1969 FORD MUSTANG tow

04-01-08
General Axle Service

04 01-08

Too/-T57L-4067-A

E 1595-A

FIG.
14
—Adjusting Side Bearing Preload—Typical

at this time to be sure that it is still

loose.) Tightening the left nut moves

the ring gear into the pinion to de-

crease backlash, and tightening the

right nut moves the ring gear away.

3.
Install a dial indicator as shown

in Fig. 14.

4.
Tighten the right nut until it first

contacts the bearing cup. Then pre-

load the bearings from 0.008-0.012

inch case spread. Rotate the pinion

gear several revolutions in each direc-

tion while the bearings are loaded, to

seat the bearings in their cups to be

sure no bind is evident. This step is

important.

5. Again loosen the right nut to re-

lease the pre-load. If there is any

backlash between the gears as shown

by the dial indicator,(Fig.l2 or Fig. 10

Part 4-4) tighten the left nut just en-

ough to remove this backlash. At this

time,
make sure that one of the slots

in the left nut is so located that the

lock can be installed without turning

the nut. Carefully, tighten the right

nut until it just contacts the cup.

6. Torque the differential cap bolts

to specification.

On integral carrier type axles, set a

preload of 0.008 to 0.012 inch case

spread for new bearings and 0.003 to

0.005 for the original bearings.

On removable carrier type axles,

the preload is 0.008 to 0.012 inch case

spread for new bearings and 0.005 to

0.008 for the original bearings. As

preload is applied from the right side,

the ring gear is forced away from the

pinion and usually results in the cor-

rect backlash.

7.
Measure the backlash on several

teeth around the ring gear. If the

measurements vary more than 0.003

inch (both integral and removable car-

rier) there is excessive runout in the
gears or their mountings, which must

be corrected to obtain a satisfactory

unit. If the backlash is out of specifi-

cation, loosen one adjusting nut and

tighten the oposite nut an equal a-

mount to move the ring gear away

from or toward the pinion. When

moving the adjusting nuts, the final

movement should always be made in a

tightening direction. For example, if

the left nut had to be loosened one

notch, loosen the nut two notches,

then tighten it one. This insures that

the nut is contacting the bearing cup,

and that the cup cannot shift after

being put in service. After all such ad-

justments, check to be sure that the

case spread remains as specified for

the new or original bearings used.

8. Again check the tooth contact

pattern. If the pattern is still incor-

rect, a change in pinion location (shim

thickness) is indicated.

PINION LOCATION

Removable Carrier Type Axle

1.
Remove the attaching bolts and

the pinion and bearing retainer assem-

bly from the carrier.

2.
Measure the original shim thick-

ness with a micrometer. Increase or

decrease the shim thickness as indicat-

ed by the tooth pattern check des-

cribed in Section 1.

3.
Replace the pinion retainer O-

ring (Fig. 39, Part 4-2). Coat the O-

ring with axle lubricant before install-

ing. Do not roll the O-ring into the

groove. Snap it into position.

4.
Being careful not to pinch the

O-ring, install the pinion and bearing

retainer assembly in the carrier with

the corrected shim pack.

Before installing the pinion and

bearing retainer assembly, determine

which type of gear set is being used.
The non-hunting and pantial non-

hunting types can be identified by the

paint timing marks on the gear teeth

(Fig. 51, Part 4-2). Part 4-5 can also

be referred to for identification.

If the gear set is of the non-hunting

or partial non-hunting type clean the

teeth on both the pinion and drive

gear so that the timing marks are vis-

ible.
Rotate the differential case and

ring gear assembly in the carrier until

the marked teeth on the ring gear are

opposite the pinion entry hole. Place

the assembly in the carrier so that the

marked tooth on the pinion indexes

between the marked teeth on the ring

gear (Fig. 51, Part 4-2).

In almost every case of improper

assembly (gear assembled out of time)

the noise level and probability of fai-

lure will be higher than they would be

with properly assembled gears.

When installing the hunting type

gear set (no timing marks), assemble

the pinion and retainer assembly into

the carrier without regard to the

matching on any particular gear teeth.

5.
Install the retainer-to-carrier

mounting bolts and torque to specifi-

cations.

6. Adjust the backlash between the

ring gear and pinion as outlined in the

foregoing procedures.

7.
Make a tooth pattern check. If

the pattern is still unsatisfactory, re-

peat this procedure changing the shim

thickness each time until a satisfactory

tooth pattern is obtained.

Integral Carrier Type Axle

1.
Remove the differential case and

the drive pinion from the carrier cast-

ing, and then remove the pinion bear-

ings as described under Removal of

Differential Case and Drive Pinion in

Section 4.

2.
Measure the original shim thick-

ness with a micrometer. Increase or

decrease the shim thickness as indicat-

ed by the tooth pattern check des-

cribed in the foregoing Section 1 and

shown in Fig. 4.

3.
Install the corrected shim pack

and the bearings on the pinion, and

then install the pinion and the differ-

ential case in the carrier casting as

outlined under Installation of Drive

Pinion and Differential Case in Sec-

tion 4 of Part 4-3.

4.
Adjust the backlash between the

ring gear and pinion as outlined in the

foregoing procedure.

5.
Make a tooth pattern check. If

the pattern is still unsatisfactory, re-

peat this procedure changing the shim

thickness each time until a satisfactory

tooth pattern is obtained.procarmanuals.com

REAR SPRING

5560

VENT

TUBE

INDENT TOWARD

FRONT OF VEHICLE
UPPER ARM

5500

LEFT ARM INDENTED

BY 2 NOTCHES IN BUSHING FLANGE

F 1353-A

f/Q.
J3—Rear Axle Installation—Typical Coil Spring Suspensionprocarmanuals.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

04-04-02
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

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

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

RUNOUT CHECK

E 1573-A

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

All service operations on the differ-

ential case assembly can be performed

with the axle housing in the vehicle.

1.
Raise the vehicle on a hoist.

2.
Position the drain pan under the

axle housing. Loosen the housing

cover attaching bolts. Drain the lubri-

cant from the housing.

3.
Make scribe marks on the drive

shaft end yoke and the rear axle shaft

companion flange to insure proper po-

sition of the drive shaft at assembly.

Disconnect the driveshaft from the

rear axle companion flange. Be care-

ful to avoid dropping the loose univer-

sal joint bearing cups. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their origi-

nal position in relation to the flange

when they are reassembled. Remove

the drive shaft from the transmission

extension housing. Install an oil seal

replacer tool in the transmission ex-

tension housing to prevent transmis-

sion leakage. Refer to the transmis-

sion group for the appropriate tool.

4.
Raise the vehicle and place

jack-type stands under the rear frame

crossmember. Lower the vehicle on a

hoist and allow the axle to lower as

far as possible.

5.
Remove the axle housing cover

and gasket. Discard the gasket.

6. Perform the Inspection Before

Disassembly of Carrier procedure.

Refer to Part 4-1, Section 3 of this

Shop Manual.

7.
Remove the attaching (Tinner-

man) nuts that secure the rear brake

drums to the axle shaft flanges, and

then remove the drums.

8. Working through the differential

case opening, remove the pinion shaft

lock bolt and pinion shaft (Fig. 2).

9. Push the axle shafts inward

toward the center of the axle housing.

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

inner ends of the rear axles. Remove

the axle shafts from the housing. Ex-

treme care must be used to avoid con-

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

seal journal.

10.
Remove the bearings and oil

seals from the axle housing as shown

in Fig. 4.

11.
Remove the pinion side gears

and the side gear thrust washers.

12.
Remove both side bearing ad-

justing nut locks (bolts).

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

and check and record the backlash

and ring gear runout.

14.
Mark one differential bearing

cap and the case to help in positioning

the parts properly during assembly.

15.
Remove the bearing cap retain-

ing bolts. Remove the bearing caps,

cups,
adjusting nuts and case assem-

bly.

16.
Hold the drive pinion flange

and remove the pinion nut (Fig. 11).

Discard the nut.

17.
Remove the pinion flange (Fig.

12).

18.
Drive the pinion out of the

front bearing cone and remove it from

the carrier housing. Remove and dis-

card the bearing spacer.

19.
With a hammer and drift re-

move the pinion shaft oil seal out

through the front of the carrier hous-

ing.

20.
Remove the pinion rear bearing

from the drive pinion shaft (Fig. 13).

21.
Measure the shim which is

found under the bearing cone with a

Tool-T57L-485T-A

or 4851-K

El 906A
Tool
-
T6SL-485UA
\

E 1574-A

FIG. 12—Drive Pinion Flange

Removal

1575-A

FIG. 13—Pinion Rear Bearing

Removal

00/
- T57L-4220-A

FIG. 11—Typical Drive Pinion

Shaft Nut Removal
E 1576-A

FIG. 14—Differential Bearing

Removal

micrometer. Record the thickness of

the shim.

DISASSEMBLY OF

DIFFERENTIAL CASE

1.
If the 2 differential side bearings

are to be removed from the differen-

tial case, use the tool shown in Fig.

14.procarmanuals.com

05-01-03
Drive Shaft

05-01-03

DUST SEAL-4859

BALL SOCKET-4A031

UNIVERSAL

JOINT KIT-4635

WASHER

BALL SEAT i \ SPRING

BEARING \\ RETAINER

SEAL

0 \ X \
CENTER

\ \ RETAINER \ YOKE-47R4

SPRING \

BALL SOCKET-4A031

SLIP YOKE-4841

C1770-A

FIG.
3—Drive Shaft and Universal Joints Disassembled —Thunderbird, Continental Mark

REMOVAL AND INSTALLATION

REMOVAL

1.
To maintain drive line balance,

mark the relationship of the rear drive

shaft yoke and the drive pinion flange

of the axle (if the yellow alignment

marks are not visible) with the shaft

so that they may be installed in their

original positions.

2.
Disconnect the rear U-joint or

rear double cardan joint from the

companion flange. Wrap tape around

the loose bearing caps to prevent

them from falling off the spider. Pull

the drive shaft toward the rear of the

vehicle until the slip yoke clears the

transmission extension housing and

the seal. On Lincoln Continental

models, remove the three roller bear-

ing assemblies off the spline teeth in-

side the slip yoke (Fig. 3). Install the

appropriate tool in the extension

housing to prevent lubricant leakage.

INSTALLATION

1.
If either the rubber seal on the

output shaft or the seal in the end of

the transmission extension housing is
damaged in any manner, replace the

seal or seals as required. Also, if the

lugs on the axle pinion flange are

shaved or distorted so that the bear-

ings slide, replace the flange.

2.
On Lincoln Continental models,

install the bearing assemblies over the

spline teeth in the slip yoke. Lubricate

the yoke spline with B8A-19589-A lu-

bricant. This spline is sealed so that

the transmission fluid does not

"wash" away the spline lubricant

(Figs.
4 and 5). Remove the tool from
the extension housing. Install the yoke

on the transmission output shaft. Do

not allow the yoke assembly to bot-

tom on the output shaft with excessive

force.

Install the drive shaft so that the

index marks or the yellow mark (if

visible) on the yoke (light side) is in

line with the yellow mark on the com-

panion flange. This prevents vibration

which occurs when the balance of the

shaft and balance of the axle pinion

flange become additive instead of neu-

01L SEAL (AUTOMATIC TRANSMISSION ONLY)

YOKE

SNAP RING (WRAP TYPE)

. 4—Output Shaft Spline Seal — All except Continental

Mark III and Thunderbird
E U73-Cprocarmanuals.com

06-02-09
Ford Design Three Speed Transmission

06-02-09

PRESS
RAM

OUTPUT SHAFT

SYNCHRONIZER
PRESS
RAM

OUTPUT SHAFT
Tool-T63P7025-A

SYNCHRONIZER

HUB

REMOVAL INSTALLATION c 1718-A

FIG. 22—Removing
and
Installing First
and
Reverse Synchronizer

5.
The
first
and
reverse synchroniz-

er
hub is a
press
fit on the
output

shaft.
To
eliminate
the
possibility
of

damaging
the
sychronizer assembly,

install
the
synchronizer
hub
with
the

teeth
end of the
gear facing toward

the rear
of the
shaft, using
an
arbor

press
as
shown
in Fig. 22. Do not at-

tempt
to
remove
or
install
the hub by

hammering
or
prying.

6. Place
the
blocking ring
on the

tapered machined surface
of the
first

gear.

7.
Slide
the
first gear onto
the out-

put shaft with
the
blocking ring

toward
the
rear
of the
shaft. Rotate

the gear
as
necessary
to
engage
the

three notches
in the
blocking ring with

the synchronizer inserts. Secure
the

first gear with
the
thrust washer
and

snap ring.

8. Slide
the
blocking ring onto
the

tapered machined surface
of the sec-

ond gear. Slide
the
second gear with

blocking ring
and the
second
and
third

gear synchronizer onto
the
mainshaft.

The tapered machined surface
of the

second gear must
be
toward
the
front

of
the
shaft. Make sure that
the

notches
in the
blocking ring engage

the synchronizer inserts. Secure
the

synchronizer with
a
snap ring.

9. Coat
the
bore
of the
input shaft

and gear with
a
thin film
of
grease.
A

thick film
of
grease will plug
the lu-

bricant holes
and
prevent lubrication

to
the
bearings. Install
the 15
bearings

(Fig.
15) in the
bore.

10.
If
working
on a RAT
model

transmission, install
the
input gear

and bearing through
the top of the

case
and
through
the
bore
in
front
of

the case.
On RAN
models,
me
input

shaft
is
installed through
the
front
of

the transmission. Install
the
snap ring

in
the
bearing groove.
11.
Position
the
output shaft
as-

sembly
in the
case. Position
the sec-

ond
and
third-speed shift fork
on the

second
and
third-speed synchronizer.

12.
Place
a
detent plug spring
and

a plug
in the
case
(Fig. 9).
Place
the

second
and
third-speed synchronizer
in

the second speed position (toward rear

of transmission). Align
the
fork
and

install
the
second
and
third-speed shift

rail.
It
will
be
necessary
to
depress
the

detent plug
to
enter
the
rail
in the

bore.
Move
the
rail inward until
the

detent plug engages
the
forward notch

(second-speed position).

13.
Secure
the
fork
to the
shaft

with
the set
screw. Move
the
synchro-

nizer
to the
neutral position.

14.
Install
the
interlock plug
in the

case.
If the
second
and
third-speed

shift rail
is in the
neutral position,
the

top
of the
interlock will
be
slightly

lower than
the
surface
of the
first
and

reverse shift rail bore.

15.
Move
the
first
and
reverse
syn-

chronizer forward
to the
first-speed

position. Place
the
first
and
reverse

shift fork
in the
groove
of the
first

and reverse synchronizer. Rotate
the

fork into position
and
install
the
first

and reverse shift rail. Move
the
rail

inward until
the
center notch (neutral)

is aligned with
the
detent bore. Secure

the fork
to the
shaft with
the set

screw.

16.
Install
a new
shift rail expan-

sion plug
in the
front
of the
case.

17.
Hold
the
input shaft
and
block-

ing ring
in
position. Then move
the

output shaft forward
to
seat
the
pilot

in
the
roller bearings
of the
input

gear.

18.
Tap the
input gear bearing into

place
in the
case while holding
the

output shaft
to
prevent
the
roller bear-

ings from dropping. Install
the
front
C1806-A

FIG. 23—Installing Output Shaft

Rear Bearing

bearing retainer
and new
gasket
mak-

ing sure that
the oil
return slot
is at

the bottom
of the
case. Install
and

torque
the
attaching screws
to
specifi-

cation.

19.
Install
the
large snap ring
on

the rear bearing. Place
the
bearing
on

the output shaft with
the
snap ring

end toward
the
rear
of the
shaft. Press

the bearing into place with
the
tool

shown
in Fig. 23.
Secure
the
bearing

to
the
shaft with
a
snap ring.

20.
On
some models, hold
the

speedometer drive gear lock ball
in

the detent
and
slide
the
speedometer

drive gear into place. Secure
the
gear

with
a
snap ring.
On
models equipped

with
the new
design retainer, install

the speedometer drive gear retaining

clip
on the
shaft with
the
lower tang

in
the
retaining hole. Align
the
groove

in
the
gear with
the
clip
and
slide
the

gear forward until
the
upper tang
on

the clip locks
the
gear
(Fig. 9).

21.
Place
the
transmission
in the

vertical position. Working through
the

drain hole
in the
bottom
of the
case,

align
the
bore
of the
countershaft gear

and
the
thrust washers with
the
bore

of
the
case with
a
screwdriver.

22.
Working from
the
rear
of the

case,
push
the
dummy shaft
out of the

countershaft gear with
the
counter-

shaft. Before
the
countershaft
is com-

pletely inserted
in the
bore, make sure

that
the
hole that accommodates
the

roll
pin is
aligned with
the
hole
in the

case.
Drive
the
shaft into place
and in-

stall
the
roll
pin. On all 8
cylinder
ve-

hicles
and
Ford
6
cylinder models,
the

countershaft
is a
press
fit in the
case.

On
6
cylinder models with model

RAN transmissions there
is a
counter-

shaft-to-case clearance
of
0.020 inch

at
the
front bore
and 0.010 at the
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