1969 FORD MUSTANG axle

04-01-10
General Axle Service

04-01-10

The pattern taken during disassem-

bly should be helpful in judging if

gears can be re-used. Worn gears can-

not be rebuilt to correct a noisy condi-

tion. Gear scoring is the result of ex-

cessive shock loading or the use of an

incorrect lubricant. Scored gears can-

not be re-used.

Examine the teeth and thrust surfa-

ces of the differential gears. Wear on

the hub of the differential gear can

cause a chucking noise known as

chuckle when the vehicle is driven at

low speeds. Wear of splines, thrust

surfaces, or thrust washers, can con-

tribute to excessive drive line back-

lash.

BEARING CUPS AND

CONE AND ROLLER

ASSEMBLIES

Check bearing cups for rings,

scores, galling, or excessively worn

wear patterns. Pinion cups must be

solidly seated. Check by attempting to

insert a 0.0015-inch feeler between

these cups and the bottoms of their

bores.

When operated in the cups, cone

and roller assemblies must turn with-

out roughness. Examine the roller

ends for wear. Step-wear on the roller

ends indicates the bearings were not

preloaded properly, or the rollers were

slightly misaligned.

If inspection reveals either a defec-

tive cup or a defective cone and roller

assembly, both parts should be re-

placed to avoid early failure.

DIFFERENTIAL BEARING

ADJUSTING NUTS

Temporarily install the bearing caps

and test the fit of the adjusting nuts in

their threads. The nuts should turn

easily when the caps are tightened to

25 ft-lbs. The faces of the nuts that

contact the bearing cups must be

smooth and square. Replace the nuts

or examine the threads in the carrier
if their fit is not proper. Be sure that

the bearing caps and adjusting nuts

are on the side they were machined to

fit. Observe the punch marks and

scribe marks made during disassem-

bly.

U-JOINT FLANGE

Be sure that the eai» of the flange

have not been damaged in removing

the drive shaft or in removing the

flange from the axle. The end of the

flange that contacts the front pinion

bearing inner race as well as the flat

surface of the pinion nut counterbore

must be smooth. Polish these surfaces

if necessary. Roughness aggravates

backlash noises and causes wear of

the flange and pinion nut with a resul-

tant loss in pinion bearing preload.

PINION RETAINER

Be sure that the pinion bearing cups

are seated. Remove any chips or burrs

from the mounting flange. Clean the

groove for the O-ring seal and all lu-

bricant passages. If the cups were re-

moved, examine the bores carefully.

Any nicks or burrs in these bores

must be removed to permit proper

seating of the cups.

CARRIER HOUSING

Make sure that the differential

bearing bores are smooth and the

threads are not damaged. Remove any

nicks or burrs from the mounting sur-

faces of the carrier housing.

DIFFERENTIAL CASE

Make sure that the hubs where the

bearings mount are smooth. Carefully

examine the differential case bearing

shoulders, which may have been dam-

aged when the bearings were removed.

The bearing assemblies will fail if they

do not seat firmly against the shoul-

ders.
Check the fit (free rotation) of
the differential side gears in their

counterbores. Be sure that the mating

surfaces of the two parts of the case

are smooth and free from nicks or

burrs.

LIMITED SLIP AND

TRACTION-LOK

DIFFERENTIAL PARTS

Inspect the clutch plates for uneven

or extreme wear. The dog-eared clutch

plates must be free from burrs, nicks

or scratches which could cause excess-

ive or erratic wear to the bonding ma-

terial of the internally splined clutch

plates.
The internally splined clutch

plates should be inspected for condi-

tion of the bond, bonding material,

and wear. Replace the bonded plates

if their thickness is less than 0.085

inch or if the bonded material is

scored or badly worn. Inspect the

bonded plate internal teeth for wear.

Replace them, if excessive wear is evi-

dent. Bonded plates should be re-

placed as a set only

Examine all thrust surfaces and

hubs for wear. Abnormal wear on

these surfaces can contribute to a

noisy axle.

Inspect the Belleville spring (limited

slip) for proper free height of 1/4

inch.

LUBRICANT LEVEL

The lubricant level should be

checked every 6000 miles with the ve-

hicle in normal curb attitude. The lu-

bricant level should be at the lower

edge of the filler plug hole located in

either the carrier casting or housing

cover. It is unnecessary to periodically

drain the axle lubricant. The factory

fill should remain in the housing for

the life of the vehicle, except when re-

pairs are made. The specified lubri-

cant should be installed when the axle

is overhauled.procarmanuals.com

04-02-01

Rear Axle
—
Removable Carrier Type

04-02-01

PART
4-2
Rear Axle—Removable Carrier Type

COMPONENT INDEX

AXLE HOUSING (Coil Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE HOUSING (Leaf Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

CONVENTIONAL DIFFERENTIAL

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND RING

GEAR

Adjustment

Cleaning and Inspection

Removal and Installation

DIFFERENTIAL CARRIER

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

LIMITED SLIP DIFFERENTIAL

Cleaning and Inspection

Description

Disassembly and Overhaul

Removal and Installation

PILOT BEARING

Cleaning and Inspection

Removal and Installation

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING

Cleaning and Inspection

Removal and Installation

PINION BEARING RETAINER

Cleaning and Inspection

Removal and Installation

PINION SPACER (Collapsible)

Removal and Installation

PINION OIL SEAL

Removal and Installation
MODEL APPLICATION
All
Models

01-10

02-04

01-10

02-13

02-08

02-19

01-10

02-19

01-10

02-13

02-08

01-10

02-03

02-13

02-13

01-10

02-15

01-10

02-15

01-10

02-15

01-10

02-15

02-04
J

01-09

02-08

N/A

N/A

02-17
Mercury
01-09

02-08

N/A

N/A

N/A
Meteor
01-09

02-08

N/A

N/A

02-17
Cougar
N/A

N/A

01-09

02-11

02-17
Fairlane
N/A

N/A

01-09

02-11

02-17
Falcon
N/A

N/A

01-09

02-11

02-17
Montego
N/A

N/A

01-09

02-11

02-17
Mustang
N/A

N/A

01-09

02-11

02-17
Lincoln-
Continental
N/A

N/A

01-09

02-11

N/A
Thunderbird
01-09

02-08

N/A

N/A

N/A
Continental-
Mark
III
01-09

02-08

N/A

N/A

N/A

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

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

04-02-02

Rear Axle — Removable Carrier Type

04-02-02

COMPONENT INDEX

PINION SPACER (Solid)

Determining Spacer Size

Removal and Installation

REAR WHEEL BEARINGS AND SEALS

Cleaning and Inspection

Removal and Installation

TRACTION-LOK DIFFERENTIAL

Cleaning and Inspection

Description

Disassembly and Overhaul

Removal and Installation

U-JOINT FLANGE

Cleaning and Inspection

Removal and Installation
MODEL APPLICATION
All
Models

02-18

02-18

01-10

02-04

01-10

02-07
Ford
N/A

N/A

N/A

N/A
Mercury
N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

JN/A
Cougar
01-10

02-03

02-22

02-13
Fairlane
01-10

02-03

02-22

02-13
Falcon
01-10

02-03

02-22

02-13
Montego
01-10

02-03

02-22

02-13
Mustang
01-10

02-03

02-22

02-13
Lincoln-
Continental
N/A

02-03

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

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.

1 DESCRIPTION

CONVENTIONAL AXLE

The rear axle is of the banjo-

housing, hypoid gear type using an 8
3/4, 9 or 9 3/8 inch ring gear, in

which the centerline of the pinion is

mounted below the centerline of the

ring gear (Fig. 1).
The pinion gear and the pinion

bearings are assembled in a pinion re-

tainer, which is bolted to the carrier.

The pinion is straddle mounted; that

LEFT AXLE SHAFT

4235

DRIVE PINION

4209

TAPERED ROLLER

BEARINGS 4621

SEAL - 4676

FIG.
1
—
Rear
Axle Assembly—Integral Pinion Gear and Shaft—8-3/4, 9, or 9-3/8 Inch Ring Gear—Typical
procarmanuals.com

04-02-03
Rear Axle — Removable Carrier Type

04-02-03

is,
it is supported by bearings both in

front of and to the rear of the pinion

gear. Two opposed tapered roller

bearings support the pinion shaft in

front of the pinion gear with a col-

lapsible spacer for 8-3/4 inch or 9

inch ring gear, and a solid spacer used

with the 9 3/8 inch ring gear. A

straight roller (pilot) bearing supports

the pinion shaft at the rear of the pi-

nion gear. Pinion and ring gear tooth

contact is adjusted by adding or re-

moving shims from between the pinion

retainer and the carrier housing.

The differential assembly is mount-

ed on two opposed tapered roller

bearings, which are retained in the

carrier by removable caps. The entire

carrier assembly is bolted to the axle

housing.

Ball bearing assemblies (rear wheel

bearings) are pressed onto the outer

ends of the axle shafts and set in the

outer ends of the axle housing. These

bearings support the semi-floating

axle shafts at the outer ends. The

inner ends of the shafts spline to the

differential side gears. Bearing retain-

er plates hold the shafts in the hous-

ing. The left and right axle shafts are

not interchangeable, the left shaft

being shorter than the right.
CASE

COVER

BELLEVILLE

SPRING

CLUTC

HUB
STEEL

PLATES

BONDED

PLATES

E1741-A

FIG. 2—Limited-Slip Differential

LIMITED-SUP DIFFERENTIAL

The axle assembly, except for the

differential case and its internal com-

ponents, is identical to the convention-

al axle.

A constant-friction locking differen-

tial,
which employs clutch plates to

control differential action, is available

as optional equipment (Fig. 2).

Four steel clutch plates are locked

into the differential cover. Three

bronze, bonded clutch plates are

splined to a clutch hub which, in turn,
is splined to the left axle shaft. A

Belleville spring washer maintains a

constant pressure between the steel

and bonded clutch plates so that the

clutch is always engaged.

TRACTION-LOK

DIFFERENTIAL

The Traction-Lok (torque sensitive)

locking differential (Fig. 3) employs a

multiple disc clutch to control differ-

ential action. Shim(s), which control

side gear mounting distance, four

steel, four friction and one composite

plate (steel on one side and friction

material on the other) stacked on a

clutch hub, and four ear guides are

housed in the differential cover. Lo-

cated in the differential case between

the side gears is a one-piece pre-load

plate and block (four-pinion) and four

calibrated pre-load springs, which

apply an initial force to the clutch

pack. Additional clutch capacity is

derived from the side gear thrust

loads.
The four friction plates are

splined to the clutch hub which in turn

is splined to the left axle shaft, and

the eared steel plates are dogged to

the case; thus, the clutch is always en-

gaged.

PINION SHAFT

4211

PINION SHAFT

RETAINING PINS

359475-S
DIFFERENTIAL

CASE-4204

CASE-TO-COVER

RETAINING SCREWS

50025-S2

SIDE GEAR

THRUST WASHER

4228

CENTER BLOCK

(SHORT PINION PINION

SHAFT SEAT) SHAFT

4420 44207
7
PINION GEAR

THRUST WASHER

4230

PINION GEARS

4215

PINION GEAR

THRUST WASHER

4230

PINION SHAFT

44207
SHIM(S)

(AS REQ'D.)

4A324

DIFFERENTIAL

CASE COVER

4204

PINION GEAR

THRUST WASHER

4230
PRE-LOAD SPRING

PINION GEAR PLATE-4A326

THRUST WASHER

4230

CLUTCH PLATE

EAR GUIDES
(4)

4A323

E 1896-A

FIG. 3—Traction-Lok Differentialprocarmanuals.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

04-02-05
Rear Axle
—
Removable Carrier Type

04-02-05

Bridge

Side Rail

_J f.

Detail 4

Tool-T60K-1225-A

Press
Ram

FOR

ADJUSTABLE

BED PRESS

Press
Ram

BEARING
'—
Support
Plat*
—*

BEARING INSTALLATION

VIEW
2

1
Support Plate

BEARING REMOVAL

VIEW
1
FOR FIXED

BED PRESS
Press
Ram

Press
Ram

BEARING
LSupport Flange^

BEARING REMOVAL

VIEW
3

Adapter Ring

1—
Support Plate
—»

BEARING INSTALLATION

VIEW
4

FOR

PUSH-PULLER

OPERATION

BEARING REMOVAL

VIEW
5

BEARING

BEARING

INSTALLATION

VIEW
6

E1269-B

FIG.
6—Removing
and
Installing Wheel Bearingprocarmanuals.com

04-02-06

Rear Axle — Removable Carrier Type

04-02-06

FIG. 7—Removing Wheel Bearing

leakage. Refer to the transmission

group for the appropriate tool.

3.
Install an in-lb torque wrench on

the pinion nut. Record the torque re-

quired to maintain rotation of the pi-

nion shaft through several revolutions.

4.
Scribe the pinion shaft and the

U-joint flange inner surface for as-

sembly realignment. While holding the

flange with the tool shown in Fig. 22

or Fig. 23, remove the integral pinion

nut and washer.

5.
Clean the pinion bearing retainer

around the oil seal. PlaSe a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

6. Using the tool shown in Fig. 24

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

7.
Using the tool shown in Fig. 26

remove the drive pinion oil seal.

8. Clean the oil seal seat.

9. Install the new seal in the retain-

er, using the applicable tool shown in

Fig. 47.

10.
Check splines on the pinion

shaft to be sure they are free of burrs.

If burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion. Wipe the pinion

shaft clean.

11.
Apply a small amount of lubri-

cant to U-joint splines.

Align scribe marks on U-joint

flange and pinion shaft.

12.
Install the U-joint flange using

the tool shown in Fig. 46.
SCRIBE MARKS

AXLE SHAFT

FLANGE

Tool

4621-A

E1921A

FIG. 9—Installing Wheel Bearing

13.
Install a new integral nut and

washer on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut).

14.
Hold the flange with the tool

shown in Fig. 24 or Fig. 25 while

tightening nut.

15.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, and take

frequent preload readings until the

preload is at the original recorded

reading established in step 3.

16.
After original preload has been

reached, tighten the pinion nut slowly,

until an additional preload of 8 to 14

in-lb over the original reading is

reached. The preload should not ex-

ceed 8 to 14 in-lb over the original

reading, or bearing failure may result.

Under no circumstances should the pi-

nion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. In

addition, the U-joint flange must

never be hammered on, or pneumatic

tools used.

17.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission output

shaft.

18.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

Tool-1177

or 4245-B

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

4 REQ'D.

12-15
LB.
FT.

IE 1783-A

FIG. 8—
Removing
Rear Wheel

Bearing Oil Seal
FIG. 70—Installing Rear Wheel

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

U-Joint Connection

drive shaft end yoke and the axle U-

joint flange (Fig. 11).

19.
Check the lubricant level Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole.

SOLID SPACER

The drive pinion oil seal can be re-

placed without removing the differen-

tial carrier assembly from the axle

housing.

1.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

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

connect the drive shaft from the axle

U-joint flange. Be careful to avoid

dropping the loose universal joint

bearing cups. Hold the cups on the

spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

2.
Make punch marks on the end

of the pinion shaft and the U-joint

flange inner surface for realignment.

While holding the flange with the tool

shown in Fig. 22 or Fig. 23, remove

the integral pinion nut and washer.

3.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

4.
Using the tool shown in Fig. 24

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

5.
Using the tool shown in Fig. 26

remove the drive pinion oil seal.

6. Clean the oil seal seat.

7.
Install the new seal in the retain-

er, using the applicable tool shown in

Fig. 47.

8. Check splines on the pinion shaft

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

04-02-07
Rear Axle — Removable Carrier Type

04-02-07

burrs are evident, remove them with a

fine crocus cloth, working in a rota-

tional motion, then wipe clean. Apply

a small quantity of lubricant to U-

joint splines.

9. Install the U-joint flange using

the tool shown in Fig. 46.

10.
Install a new integral attaching

nut and washer on the pinion shaft.

11.
Tighten the pinion attaching

nut, rotating the pinion several times

to seat the bearing, then torque the pin-

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

flange with the tool shown in Fig. 22

or Fig. 23 while the nut is being tight-

ened.

12.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission output

shaft.

13.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange.

14.
Check the lubricant level, and

add whatever amount of specified lu-

bricant is necessary to reach the lower

edge of the filler plug hole. Make sure

the axle is in running position when

the level is checked

ORIGINAL U-JOINT FLANGE

(IN VEHICLE REPLACEMENT)

Use procedure as outlined under

Drive Pinion Oil Seal Replacement.

Synthetic seals must not be cleaned,

soaked or washed in cleaning solvent.

INSTALLATION OF A NEW

UNIVERSAL JOINT FLANGE

COLLAPSIBLE SPACER

1.
Raise the vehicle and install

safety stands. Remove both rear wheels

and brake drums.

2.
Disconnect the drive shaft from

the axle U-joint flange. Be careful to

avoid dropping the loose universal

joint bearing cups. Hold the cups on

the spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission fluid

leakage. Refer to the transmission

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

the pinion nut. Record the torque re-

quired to maintain rotation of the pin-

ion shaft through several revolutions.

4.
While holding the flange with the

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

move the integral pinion nut and

washer.

5.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear. Syn-

thetic seals must not be cleaned,

soaked or washed in cleaning solvent.

6. Using the tool shown in Fig. 23

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

7.
Check splines on the pinion shaft

to be sure they are free of burrs. If

burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion, then wipe clean.

Apply a small amount of lubricant

to U-joint splines.

8. Install the U-joint flange using

the tool shown in Fig. 46.

9. Install a new integral nut and

washer on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 23 or Fig. 24 while the

nut is being tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, and take

frequent preload readings until the

preload is at the original recorded

reading established in step 3.

12.
After original preload has been

reached, tighten the pinion nut slowly,

until an additional preload of 8 to 14

in-lb over the original reading is

reached. (The preload should not ex-

ceed 8 to 14 in-lb over the original

reading, or bearing failure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. In

addition, the U-joint flange must

never be hammered on, or power tools

used.

13.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange.

15.
Check the lubricant level. Make

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

bricant is required to reach the lower

edge of the filler plug hole.

SOLID SPACER

1.
Disconnect the drive shaft from

the axle U-joint flange. Be careful to

avoid dropping the loose universal

joint bearing cups. Hold the cups on

the spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission leak-

age.
Refer to the transmission group

for the appropriate tool.

2.
While holding the flange with the

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

move the integral pinion nut and

washer.

3.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear.

4.
Using the tool shown in Fig. 23

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

5.
Check splines on the pinion shaft

to be sure they are free of burrs. If

burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion, then wipe clean.

Apply a small amount of lubricant to

U-joint splines.

6. Install the U-joint flange using

the tool shown in Fig. 46.

7.
Install integral attaching nut and

washer on the pinion shaft.

8. Tighten the pinion attaching nut,

rotating the pinion several times to

seat the bearing, then torque the pin-

ion attaching nut to 180-220 ft-lbs.

Hold the flange with the tool shown in

Fig. 23 or Fig. 24 while the nut is

being tightened.

9. Remove the oil seal replacer tool

from the transmission extension hous-

ing. Install the front end of the drive

shaft on the transmission output shaft.

10.
Connect the rear end of the

drive shaft to the axle U-joint flange.

11.
Check the lubricant level, and

add whatever amount of specified lu-

bricant is necessary to reach the lower

edge of the filler plug hole. Make sure

the axle is in running position when

the level is checked.

DRIVE SHAFT PINION ANGLE

ADJUSTMENT

Refer to Group 3, Part 3-2 for this

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