1969 FORD MUSTANG air suspension

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

03-13-01
Specifications

03-13-01

PART 3-13 Specifications

FRONT
WHEEL
ALIGNMENT

Vehicle

Model

Mustang,
Cougar

Fairlane, Falcon

Mont
ego

Ford,
Mercury

Meteor

Thunderbird,

Mark III

Lincoln

Continental
Dimension

"C"

Inches

(I) 6.30

® 6.50

©4.20

® 4.20

©5.87
Dimension

"D"

Inches

©5.50 (Mustang)

6.35 (Cougar)

©6.72

©6.70

©6.70

©8.39
Alignment

Factors

Caster©

Camber©

Toe-in-Inches

Caster©

Camber©

Toe-in-Inches

Caster©

Camber©

Toe-in-Inches

Caster©

Camber®

Toe-in-Inches

Caster®

Camber®

Toe-in-Inches
Min.

-3/4°

+1/4°

1/16

-1
3/4°

•1/2°

1/8

0°

•1/4°

1/16

0°

•1/4°

1/16

-1/2°

•1/4°

0
Max.

+1 1/4°

+1 3/4°

5/16

+1/4°

+1°

3/8

+2°

+11/4°

5/16

+2°

+1 1/4°

5/16

-2
1/2°

+11/4°

1/4
Desired

+1/4°

+3/4°

3/16

•3/4°

+1/4°

3/16

+1°

+1/2°

3/16

+1°

+1/2°

3/16

•11/2°

+1/2°

1/8

©Maximum difference between wheels not to exceed 1/2° (setting). Maximum checking difference not to exceed 1° with caster and camber
with-

in specifications.

©Maximum difference between wheels not to exceed 1/2°.

©Vertical distance between bottom surface of spring tower on centerline of rebound bumper bolt and point on flat surface of upper suspension

arm midway between ball joint rivets.

©Shortest vertical distance between point on side member and axle housing.

©Distance from corner of lower flange sidemember front to center of bolt head (strut mounting bolt).

©Vertical distance between bottom of sidemember at center of axle bumper bracket and top of axle housing.

©Vertical distance between point on underside of crossmember pocket and point on top of drag strut.

©Distance from axle housing to surface on sidemember immediatly behind axle bumper.

WHEELBASEAND TREAD WIDTH-INCHES

FRONT WHEEL TURNING ANGLE

Vehicle Model

Mustang

Cougar

Fairlane, Montego

Falcon (except Station Wagon)

Falcon Station Wagon

Ford

Mercury, Meteor

Thunderbird (2-Door)

Thunderbird (4-Door), Mark HI

Lincoln Continental
Wheelbase

108.0

111.1

116.0

110.9

113.0

121.0

124.0

114.7

117.2

126.0
Tread

Front

58.5

58.5

58.8

58.8

58.8

63.0

63.0

62.0

62.0

62.4
Width

Rear

58.5

58.5

5«.5

58.5

58.5

64.0

64.0

62.0

62.0

61.0
Vehicle Model

Mustang,
Cougar

Fairlane, Falcon, Montego

Ford,
Mercury, Meteor

Thunderbird, Mark III

Lincoln Continental
Turning Angle of Outside Wheel

With Inside Wheel Turned 20°

18.68°

With Power Steering 17.88°

With Manual Steering 18.1°

With Power Steering 19.14°

With Manual Steering 18.96°

19.26°

17.71°

BALL JOINTS -RADIAL PLAY

STEERING WHEEL TURNING EFFORT

Vehicle Model

Cougar, Fairlane,

Falcon,
Montego,

Mustang

Ford,
Mercury,

Meteor, Thunderbird,

Mark III, Lincoln

Continental
Description

Lower Ball Joint

Upper Ball Joint

Lower Ball Joint

Upper Ball Joint
Radial Play-Max. Allowable

Replace if perceptibly loose

0.250
Inch

0.250
Inch

Replace if perceptibly loose
Vehicle Model

Ford,
Mercury, Meteor

Cougar, Fairlane, Falcon,

Montego, Mustang

Lincoln Continental, Mark III,

Thunderbird
Lbs.
Effort

5.0

6.5

3.75procarmanuals.com

03-13-05

Specifications

03-13-05

TORQUE LIMITS-FRONT SUSPENSION

MONTEGO, FALCON,
FAIR
LANE,
MUSTANG AND COUGAR

Description

Shock Absorber Upper Attachment

Shock Absorber Upper Bracket to Body

Front Suspension Compression Bumper to Body

Brake Backing Plate to Spindle

Upper Arm and Inner Shaft to Body

Spring Seat to Upper Arm

Shock Absorber to Spring Seat

Ball Joint to Spindle (Upper and Lower)

Wheel Bearing Adjusting Nut

Strut to Lower Arm

Lower Arm to Underbody

Stabilizer Bar Mounting Bracket to Underbody

Strut to Underbody

Stabilizer Bar to Lower Arm

Caliper to Spindle (Disc Brake) • Upper

- Lower

Strut to Underbody Slotted Nut
Ft • Lbs

Montego, Falcon, Fairlane

20-28

15-25

12-17

9-14 (Disc) 25-45 (Drum)

75-100

30-40

8-12

60-90 ©

17-25 ©

75-105

75-100

17-25

60-80

5-10

110-140

55-75
Mustang and Cougar

10-15

22-34

12-17

9-14 (Disc) 28-45 (Drum)

75-100

25-40

8-12

60-90 ©

17-25 ©

70-105

75-100

17-25

60-80

8-12

110-120

55-75

50-70 | 50-70

©Torquethe adjusting nut to 17-25 ft-lb. Locate nut lock on adjusting nut so ,ctstellations are aligned with cotter pin hole in spindle. Then,

backoff adjusting nut and nut lock so the next castellation aligns with the cotter pin hole.

TORQE LIMITS-fRONT SUSPENSION

FORD,
MERCURY, METEOR

Description

Lower Arm to No. 2 Crossmember

Upper Arm to Frame

Upper Arm Bumper

Brake Backing Plate and Cylinder Assembly

to Spindle

Stabilizer Bar to Lower Arm

Ball Joint to Spindle (Upper and Lower)
Ft Lbs

55-75

100-130

15-25

80-106

5-10

60-90®
Description

Brake Backing Plate to Spindle

Strut to Lower Arm

Stabilizer Bar to Frame

Strut to Frame

Shock Absorber Upper Attachment

Shock Absorber Lower Arm

Caliper to Spindle (Disc Brake)
Ft-Lbs

25-45

70-113

18-27

60-90 ©

20-28

8 12

120-130

©Torque to specification, then tighten the nut to the nearest cotter pin slot and insert the cotter pin.

TORQUE LIMITS-FRONT SUSPENSION

THUNDERBIRD, CONTINENTAL MARK

Description

Lower Arm to #2 Crossmember

Upper Arm to Frame

Upper Arm Bumper

Stabilizer Bar to Lower Arm

Ball Joint to Spindle (Upper and Lower)

Strut to Lower Arm

Stabilizer Bar to Mounting Bracket

Strut to Frame

Shock Absorber Upper Attachment

Shock Absorber to Lower Arm

Brake Splash Shield (Disc) to Spindle

Caliper to Spindle (Disc Brake)

Upper Bolt

Lower Bolt
Torque

Ft-Lbs

60-90

100-150

15-25

5-10

©60-90

70-113

8-12

©60-90

20-23

8-12

9-14

110-140

90-120

©Torque to minimum specification;
then,
tighten the nut to the nearest cotter pin slot and insert the cotter pin.procarmanuals.com

03-13-06

Specifications

03-13-06

TORQUE LIMITS-FRONT SUSPENSION

LINCOLN CONTINENTAL

Description

Brace-Front Suspension to Sidemember (Model 74A Only)

Drag Strut
to
Strut Bracket Assembly

Lower Arm Assembly to Front Crossmember
-
(Attach Bracket)

Lower Arm Assembly to No. 2 Crossmember

Drag Strut
to
Lower Arm Assembly

Wheel Spindle to Lower Arm Ball Joint

Front Wheel Spindle to Upper Arm Ball Joint Assembly

Upper Arm Inner Shaft
to
Upper Arm

Upper Arm and Shaft Assembly to No. 2 Crossmember

Shock Absorber Bracket Assembly to No. 2 Crossmember Bracket

Shock Absorber Assembly to No. 2 Crossmember Assembly (Top End)

Shock Absorber Assembly Lower Arm Spring Seat Reinforcement Assembly

Upper Ball Joint
to
Control Arm

Stabilizer Bar Assembly
to
Underbody

Stabilizer Bar
to
Lower Arm

Jounce Bumper Assembly
to
Strut (Lower Arm)

Front Splash Shield to Spindle

Caliper to Spindle
FtLbs

90-110

70-90

55-75

110-140

70-90

70-90

55-75

25-35

100-125

40-55

20-30

20-30

21-29

20-30

5-10

22-28

9-14

100-140

TORQUE LIMITS-REAR SUSPENSION

FORD, MERCURY, METEOR

Description

Shock Absorber
to
Frame (Upper Attachment)

Upper Arm to Axle Bracket (Nut)

Track Bar to Axle Track Bar Stud

Track Bar Stud to Axle

Track Bar
to
Frame (Bolt Torque)

Track Bar Stud to Axle Bracket (Nut)

Wheel Lug Nut

Brake Backing Plate and Bearing Retainer to Axle-All Cars except those with 240
or
302 CID Engines

Brake Backing Plate and Bearing Retainer to Axle-All Cars with 240
or
302 CID Engines

Shock Absorber to Axle (Lower Attachment)

Bumper Assembly
to
Frame

Lower Arm to Axle-Bolt

Lower Arm to Axle-Nut

Upper Arm
to
Frame-BoU

Upper Arm
to
Frame-Nut

Lower Arm
to
Frame-Bolt

Lower Arm
to
Frame-Nut

Bumper Assembly to No. 4 Crossmember

Universal Joint
U-Bolt
Nut

Air Leveling Compressor
to
Apron

Height Control Valve to Bracket

Height Control Valve Bracket to No. 4 Crossmember
FtLbs

20-28

90-100

80-105

100-130

80-105

80-105

70-115

50-70

20-30

50-35

9-13

90-120

70-90

90-120

70-90

90-120

70-90

9-13

10-15

10-13

17-25

9-13procarmanuals.com

03-13-07

Specifications

03-13-07

TORQUE LIMITS-REAR SUSPENSION

MONTEGO, FALCON, FAIR LANE, MUSTANG AND COUGAR

Description

Spring Shackle Bars to Body and Spring

Shock Absorber
to
Upper Mounting Bracket

Shock Absorber to Spring Clip Plate

Spring to Axle U-Bolt Nut

Wheel Lug Nut 5-Lug Wheel

Spring to Spring Front Hanger
•
Bolt

Spring to Spring Front Hanger
•
Nut

Universal Joint U-Bolt Nut -Std. Trans.

Universal Joint U-Bolt Nut -Auto. Trans.
Mont
ego,
Falcon, Fair lane

15-22

20-28

20-28

35-50

70-115

90-120

40-60

6-11

10-15
Mustang and Cougar

15-22

20-28

20-28

35-50

70-115

60-85

40-60

6-11

10-15

TORQUE LIMITS-REAR SUSPENSION

LINCOLN CONTINENTAL

Description

Brake Backing Plate Bearing Retainer to Axle

Spring Center Bolt

Spring Front Bracket Assembly to Rear Floor Sidemember Assembly

Spring Front Eye Stud and Washer Assembly to Spring Front Hanger Bracket

Spring U-Bolt

Spring Assembly
to
Spring Shackle Assembly

Spring Shackle Assembly
to
Spring Rear Bracket Assembly

Spring Rear Bracket Assembly
to
Rear Floor Sidemember Assembly

Shock Absorber Upper Attaching Bracket
to
Body Crossmember

Shock Absorber Assembly
to
Shock Absorber Upper Attaching Bracket

Shock Absorber Assembly to Axle

Axle Bumper Bracket
to
Underbody

Pinion Bumper Assembly to Axle Carrier
Ft Lbs

30-55

15-20

70-90

76-106

45-65

34-59

34-59

40-67

20-30

20-28

30-45

10-15

18-25

TORQUE LIMITS-REAR SUSPENSION

THUNDERBIRD, CONTINENTAL.MARK
III

Description

Shock Absorber
to
Frame (Upper Attachment)

Upper Arm
to
Axle (Front)

Track Bar to Axle Track Bar Stud

Track Bar Stud to Axle

Track Bar
to
Frame (Bolt Torqe)

Wheel Lug Nut

Brake Backing Plate and Bearing Retainer
to
Axle

Shock Absorber to Axle (Lower Attachment)

Bumper Assembly to Frame

Lower Arm
to
Axle - Bolt

Lower Arm
to
Axle- Nut

Upper Arm
to
Frame -Bolt

Upper Arm
to
Frame
•
Nut

Lower Arm
to
Frame • Bolt

Lower Arm to Frame
-
Nut

Bumper Assembly to No. 4 Crossmember
Ft-Lbs

20-28

70-90

80-105

100-130

70-90

70-115

50-75

50-85

Self-Tapping

90-120

70-80

90-120

70-90

90-120

70-90

Self-Tappingprocarmanuals.com

04-02-01

Rear Axle
—
Removable Carrier Type

04-02-01

PART
4-2
Rear Axle—Removable Carrier Type

COMPONENT INDEX

AXLE HOUSING (Coil Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE HOUSING (Leaf Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

CONVENTIONAL DIFFERENTIAL

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND RING

GEAR

Adjustment

Cleaning and Inspection

Removal and Installation

DIFFERENTIAL CARRIER

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

LIMITED SLIP DIFFERENTIAL

Cleaning and Inspection

Description

Disassembly and Overhaul

Removal and Installation

PILOT BEARING

Cleaning and Inspection

Removal and Installation

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING

Cleaning and Inspection

Removal and Installation

PINION BEARING RETAINER

Cleaning and Inspection

Removal and Installation

PINION SPACER (Collapsible)

Removal and Installation

PINION OIL SEAL

Removal and Installation
MODEL APPLICATION
All
Models

01-10

02-04

01-10

02-13

02-08

02-19

01-10

02-19

01-10

02-13

02-08

01-10

02-03

02-13

02-13

01-10

02-15

01-10

02-15

01-10

02-15

01-10

02-15

02-04
J

01-09

02-08

N/A

N/A

02-17
Mercury
01-09

02-08

N/A

N/A

N/A
Meteor
01-09

02-08

N/A

N/A

02-17
Cougar
N/A

N/A

01-09

02-11

02-17
Fairlane
N/A

N/A

01-09

02-11

02-17
Falcon
N/A

N/A

01-09

02-11

02-17
Montego
N/A

N/A

01-09

02-11

02-17
Mustang
N/A

N/A

01-09

02-11

02-17
Lincoln-
Continental
N/A

N/A

01-09

02-11

N/A
Thunderbird
01-09

02-08

N/A

N/A

N/A
Continental-
Mark
III
01-09

02-08

N/A

N/A

N/A

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

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

04-02-11
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