1969 FORD MUSTANG light

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

04-02-18
Rear Axle — Removable Carrier Type
04-02-18

E 1195-C

FIG. 41—Removing
or
Installing

Pinion
and
Retainer Assembly

10.
Hold
the
flange with
the
tool

shown
in Fig. 22
(Ford)
or Fig. 23

(Mercury),
and
torque
the
pinion shaft

nut
to 175
ft-lbs.
Do not
exceed
175

ft-Ibs
at
this time.

11.
Check
the
pinion bearing
pre-

load
as
shown
in Fig. 42.
Correct

pre-load will
be
obtained when
the

torque required
to
rotate
the
pinion
in

the retainer
is as
specified
in
Part
4-3.

If
the
torque required
to
rotate
the pin-

ion
is
less than specified, tighten
the

pinion shaft
nut a
little
at a
time until

Inch-Pound

Torque Wrench

E1899A

FIG. 42—Checking Pinion Bearing

Preload
the proper preload
is
established.
Do

not overtighten
the nut. If
excessive

preload
is
obtained
as a
result
of
over-

tightening, replace
the
collapsible

bearing spacer.

Do
not
back
off the
pinion shaft
nut

to establish pinion bearing preload.
If

the torque
on the
pinion shaft
nut is

less than
175
ft-lbs after bearing
pre-

load
is
established,
a new
collapsible

spacer must
be
used.

SOLID PINION BEARING

SPACER INSTALLATION

The spacer
is
serviced
in 20
sizes

listed
in
Part
4-5. The
manner
of sel-

ecting
the
size spacer required
for ob-

taining correct preload
is
included
in

the following assembly procedure.

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

pinion shaft
as
shown
in
Figs.
38 or

39.

2.
Select
a new
solid spacer
of a

larger size (0.485 inch thick),
and
slide

it over
the
pinion shaft against
the

rear bearing.

The pinion bearing preload
can be

accurately measured only when
the

pinion shaft
nut is
torqued
to 180-

220 ft-lbs.
If a
spacer smaller than
re-

quired
was
used,
the
specified
180-

220 ft-lbs torque would damage
the

bearings.
For
this reason,
the
largest

spacer should
be
tried first. Then,
if

the bearings
are too
loose,
the
size
of

the spacer
can be
decreased until
the

correct preload
is
obtained.

3.
Position
the
bearing retainer
and

cup assembly
on the
pinion shaft
and

install
the
front bearing cone
and rol-

ler. Press
the
front bearing cone
and

roller assembly into position,
as

shown
in Fig. 38.

4.
Mount
the
retainer
in a
holding

fixture
as
shown
in Fig. 23, and
place

the slinger over
the
pinion shaft
and

against
the
front bearing.

5.
Install
the
U-joint flange with

the tool shown
in Fig. 46.

6. Hold
the
flange with
the
tool

shown
in Fig. 23 or 24, and
install
the

old pinion shaft
nut.
Using
a
ft-lb
tor-
que wrench, torque
the nut to
180-220

ft-lbs.
While tightening
the nut,
rotate

the bearing retainer
to
determine
the

existance
of any
bearing preload

which will
be
indicated
by a
slight

drag
in the
rotation
of the
retainer.

DETERMINING SPACER

SIZE FROM

PRELOAD READING

1.
If
bearing drag indicates
a pre-

load condition exists, apply
an
in-lb

torque wrench
to the
pinion
nut as

shown
in Fig. 42 and
read
the
torque

required
to
turn
the
shaft. Effort

should
be
12-1/2
to
32-1/2 in-lbs.

2.
If
preload
is the
correct valve,

proceed with assembly procedure

given
in
Final Assembly
of
Pinion
and

Retainer, which follows.

2.
If
preload exists,
but is
below

specification, select
the
correct spacer

from
Fig. 43 and
install, completing

assembly
as
shown
in
Final Assembly

of Pinion
and
Retainer.

DETERMINING SPACER

SIZE FROM
END

PLAY READING

1.
If no
perceptible preload
is
felt

when rotating
the
pinion shaft, install

a dial indicator
as
shown
in Fig. 44,

so that
the
indicator point
is
resting

on
the end of the
pinion gear shaft

(companion flange
end).

2.
Use
both hands
to
squeeze
the

pinion shaft
and the
bearing retainer

together
(Fig. 45).
Record
the
endplay

reading shown
on the
dial indicator.

3.
Disassemble
the
pinion shaft
and

retainer
and
install
the
correct spacer

as shown
in Fig. 43.

4.
Proceed with assembly
of the pin-

ion shaft
and
retainer
as
directed
in

Final Assembly
of
Pinion
and
Retain-

er.

FINAL ASSEMBLY
OF

PINION
AND
RETAINER

1.
Install
the
drive pinion rear bear-

ing cone
and
roller assembly
on the

AS
END
PLAY

READS

(10/1000 inch)

USE THIS

SPACER
0

0.481
1

0.480
2

0.479
3

0.478
4

0.476

If there
is no end
play
and
preload
on the
bearings

IF PRELOAD READS

(in-lbs.)

USE THIS SPACER
2-11

0.482
12-20

0.483
5

0.476
6

0.474
7

0.474
8

0.472
9

0.472
10

0.470
11

0.470
12

0.468
13

0.468
14

0.466
15

0.465

exists:

21-30

0.484
31-45

0.485

FIG. 43— Solid Spacer Selectionprocarmanuals.com

04-02-19
Rear Axle — Removable Carrier Type
04-02-19

POINTER RESTING ON

PINION NUT

E 1505-B

FIG.
44
— End Play Indicator

Installation

pinion shaft as shown in Figs. 37 and

38.

2.
Slide the correct spacer over the

pinion shaft against the rear bearing.

3.
Position the bearing retainer and

cup assembly on the pinion shaft and

install the front bearing cone and rol-

ler. Press the front cone and roller

into position, as shown in Fig. 46.

4.
Lubricate a new O-ring with axle

lubricant and install it in the groove

provided in the pinion retainer. Be

careful not to twist the O-ring. Install

it by snapping it into place.

5.
Place the proper shim on the

carrier housing and install the pinion

and retainer assembly, being careful

not to pinch the O-ring (Fig. 41).

6. Install the pinion retainer bolts.

Torque the bolts to specification.

7.
Place the slinger over the pinion

shaft and against the front bearing.
Tool - 4858-
E

E 1197-D

FIG. 46—Installing
U-Joint
Flange

8. Install a seal in the bearing re-

tainer, (Fig. 47).

9. Start a new integral nut and

washer on the pinion shaft.

10.
Hold the companion flange with

the tool shown in Fig. 20 or 22 and

torque the pinion nut to specifications

(200 ft-lbs).

11.
With a new seal installed pin-

ion bearing preload should now read

17 to 32 in-lbs for new pinion bearings

and new seal, or 8 to 14 in-lbs for ori-

ginal bearings and a new seal.

ASSEMBLY AND

INSTALLATION OF

DIFFERENTIAL CASE

Conventional

Differential Case

1.
Place a side gear and thrust

washer in the differential case bore

E 1506-B

E 1629-A

FIG. 45— Checking Pinion End

Play
FIG. 47—Installing Oil Seal
(Fig. 48). Lubricate all differential

parts liberally with axle lubricant dur-

ing assembly.

2.
With a soft-faced hammer, drive

the differential pinion shaft into the

case only far enough to retain a pin-

ion thrust washer and pinion gear.

3.
Place the second pinion and

thrust washer in position, and drive

the pinion shaft into place. Carefully

line up the pinion shaft lock pin holes.

4.
Place the second side gear and

thrust washer in position (Fig. 48),

and install the cover on the differen-

tial case. Install the pinion shaft lock

pin. A pinion or axle shaft spline can

be inserted in the side gear spline to

check for free rotation of the differen-

tial gears.

5.
Insert two 7/16 (N.F.) bolts two

inches long through the differential

case flange, and thread them three or

four turns into the ring gear as a

guide in aligning the ring gear bolt

holes.
Press or tap the ring gear into

position.

6. Install and tighten the ring gear

bolts and washers evenly, and torque

them alternately across the gear to

specification.

7.
If the differential bearings have

been removed, press them on as

shown in Figs. 49 and 50.

8. Wipe a thin coating of lubricant

on the bearing bores so that the dif-

ferential bearing cups will move easily.

9. Place the cups on the bearings.

If the gear set is of the non-hunting or

partial non-hunting type, assemble the

differential case and ring gear assem-

bly in the carrier so that the marked

tooth on the pinion indexes between

the marked teeth on the ring gear as

shown in Fig. 51.

In almost every case of improper

assembly (gears assembled out of

time),
the noise level and probability

of failure will be higher than they

would be with properly assembled

gears.

When installing the hunting type

gear set (no timing marks), assemble

the differential case and ring gear as-

sembly in the carrier without regard

to the matching of any particular gear

teeth.

10.
Slide the assembly along the

bores until a slight amount of back-

lash is felt between the gear teeth.

11.
Set the adjusting nuts in the

bores so that they just contact the

bearing cups. The nuts should be en-

gaged about the same number of

threads on each side.

12.
Carefully position the bearing

caps on the carrier. Match the marks

made when the caps were removed.procarmanuals.com

04-03-01

Rear Axles — Integral Carrier Type

04-03-01

PART 4-3 Rear Axles-Integral Carrier Type

(Except Ford Light Duty
WER
Axle)

COMPONENT INDEX

AXLE HOUSING

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

CONVENTIONAL DIFFERENTIAL CASE

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND RING

GEAR

Cleaning and Inspection

Removal and Installation

LIMITED SLIP DIFFERENTIAL CASE

Disassembly and Overhaul

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING CUPS

Cleaning and Inspection

Removal and Installation

PINION OIL SEAL

Removal and Installation

REAR WHEEL BEARINGS AND SEALS

Cleaning and Inspection

Removal and Installation

U-JOINT FLANGE

Cleaning and Inspection

Removal and Installation
MODEL APPLICATION
All
Models

01-09

01-10

01-10

01-10

01-10

01-10

01-10

01-10
Ford
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mercury
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Cougar
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Fairlane
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Falcon
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Montego
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Mustang
03-06

03-02

03-08

03-07

03-08

03-08

03-09

03-08

03-04

03-02

03-05
Lincoln-
Continental
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
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

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.

DESCRIPTION

The rear axle assembly is an integral-

type housing, hypoid design, with the

centerline of the pinion set below the

centerline of the ring gear (Fig. 1).

The semi-floating axle shafts are re-

tained in the housing by ball bearings

and a bearing retainer at the axle hous-

ing outer ends.

The differential assembly is mount-

ed on two opposed tapered roller
bearings. The bearings are retained in

the housing by removable caps. Dif-

ferential bearing preload and drive

gear backlash is adjusted by nuts lo-

cated behind each differential bearing

cup.

The drive pinion assembly is mount-

ed on two opposed tapered roller

bearings. Pinion bearing preload is

adjusted by a collapsible spacer on the
pinion shaft. Pinion and ring gear

tooth contact is adjusted by shims be-

tween the rear bearing cone and

pinion gear.

A cover on the rear of the differen-

tial housing provides access for inspec-

tion and removal and installation of

the differential assembly and drive

pinion.
procarmanuals.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

04-03-10
Rear Axles
—
Integral Carrier Type

04-03-10

in
the
case. Drive
the
shaft into place

and install
the
lock
pin
(Fig.
21).

6. Place
the
ring gear
on the
differ-

ential case
and
install
the
bolts.
Tor-

que
the
bolts
to
specification.

7.
If the
differential bearings have

been removed, press them
on as

shown (Fig.
24).

INSTALLATION
OF
DRIVE

PINION
AND
DIFFERENTIAL

CASE

1.
Place
the
shim
and
pinion rear

bearing cone
on the
pinion shaft.

Press
the
bearing
and
shim firmly

against
the
pinion shaft shoulder (Fig.

19).

PRESS RAM

Tool T54P-3044-A

Detail
7
2.
Place
a new
pinion bearing
pre-

load spacer
on the
pinion shaft.

3.
Lubricate
the
pinion rear bearing

with axle lubricant.

4.
Lubricate
the
pinion front bear-

ing cone
and
place
it in the
housing.

5.
Install
a new
pinion
oil
seal
in

the carrier casting (Fig.
11).

6. Insert
the
drive pinion shaft

flange into
the
seal
and
hold
it
firmly

against
the
pinion front bearing cone.

From
the
rear
of the
carrier casting,

insert
the
pinion shaft into
the
flange.

7.
Start
a new
pinion shaft
nut.

Hold
the
flange with
the
tool shown
in

Fig.
9 and
tighten
the
pinion shaft

nut.
As the
pinion shaft
nut is
tight-

ened,
the
pinion shaft
is
pulled into

the front bearing cone
and
into
the

flange.

As
the
pinion shaft
is
pulled into

the front bearing cone, pinion shaft

end play
is
reduced. While there
is

still
end
play
in the
pinion shaft,
the

flange
and
cone will
be
felt
to
bottom.

This indicates that
the
bearing cone

and flange have bottomed
on the col-

lapsible spacer.

From this point,
a
much greater

torque must
be
applied
to
turn
the

pinion shaft
nut,
since
the
spacer must

be collapsed. From this point, also,

the
nut
should
be
tightened very slow-

ly
and the
pinion shaft
end
play

checked often,
so
that
the
pinion bear-

ing preload does
not
exceed
the
limits

(Fig.
6).

FIG. 24—Differential Bearing

Installation
If
the
pinion shaft
nut is
tightened

to
the
point that pinion bearing
pre-

load exceeds
the
limits,
the
pinion

shaft must
be
removed
and a
new
col-

lapsible spacer installed.
Do not de-

crease
the
preload
by
loosening
the

pinion shaft
nut.
This will remove
the

compression between
the
pinion front

and rear bearing cones
and the col-

lapsible spacer
and may
permit
the

front bearing cone
to
turn
on the pin-

ion shaft.

&
As
soon
as
there
is
preload
on

the bearings, turn
the
pinion shaft
in

both directions several times
to set the

bearing rollers.

9. Adjust
the
bearing preload
to

specification. Measure
the
preload

with
the
tool shown
in Fig. 6.

10.
Apply
a
thin coating
of
lubri-

cant
on the
bearing bores
so
that
the

differential bearing cups will move

easily.

11.
Place
the
cups
on the
bearings

and
set the
differential case assembly

in
the
carrier casting (Fig.
17).

If
the
gear
set is of the
non-hunting

or partial non-hunting type, assemble

the differential case
and
ring gear
as-

sembly
in the
carrier
so
that
the

marked tooth
on the
pinion indexes

between
the
marked teeth
on the
ring

gear
as
shown
in Fig. 25.

In almost every case
of
improper

assembly (gears assembled
out of

time),
the
noise level
and
probability

of failure will
be
higher than they

would
be
with properly assembled

gears.

When installing
the
hunting type

gear
set (no
timing marks), assemble

the differential case
and
ring gear
as-

sembly
in the
carrier without regard

to
the
matching
of any
particular gear

teeth.

12.
Slide
the
case assembly along

the bores until
a
slight amount
of

backlash
is
felt between
the
gear teeth.

Hold
the
differential case
in
place.

13.
Set the
adjusting nuts
in the

PAINT MARKING INDICATES POSITION
IN
WHICH GEARS WERE LAPPED

E 1335-B

FIG. 25—Typical Gear
Set
Timing Marks
7oo/—T60K-4067-A or 4067 E

E1916A

FIG. 26—Backlash
and
Bearing

Pre-Load Adjustmentprocarmanuals.com