-03-04

1.
Remove the wheel cover, wheel

and tire from the brake drum.

2.
Remove the Tinnerman nuts that

secure the brake drum to the axle

housing flange, and then remove the

drum from the flange.

3.
Working through the hole pro-

vided in each axle shaft flange, re-

move the nuts that secure the wheel

bearing retainer plate. Then pull the

axle shaft assembly out of the axle

housing (Fig. 2). The brake backing

plate must, not be dislodged. Install

one nut to hold the plate in place after

the axle shaft is removed.

4.
If the rear wheel bearing is to be

replaced, loosen the inner retainer

ring by nicking it deeply with a cold

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

then slide off easily.

5.
Remove the bearing from the

axle shaft with the tool shown in Fig.

4 or 5. If the push-puller operation

shown in Fig. 5 is used, be sure that

the puller arms contact the flat sur-

face of the axle shaft flange rather

than the bolt heads. Also with this

method, be careful not to damage or

burr the oil seal journal as the bearing

breaks loose.

6. Whenever a rear axle shaft is re-

placed the oil seal must be replaced.

Remove the seal with the tools shown

in Fig. 8. Soak new oil seals in SAE

10 oil for 1/2 hour before installing.

7.
Inspect the machined surfaces of

the axle shaft and the axle housing for

rough spots or other irregularities

which would affect the sealing action

of the oil seal. Check the axle shaft

splines for burrs, wear or damage.

Carefully remove any burrs or rough

spots.
Replace worn or damaged

parts.

8. Lightly coat wheel bearing bores

with axle lubricant.

9. Place the retainer plate on the

axle shaft, and press the new wheel

bearing on the shaft with the tool

shown in Fig. 4 or 5. The bearing

should seat firmly against the shaft

shoulder. Do not attempt to press on

both the bearing and the inner retain-

er ring at the same time.

10.
Using the bearing installation

tool, press the bearing inner retainer

ring on the shaft until the retainer

seats firmly against the bearing.

11.
Wipe all lubricant from the in-

side of the axle housing in the area of

the oil seal before installing the new

seal.

12.
Wipe a small amount of oil res-

istant sealer on the outer edge of the

seal before it is installed. Do not put

sealer on the sealing lip.

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

corporated in production. However,

only leather seals will be used as re-

placements for the synthetic sealing

element seals. Install the new oil seal

with the tools shown in Fig. 8. Instal-

lation without use of the proper tool

will distort the seal and cause leakage.

Be sure the new seal has been soaked

in SAE 10 oil for 1/2 hour.

14.
Carefully slide the axle shaft

into the housing so that the rough

forging of the shaft will not damage

the oil seal. Start the axle splines into

the side gear, and push the shaft in

until the bearing bottoms in the housing.

15.
Install the bearing retainer plate

on the mounting bolts at the axle

housing, and install the attaching nuts.

Torque the nuts to specifications.

16.
Install the brake drum and the

drum retaining nuts.

17.
Install the wheel and tire on the

drum, and install the wheel cover.

REMOVAL AND REPLACEMENT

OF DRIVE PINION OIL SEAL

Synthetic seals must not be cleaned,

soaked or washed in cleaning solvent.

Replacement of the pinion oil seal

involves removal and installation of

only the pinion shaft nut and the uni-

versal joint flange. However, this op-

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

carefully reset when assembling.

1.
Raise the vehicle and install safe-

ty stands. Remove the rear wheels and

brake drums.

2.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

3.
Install an in-lb torque wrench on

the pinion nut Fig. 6. Record the tor-

que required to maintain rotation of

the pinion shaft through several revo-

lutions. \

4.
While holding the flange with the

tool shown in Fig. 9, remove the inte-

gral pinion nut and washer.

5.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

KJ
E
I582-A
Tool - 1175-AB

and T50T-100-A

^___ or
J
775-
AE

Torque Wrench

^ mm i e
icot
A

E 1681-A

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

Bearing Preload

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

Tool-T50T-100-A

REMOVAL
Tool-60K-1177-B

or 1177-BorC

INSTALLATION E1214-D

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

04-03-06

Rear Axles — Integral Carrier Type

04-03-06

9. Install a new integral nut and

ivasher on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 9 while the nut is being

tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, (Fig. 6)

and take frequent preload readings

until the preload is at the original rec-

orded reading established in step 3.

12.
After original preload has been

reached, tighten the pinion nut slowly,
until an additional preload of 6 to 12

in-lbs has been added.

The preload should not exceed the

amount shown above, or bearing fail-

ure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. (In

addition, the U-joint flange must

never be hammered on, or pneumatic-

-tools used.)

13.
Remove the oil seal replacer

tool from the transmission extension
housing. Install the front end of the

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

15.
Check the lubricant level. Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole, located in

the carrier casting or housing cover.

REMOVAL AND INSTALLATION

REAR AXLE HOUSING

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft at the drive

pinion flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in the

foregoing Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-
fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tools shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with me-

chanic's wire. The hydraulic brake

SCRIBE MARKS

5/16-24

4 REQ'D.

12-15
LB.
FT.

U-BOLT - 4529 2 REQ'D.

E 1783-A

FIG. 14—Drive Shaft-to-Axle

U-Joint
Connection

El231-A

FIG. 73—Rear Axle Installation—Typical
lines and the parking brake cables are

still attached to the brake carrier

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 13)

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operations.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install the

lower insulators. Torque the spring

clip nuts to specification.

2.
Place the brake backing plates in

their normal position on the axle

housing. Use new gaskets on each side

of the brake backing plates.

3.
Install new axle shaft oil seals

with the tool shown in Fig. 8. Soak

the new seals in light weight engine oil

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

ing them. Installation without use of

the proper tool will distort the seal

and cause leakage. Coat the outside

edges of the new oil seal with a non-

hardening type of sealer such as Per-

matex No. 2 or its equivalent.

4.
Install the axle shafts, brake

drums and wheels as outlined in Sec-

tion 2.

5.
Attach the hydraulic brake line

T fitting to the axle housing, and se-

cure the hydraulic brake line in its re-

tainer on the axle housing.

6. Install vent tube to brake tubeprocarmanuals.com

04-04-01

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

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

COMPONENT INDEX

AXLE HOUSING

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

DESCRIPTION

DIFFERENTIAL CASE

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND DRIVE

GEAR

Cleaning and Inspection

Removal and Installation

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING CUPS

Cleaning and Inspection

Removal and Installation
MODEL APPLICATION
AN
Models
Ford

01-09

04-04

01-10

04-06

04-01

01-10

04-07

04-06

01-10

04-08

01-10

04-08

01-10

04-08
Mercury
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Meteor
01-09

04-04

01-10

04-06

04-01

01-10

04-07

04-06

01-10

04-08

01-10

04-08

01-10

04-08
Cougar
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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

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

DESCRIPTION

A light-duty, integral-carrier, con-

ventional-type rear axle assembly (Fig.

1) is used in Ford and Meteor passen-

ger vehicles equipped with 240-IV and

302 2V engines and related transmis-

sions.
The axle (model WER) incor-

porates the following features:

The hypoid gear set consists of an

8.50 inch diameter ring gear and an

overhung drive pinion which is sup-

ported by two opposed tapered roller

bearings. A drive pinion pilot bearing

is not used in this axle.

The differential carrier is the non-

removable type, with a stamped bolt-

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

and uses a
1/2-14
tapered pipe plug

with a 3/8 inch square female drive. A

bumper pad is machined on the pinion

nose portion of the carrier. The rub-

ber bumper is mounted on the vehicle

underbody.

The differential case is a one-piece

design, with openings allowing assem-

bly of the internal components and lu-

bricant flow. The differential pinion

shaft is retained with a threaded bolt

(lock) assembled to the case.

The axle housing assembly consists

of tube assemblies pressed and welded

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

board of the outer edges of the tubes,

and allows assembly of the backing

plate, independent of the axle shafts.

The roller-type wheel bearings have

no inner race, and contact the bearing

journals of the axle shafts.

The axle shafts do not use an inner

or outer bearing retainer. They are

held in the axle by means of C-locks,

positioned in a slot on the splined end.

These C-locks also fit into a machined

recess in the differential side gears

within the differential case. There is

no retainer bolt access hole in the axle

shaft flange.
procarmanuals.com

04-04-02
Rear Axle
—
Ford Light-Duty (WER)
04-04-02

DIFFERENTIAL

PINION-4215
RING GEAR
-

4209
LEFT AXLE

SHAFT
-
4235

1

DRIVE PINION
-

4209

SEAL
-
4676

FLANGE-4851

DEFLECTOR -4859

SEAL-
1177

f\G.
7
—Rear Axle Assembly—Light Duty
(WER)
Axle
E 1632-A

IN-VEHICLE ADJUSTMENTS AND REPAIRS

REAR AXLE SHAFT, WHEEL

BEARING
AND OIL
SEAL

REPLACEMENT

REMOVAL

Synthetic wheel bearing seals
are

used
for
production
and as
service
re-

placements. Removal
and
insertion
of

rear axle shafts must
be
performed

with caution.
The
entire length
of the

shaft (including spline)
up to the
seal

journal must pass through
the
seal

without contact.
Any
roughing
or cut-

ting
of the
seal element during axle

removal
or
installation will result
in

early seal failure.

1.
Raise
the
vehicle
on a
hoist.
2.
Remove
the
wheel(s)
and
tire(s)

from
the
brake drum(s).

3.
Position
a
drain
pan and
loosen

the cover
to
differential housing
re-

taining bolts. Drain
the
housing.

4.
Remove
the
attaching (Tinner-

man) nuts that secure
the
brake

drum(s)
to the
axle shaft flange(s),

and then remove
the
drum(s).

5.
Remove
the
differential housing

cover bolts, cover
and
gasket. Discard

the gasket. Remove
the
drain
pan.

6. Position safety stands under
the

rear frame member. Lower
the
hoist

and allow
the
axle
to
lower
as far as

possible.

7.
Working through
the
differential

case opening, remove
the
pinion shaft
lock bolt
and the
pinion shaft
(Fig. 2).

8. Push
the
axle shaft(s) inward

toward
the
center
of the
axle housing.

Remove
the
C-lock(s)
(Fig. 3)
from

the inner
end of the
axle(s). Remove

the axle shaft(s) from
the
housing.
Ex-

treme care must
be
used
to
avoid
con-

tact
of the
axle shaft seal
lip
with
any

portion
of the
axle shaft except
the

seal journal.

9. Remove
the
bearing
and oil
seal

from
the
housing
as
shown
in Fig. 4.

10.
Inspect
the
machined surface
of

the axle shaft
and the
axle housing
for

rough spots
or
other irregularities

which would affect
the
sealing action

of
the oil
seal. Check
the
axle shaft

splines
for
burrs, wear
or
damage.procarmanuals.com