group 4 rear axle

4-1

PAGE. .4-31

PAGE. . . . . . . .4-1

PART 4-3SPECIFICATIONS. . . . .

PART 4-1GENERAL AXLE SERVICE

PART 4-2REAR AXLES 4-11

AXLE SERVICEGENERAL

Page. . .4-8.. .4-9. . .4-9.. .4-9

Section Page1 Diagnosis and Testing 4-1

Diagnosis Guide 4-1Rear Axle Noise Diagnosis 4-1Limited-Slip Differential 4-2Gear Tooth Contact Pattern Check .4-3The Ideal Tooth Pattern 4-3Hunting Gear Set 4-3Non-Hunting Gear Set 4-4Partial Non-Hunting Gear Set. . . . . . . . . .. . . .4-5Shim and Backlash Changes. . . . . . . . . . . . . . . .4-5

2 Common Adjustments and Repairs. . . . . . . . . . .4-7Pinion and Drive Gear Tooth Contact

Adjustments 4-7Backlash and Differential Bearing Preload

Adjustments 4-7

SectionPinion Location. . . . . . . . . . . . . . . . . . . . . . .

3 Cleaning and Inspection. . . . . . . . . . . . . . . .Inspection Before Disassembly of Carrier.Inspection After Disassembly . . .Bearing Cups and Cone and Roller

Assemblies 4-10Differential Bearing Adjusting Nuts. . . . . . . . . .4-10Drive Pinion Flange 4-10Pinion Retainer 4-10Carrier Housing 4-10Differential Case 4-10Limited-Slip Differential Parts. . . . . . . . . . . . . .4-10

ential carrier is bolted to the axlehousing and can be removed fromth,e housing for service. A limited-slip differential is available as op-tional equipment in either type axle.

Two t)'pes of axles are covered inthis group. The integral carrier typeaxle is used only in Mustang andFalcon 6-cylinder models. In this typeaxle, the differential carrier is inte-

gral with the axle housing. The re-movable carrier type axle is used inMustang and Falcon 8-cylinder mod-els, and all Comet and Fairlanemodels. In this type axle, the differ-

D DIAGNOSIS AN D TESTINGDIAGNOSIS GUIDE noise is in no way a sign of trouble

Certain rear axle and drive line in the axle.trouble symptoms are also common . ~ere noise is present in an ob-to the engine, transmission, tires, and ]ectIonable form, loud and/ or at allother parts of the car. For this rea- speeds, the first efforts should beson, be sure that the cause of the made to isolate the noise. Rear axletrouble is in the rear axle before ad- noise is quite often confused with oth-justing, repairing, or replacing any of er. n.oises s';1ch as. tire noise~ tra.ns-the axle parts. mISSIon noIse, dnveshaft vIbration

and universal joint noise. Isolation ofREAR AXLE NOISE DIAGNOSIS the noise in anyone unit requires

Noise characteristics in a rear skill and experience. An attempt toaxle are more difficult to diagnose eliminate a slight noise may baffleand repair than mechanical failures. even the best diagnostic experts. AxleSlight axle noise heard only at a cer- noises fall into two basic categories:tain speed or under remote conditions gear noise and/ or bearing noise.must be considered normal. Axlenoise tends to peak or be more pro- Gear Noisenounced at varying speeds and the Abnormal gear noise can be rec-

ognized since it produces a cyclingpitch and will be very pronounced inthe ~peed range at which it occurs,usually under drive, float, cruise orcoast conditions. Gear noise tends topeak in a narrow speed range orranges, while bearing noise will tendto remain constant in pitch.

Bearing NoiseDefective bearings will produce a

whine that is constant in pitch andvaries with vehicle speed. This factwill help distinguish between bearingand/ or gear noise.

1. Pinion bearing noise can beidentified as a constant grindingnoise. Pinion bearings are rotating ata higher speed than differential side

4-2 GROUP 4 - REAR AXLE

shaft. Be sure that the transmissionis in neutral gear, one rear wheel ison the floor, and the other rearwheel is raised off the floor. Thetorque required to continuously ro-tate the shaft should be a specifiedin Part 4-3. The initial breakawaytorque may be higher than the con-tinuous turning torque, but this isnormal. The axle shaft should turnwith even pressure throughout thecheck without slipping or binding.

checked for proper operation with-out removing the carrier from theaxle housing.

Jack up one rear wheel and re-move the wheel cover. On a car witha removable carrier type axle, installtool T59L-4204-A on the axle shaftflange studs as shown in Fig. 1. Ona car with an integral carrier typeaxle, use tool T65K-4204-A.

Using a torque wrench of at least200 ft-ibs capacity, rotate the axle

bearings or axle shaft bearings. Thenoise is most noticeable at a slightpull between 18 to 25 miles per hour.

2. Wheel bearing noise may beconfused with rear axle noise. Todifferentiate between wheel bearingsand rear axle, drive the car on asmooth road at medium low speed.With traffic permitting, turn the carsharply right and left. If noise iscaused by wheel bearings, the noisewill increase on the defective bear-ing because of side loading.

3. Side bearings will produce aconstant grinding noise of a slowernature than pinion bearing, (sidebearing noise cannot be determinedby the wheel bearing test), but willbe in the same frequency as axleshaft bearings.

Also, certain trouble symptoms arecommon to both the conventionaland locking differential axles, whilestill other symptoms are found onlyin the locking differential.

To determine whether the car isequipped with a conventional or alocking differential, check the carwarranty plate and the axle ratio tag.Refer to CAR IDENTIFICATIONat the front of this manual.

LIMITED-SLIP DIFFERENTIAL

The limited-slip differential can be FIG. 1-Checking Limited-Slip Differential

REAR AXLE TROUBLE SYMPTOMS AND POSSIBLE CAUSES

Noise caused by a worn or dam-aged wheel bearing is often loudestwhen the car is coasting at lowspeeds, and it usually stops when thebrakes are gently applied. To find thenoisy bearing, jack up each wheel andcheck each bearing for roughnesswhile the wheel is rotating, providedthat the car is equipped with a con-ventional differential.

If all possible external sources ofnoise have been checked and elimi-nated, and the noise still exists, road-test the rear axle under all four driv-ing conditions-drive, cruise, float,and coast. Any noise produced by thesidegears and pinions in the differen-tial case will be most pronounced onturns. A continuous whine under alight load between 20 and 35 milesper hour indicates rough or brinnelledpinion bearings. If the tone of drive,coast and float noise differs withspeed and if the noise is very roughand irregular; worn, rough or loosedifferential or pinion shaft bearingsare indicated. Remove, disassemble,and inspect the axle.

EXCESSIVE REAR AXLENOIS£ (ALL REAR AXLES)

Since gears are in mesh, some rearaxle noise is normal. However, exces-sive noise often indicates the begin-ning of other troubles in the axle.

A road test can help determinewhether the noise is being caused bytrouble in the rear axle or in otherparts of the car. Before road-testingthe car, make sure that the tire pres-sures and the rear axle lubricantlevel are normal. Then drive the carfar enough to warm the axle lubri-cant to its normal operating tem-perature.

With the car stopped and the trans-mission in neutral, run the engine atvarious speeds. If the noise still existsduring this test, it probably comesfrom the engine or the exhaust sys-tem.

To determine if the noise is beingcaused by the rear axle or the tires,drive the car over several differenttypes of road surfaces. Smooth as-phalt or black-top roads minimizetire noises. Tire noises may be elimi-nated by cross-switching the tires.Snow tires often cause noises notheard with conventional tires.

PART 4-1 - GENERAL AXLE SERVICE 4-3

REAR AXLE TROUBLE SYMPTOMS AND POSSIBLE CAUSES (Continued)

Excessive backlash in the axledriving parts may be caused by wornaxle shaft splines, loose axle shaftflange nuts, loose V-joint flangemountings, excessive backlash be-

tween the drive pinion and ring gear,excessive backlash in the differentialgears, or bearings which are worn orout of adjustment.

EXCESSIVE REAR AXLEBACKLASH (ALL REARAXLES)

Use the procedure given underlimited-slip differential for checkingthe locking differential while the unitis in the car. If the torque requiredto rotate one rear wheel is less than

the specified minimum, the differen-tial is not functioning properly. Torepair the unit, remove it from theaxle housing.

ONE WHEEL SPINSEXCESSIVELY (LIMITED-SLIPDIFFERENTIAL ONLY)

Drive the car in a fairly tight cir-cle, making five circles clockwise andfive counterclockwise. This will per-mit the lubricant to work in betweenthe clutch plates. If the noise doesnot disappear during this driving test,it is probable that the axle does nothave the approved Ford lubricant.

The lubricant may be checked bydraining two tablespoonfuls from theaxle and mixing it with an equalamount of white alcohol, such asrubbing alcohol. Mix the lubricantand alcohol thoroughly and let it

AXLE HAS AHIGH-PITCHED, CHATTERINGNOISE ON TURNS(LIMITED-SLIP DIFFERENTIALONLY)

stand for at least two minutes. If thesample now has a blue tint, the lu-bricant is approved Ford lubricant. Ifit has a yellow tint, it is not the cor-rect lubricant. Drain and refill theaxle with the approved lubricant. Itis not necessary to flush the axlehousing.

After reffiling the axle drive thecar in fairly tight circles clockwiseand counterclockwise. The chatteringnoise should disappear as soon as thenew lubricant works in between theclutch plates.

types of gear sets as well as differ-ences between individual gear sets ofthe same type will result in patternsthat are acceptable yet different fromthose shown in Fig. 3.

If the torque reading is less thanthe specified minimum, check the dif-ferential for improper assembly.

A car equipped with a limited-slipdifferential will always have bothwheels driving. If, while the car isbeing serviced, only one wheel israised off the floor and the rear axleis driven by the engine, the wheel onthe floor will drive the car off thestand or jack.

HUNTING GEAR SET

In a hunting-type gear set, anyonepinion gear tooth comes into contactwith all drive gear teeth. In this type,several revolutions of the ring gearare required to make all possible gearcombinations.GEAR TOOTH CONTACT

PATTERN CHECK

Paint the gear teeth and roll a pat-tern as described in Section 3. Afterdiagnosing the tooth pattern as ex-plained here, make the appropriateadjustments as outlined in Section 2.

m making a final gear tooth con-tact pattern check, it is necessary torecognize the fact that there are threedifferent types of gear set, hunting,non-hunting and partial non-hunting.Each type is determined by the ratioand the number of teeth in the gears.The non-hunting and partial non-hunting types can be identified by thepaint timing marks on the pinion andring gear teeth (Part 4-2, Fig. 30).See Part 4-3 for complete identifica-tion specifications.

Acceptable Pa"ern

The drive pattern shown in Fig.4 was rolled on a hunting-type gearset. Since each pinion tooth came intocontact with each ring gear tooth,the pattern is a result of the com-

THE mEAL TOOl1l PATTERNFigs. 2 and 3 show the ideal tooth

pattern. This pattern is not a rigidstandard but merely a general role.

In general, desirable tooth pat-terns should have the following char-acteristics:

(a) The drive pattern should befairly well centered on the tooth.

(b) The coast pattern should becentered on the tooth but may beslightly toward the toe.

(c) Some clearance between thepattern and the top of the tooth isdesirable.

(d) There should be no hard lineswhere the pressure is high.

The individual gear set need notconform exactly to the ideal patternin order to be acceptable. Character-istic differences between the three

COAST SIDEDRIVE SIDE

HEELE L -- ---SHIM CORRECT

BACKLASH CORRECTHEEL

TOE

E1468.A

FIG. 2-ldeal Tooth Pattern-Integral Carrier Type Axle

4-4

DRIVE SIDE COAST SIDE

HEEL

DESIRABLE PATTERN

CORRECT SHIMCORRECT BACKLASH

E1336-A

FIG. 3-ldeal Tooth Pattern-Removable Carrier Type Axle

FIG. 6-UnacceptableNon-Hunting Pattern-Center-Heel-Center

bined tooth contacts. Therefore, thepattern is uniform from tooth totooth.

Unacceptable Pattern

An erratic tooth pattern on a hunt-ing gear set indicates gear runoutand possible need for gear replace-ment.

A pattern that is uniform, but offcenter indicates a change in shim orbacklash (Figs. 9 or 10).

NON.HUNTING GEAR SETIn a non-hunting type gear set, any

one pinion gear tooth comes into con-tact with only a few ring gear teeth.In this type, only one revolution ofthe ring gear is required to make allpossible tooth contact combinations.

Acceptable PatternsThe drive patterns shown in Figs.

5 and 6 were rolled on two differentnon-hunting type gear sets. The pat-tern in Fig. 5 runs from the toothcenter toward the toe and then back

FIG. 5-UnacceptableNon-Hunting Pattern-Center-roe-Center

to center. The pattern in Fig. 6 runsfrom the tooth center toward the heeland then back to center. Thesepatterns are not unusual for non-hunting gear sets ana are acceptable.The pattern on anyone ring geartooth was formed by only one pin-ion tooth coming into contact withit. Because of this limited toothcontact, the non-hunting pattern canbe more erratic than the huntingpattern and still be acceptable. Like-wise, the coast pattern on a non-hunting gear set is usually less uni-form tooth to tooth than it wouldbe on a hunting gear set (Fig. 7).

Fig. 8 shows a pattern rolled onanother gear set. In this case, the pat-tern is fairly uniform from tooth totooth.

Unacceptable PatternsA non-hunting gear set should be

checked for runout and possible re-placement if the pattern runs fromthe tooth center toward the toe and

4-5PART 4-1 - GENERAL AXLE SERVICE

the tooth, and the coast pattern isrolled on the concave side.

The movement of tooth contactpatterns with changes in backlashand shimming can be summarized asfollows:

set, anyone pinion tooth comes intocontact with only part of the ringgear teeth, but more than one revo-lution of the ring gear is required tomake all possible gear tooth combi-nations.

Tooth to tooth pattern uniformitywill usually be in between the hunt-ing and the non-hunting patterns.Partial non-hunting gear set patternswill usually be less uniform thanhunting gear set patterns, but moreuniform than non-hunting gear setpatterns.SHIM AND BACKLASHCHANGES

The patterns shown in Figs. 9 and10 are typical of gear sets that haveeither an incorrect backlash or an in-correct shim adjustment. Since eachgear set rolls a characteristic pattern,the patterns in Figs. 9 and 10 shouldbe considered as typical only andshould be used as a guide ratherthan a rigid standard. The drive pat-tern is rolled on the convex side of

E1341-A

FIG. 8-Acceptable Non-HuntingPattern-Uniformchange in shimming or backlashwhen its pattern tends to concentratetoward the heel or toe, top or bot-tom of most teeth (Figs. 9 and 10).PARTIAL NON.HUNTINGGEAR SET

In a partial non-hunting type gear

DRIVE SIDE COAST SlOE

Integral Carrier Type Axle

1. Thinner shim with the backlashconstant moves the pinion fartherfrom the ring gear.

8. Drive pattern moves towardthe top of the tooth (face contact)and toward the heel.

b. Coast pattern moves towardthe top of the tooth and slightly to-ward the toe.

2. Thicker shim with the backlashconstant moves the pinion closer tothe ring gear.

8. Drive pattern moves deeper onthe tooth (flank contact) and slight-ly toward the toe.

b. Coast pattern moves deeper onthe tooth and toward the heel.

3. Decreasing backlash moves thedrive gear closer to the pinion:

8. Drive pattern (convex side ofgear) moves slightly lower and to-ward the toe.

b. Coast pattern (concave side ofgear) moves lower and toward thetoe.

4. Increasing backlash moves thering gear away from the pinion:

8. Drive pattern moves slightlyhigher and toward the heel.

b. Coast pattern moves higher andtoward the heel.

If the patterns are not correct,make the changes as indicated. Thedifferential case and drive pinion willhave to be removed from the carriercasting to change a shim. When re-installing the pinion and ring gear ofa non-hunting or partial non-huntinggear set, be sure that the markedtooth on the pinion indexes betweenthe marked teeth on the ring gear(Fig. 30, Part 4-2). Refer to Pin-ion and Ring Gear Tooth ContactAdjustment, Section 2.

SHIM CORRECTDECREASE BACKLASH

.004

SHIM CORRECTINCREASE BACKLASH

.004

E1469.A

Removable Carrier Type Axle

1. Thicker shim with the backlashconstant moves the pinion fartherfrom the ring gear:

a. Drive pattern moves toward thetop of the tooth (face contact) andtoward the heel.

b. Coast pattern moves toward thetop of the tooth and slightly towardthe toe.

FIG. 9-Typical Gear Tooth Contact Patterns Indicating Shim orBacklash Change-Integral Carrier Type


DRIVE SIDE COAST SIDE

HEEL

TOE

1. BACKLASH CORRECT0.004 THICKERSHIM REQUIRED

2. BACKLASH CORRECT0.004 THINNERSHIM REQUIRED

3. SHIM CORRECTDECREASEBACKLASH

0.004

4. SHIM CORRECTINCREASEBACKLASH

0.004

E1342-A

b. Coast pattern moves higher andtoward the heel.

If the patterns are not correct,make the changes as indicated. Thepinion need not be disassembled tochange a shim. All that is required isto remove the pinion, bearing, andretainer assembly and install a differ-

FIG. 10-Typical Gear Tooth Contact Patterns Indicating Shim or BacklashChange-Removable Carrier Type

1. Thinner shim with the backlash ring gear closer to the pinion:constant moves the pinion closer to a. Drive pattern moves slightlythe ring gear. lower and toward the toe.

a. Drive pattern moves deeper on b. Coast pattern moves lower andthe tooth (flank contact) and slight- toward the toe.ly toward the toe. 4. Increasing backlash moves the

b. Coast pattern moves deeper on ring gear away from the pinion:the tooth and toward the heel. a. Drive pattern moves slightly

3. Decreasing backlash moves the higher and toward the heel.


set, be sure that the marked toothon the pinion indexes between themarked teeth on the ring gear (Fig.

30, Part 4-2). Refer to Pinion andRing Gear Tooth Contact Adjust-ment, Section 2.

ent shim. When reinstalling the pin-ion and retainer assembly of a non-hunting or partial non-hunting gear

COMMON ADJUSTMENTS AND REPAIRS

~~c: < ~

J.~~I;.;.;;,...

~i~"-:'-"'~

J; , -"NuT -

~--NlJT"'~',,1 BACKLASH~ ADJUSTMENT E1409-A

FIG. 12-Pinion and RingGear Tooth Contact Adjustment-Removable Carrier Type Axles

shims should be added to or removedfrom the original shim pack only asindicated by the tooth pattern checkdescribed in the foregoing Section 1.When adjusting the integral carriertype axle, add shims to move the pin-ion toward the ring gear; removeshims to move the pinion away fromthe ring .sear (Fig. 11). When adjust-ing the removable carrier type axle,remove shims to move the pinion to-ward the ring gear; add shims tomove the pinion away from the ringgear (Fig. 12).

The tooth pattern check also indi-cates whether the ring gear shouldbe adjusted away from or toward thepinion to increase or decrease back-lash between the gears.

If the tooth pattern check indicatesa change in backlash only, follow theprocedure under Backlash and Bear-ing Preload Adjustments. If the toothpattern indicates a change in shimthickness, follow the procedure underPinion Location.

BACKLASH AND DIFFEREN-TIAL BEARING PREWADADJUSTMENTS

To secure a u :')re uniform controlof differential si' ,e bearing preload inservice repairs, a dial indicator set-up such as shown in Fig. 13 is used.

PINION AND RING GEARTOOTH CONTACTADJUSTMENT

Two separate adjustments affectpinion and ring gear tooth contact.They are pinion location and back-lash (Figs. 11 and 12).

Individual differences in matchingthe differential housing and the gearset require the use of shims to locatethe pinion for correct contact withthe ring gear. On the integral carriertype axle, the pinion locating shimpack is installed between the pinionrear bearing cone and the piniongear (Fig. 11), whereas, on the re-movable carrier type axle, the shimsare installed between the pinion re-tainer and the carrier (Fig. 12). Dueto this difference in shim position, itshould be noted that adding or re-moving shims in the integral carriertype (Fig. 11) causes the pinion tomove in a direction exactly oppositeto the pinion movement caused byadding or removing shims in the re-movable carrier type (Fig. 12).

When adjusting either type axle,

rtPINION LOCATIa'iADJUSTMENT c

"'"",SPACER

PINla-I

\ OCATING SHIM

PACK

In both types of axle (Fig. 11 and12), the ring gear is moved awayfrom or toward the pinion as de-scribed in the following procedure.

1. Remove the adjusting nut locks,loosen the differential bearing capbolts, then torque the bolts to (15ft-lbs on integral carrier type axles;20 ft-lbs on removable carrier typeaxles) before making adjustments.

2. The left adjusting nut is on thering gear side of the carrier. Theright nut is on the pinion side. Loos-en the right nut until it is away fromthe cup. Tighten the left nut until thering gear is just forced into the pin-ion with no backlash then rotate thepinion several revolutions to be sureno binding is evident. (Recheck theright nut at this time to be sure thatit is still loose.) Tightening the leftnut moves the ring gear into the pin-ion to decrease backlash, and tight-ening the right nut moves the ringgear away.

3. Loosen the left adjusting nut 1to 11/2 notches. Tighten the right nutuntil it first contacts the bearing cup.Rotate the drive gear several revolu-tions in each direction while the bear-ings are loaded, to seat the bearingsin their cups to be sure no bind isevident. This step is important.

4. Install a dial indicator asshown in Fig. 13.

S. Again loosen the right nut torelease the pre-load. If there is anybacklash between the gears as shownby the dial indicator, tighten the leftnut just enough to remove this back-lash. At this time, make sure that oneof the slots in the left nut is so lo-cated that the lock can be installedwithout turning the nut. Carefullytighten the right nut until it just con-tacts the cup. On integral carrier typeaxles, set a preload of 0.008 inchcase spread for new bearings and0.003 to 0.005 for the original bear-ings. On removable carrier typeaxles, the preload is 0.012 inch casespread for new bearings and 0.005to 0.008 for the original bearings. Aspreload is applied from the right side,the ring gear is forced away fromthe pinion and usually results in thecorrect backlash.

BACKLASH

ADJUSTMENt

"'"

III

oJ, If~ DIFFERENTIAL BEARING,..J ~~ ADJUSTING NUTS

E1476-A

FIG. 11-Pinion and Ring GearTooth Contact Adjustment-Integral Carrier Type Axles

SHI

t?l

4-8 GROUP 4 REAR AXLE

FIG. 13-Adjusting Side Bearing Preload

6. Torque the differential cap bolts

to specification (15ft-Ibs).7. Measure the backlash on sev-

eral teeth around the ring gear. If

the measurements vary more than(0.002 inch-integral carrier type;

0.003 inch-removable carrier type)there is excessive runout in the gearsor their mountings, which must becorrected to obtain a satisfactoryunit. If the backlash is out of speci-fication, loosen one adjusting nut andtighten the opposite nut an equal

amount, to move the ring gear awayfrom or toward the pinion. Whenmoving the adjusting nuts, the finalmovement should always be made ina tightening direction. For example,if the left nut had to be loosened onenotch, 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 afterbeing put in service. After all suchadjustments, check to be sure that thecase spread remains as specified forthe new or original bearings used.

8. Again check the tooth contactpattern. If the pattern is still incor-rect, a change in pinion location(shim thickness) is indicated.

rier casting, and then remove the pin-ion bearings as described under Re-moval of Differential Case and Drive

Pinion in Section 4.

2. Measure the original shimthickness with a micrometer. Increaseor decrease the shim thickness as in-dicated by the tooth pattern checkdescribed in the foregoing Section 1and shown in Fig. 9.

3. Install the corrected shim packand the bearings on the pinion, andthen install the pinion and the differ-ential case in the carrier casting asoutlined under Installation of DrivePinion and Differential Case in Sec-

tion 4 of Part 4-2.

4. Adjust the backlash between thering 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 theshim thickness each time until a sat-isfactory tooth pattern is obtained.

Removable Carrier TypeAxle

1. Remove the attaching bolts andthe pinion and bearing retainer as-sembly from the carrier.

2. Measure the original shimthickness with a micrometer. Increaseor decrease the shim thickness as in-dicated by the tooth pattern checkdescribed in Section 1.

3. Replace the pinion retainer 0-ring (Fig. 47, Part 4-2). Coat theO-ring with axle lubricant before in-stalling. Do not roD the O-ring intothe groove. Snap it into position.

4. Being careful not to pinch theO-ring, install the pinion and bearingretainer assembly in the carrier withthe corrected shim pack.

Before installing the pinion andbearing retainer assembly, determinewhich type of gear set is being used.The non-hunting and partial non-hunting types can be identified by thepaint timing marks on the gear teeth(Fig. 30, Part 4-2).

If the gear set is of the non-hunt-ing or partial non-hunting type, cleanthe teeth on both the pinion and ringgear so that the timing marks arevisible. Rotate the differential caseand drive gear assembly in the car-rier until the marked teeth on thering gear are opposite the pinion en-try hole. Place the pinion retainerassembly in the carrier so that themarked tooth on the pinion indexesbetween the marked teeth on the ringgear (Fig. 30, Part 4-2).

In almost every case of improperassembly (gear assembled out oftime), the noise level and probabilityof failure wiD be higher than theywould be with properly assembled

gears.When installing the hunting type

gear set (no timing marks), assem-ble the pinion and retainer assemblyinto the carrier without regard to thematching of any particular gearteeth.

5. Install the retainer-to-carriermounting bolts and torque to speci-fications.

6. Adjust the backlash between thering gear and pinion as outlined inthe foregoing procedure.

7. Make a tooth pattern check. Ifthe pattern is still unsatisfactory, re-peat this procedure changing theshim thickness each time until a sat-isfactory tooth pattern is obtained.

PINION LOCATION

Integral Carrier Type Axle

1. Remove the differential caseand the drive pinion from the car-


FIG. 17-Checking Drive GearRunout-Removable Carrier TypeAxle

ways use new solvent when cleaningbearings. Do not spin bearings withcompressed air. Oil the bearings im-mediately to prevent rusting. Inspectthe parts for any major defects.Clean the inside of the housing be-fore rebuilding and installing theparts.

When a scored gear set is re-placed, the axle housing should bewashed thoroughly and steamcleaned. This can only be done effec-tively if the axle shafts and shaft sealsare removed from the housing. In-spect individual parts as outlined be-low.

GEARSExamine the pinion and ring gear

teeth for scoring or excessive wear.Extreme care must be taken not todamage the pilot bearing surface ofthe pinion.

The pattern taken during disas-sembly should be helpful in judgingif gears can be re-used. Worn gearscannot be rebuilt to correct a noisy

- - ~ E1309-A

FIG. 1S-Checking Backlash-Removable Carrier Type Axle

be detected by an erratic pattern onthe teeth. However, a dial indicatorshould be used to measure the run-out of the back face of the ring gear,as shown in Fig. 16 or 17. Refer toSpecifications Section for maximumallowable runout.

Loosen the differential bearing capbolts, and then torque to specifica-tion. Remove the adjusting nut locks.Carefully loosen one of the adjustingnuts to determine if any differentialbearing preload remains. If at leastone notch of preload remains, thedifferential bearings may be re-used,provided they are not pitted or dam-Iaged.

INSPECTION AFTERDISASSEMBLY

Thoroughly clean all parts. AI-

BACKLASH CHECK

FIG. 16-Checking Backlash and Runout-lnte~ral Carrier Type Axle

FIG. 14-Bench Fixture forCarrier Overhaul-RemovableCarrier Type Axle

Wipe the lubricant from the in-ternal working parts, and visually in-spect the parts for wear or damage.

Rotate the gears to see if there isany roughness which would indicatedefective bearings or chipped gears.Check the gear teeth for scoring orsigns of abnormal wear.

Check the differential case and thedrive pinion for end play.

Set up a dial indicator (Fig. 15 or16) and check the backlash at sev-eral points around the ring gear.

Backlash should be within specifi-cations as outlined in the Specifica-tions Section, Part 4-3.

To check the gear tooth contact,paint the gear teeth with the specialcompound furnished with each serv-ice ring gear and pinion. Wrap acloth around the drive pinion flangeto act as a brake. Rotate the ringgear back and forth (use a boxwrench on the ring gear attachingbolts for a lever) until a clear toothcontact pattern is obtained.

Certain types of gear tooth contactpatterns on the ring gear indicate in-correct adjustment. Noise caused byincorrect adjustment can often becorrected by readjusting the gears.Typical patterns and the necessarycorrections are explained under GearTooth Contact Pattern Check in Sec-tion 1.

Gear tooth runout can sometimes

INSPECTION BEFOREDISASSEMBLY OF CARRIER

The differential case assembly andthe drive pinion should be inspectedbefore they are removed from thehousing. These inspections can helpto find the cause of the trouble andto determine the correction needed.

On removable carrier type axles,mount the carrier in the holding fix-ture shown in Fig. 14.

GROUP 4 REAR AXLE4-10

condition. Gear scoring is the resultof excessive shock loading or the useof an incorrect lubricant. Scoredgears cannot be re-used.

Examine the teeth and thrust sur-faces of the differential gears. Wearon the hub of the differential sidegear can cause a chucking noiseknown as chuckle when the car isdriven at low speeds. Wear on splines,thrust surfaces, or thrust washers cancontribute to excessive drive linebacklash.

BEARING CUPSCheck bearing cups for rings,

scores, galling, or erratic wear pat-terns. Pinion bearing cups must besolidly seated. Check by attemptingto insert a O.OOI5-inch feeler betweenthese cups and the bottoms of theirbores.

CONE AND ROLLERASSEMBLIES

When operated in the cups, bear-ing rollers must turn without rough-ness. Examine the roller ends forwear. Step-wear on the roller ends in-dicates that the bearings were notpreloaded properly or that the rollerswere slightly misaligned.

If inspection reveals either a de-fective cup or a defective cone androller assembly, both parts should bereplaced to avoid early failure.

DIFFERENTIAL BEARINGADJUSTING NUTS

Temporarily install the bearingcaps and test the fit of the adjustingnuts in their threads.

The nuts should turn easily whenthe caps are tightened to 15 ft-lbs(integral carrier type) or 20 ft-lbs

(removable carrier type). The facesof the nuts that contact the bearingcups must be smooth and square. Pol-ish these with a fine abrasive on aflat surface. Replace the nuts or ex-amine the threads in the carrier, iftheir fit is not proper. Be sure thatthe bearing caps and adjusting nutsare on the side which they were ma-chined to fit by observing the punchmarks and scribe marks made dur-ing disassembly operations.

DRIVE PINION FLANGEBe sure that the ears of the flange

have not been damaged in removingthe drive shaft or in removing theflangt: from the pinion. The end ofthe flange that contacts the bearingcone (integral carrier type) or the oilslinger (removable carrier type) aswell as the flat surface of the pinionnut counterbore must be smooth.Polish these surfaces if necessary.Roughness aggravates backlashnoises, and causes wear of the flangewith a resultant loss in pinion bear-ing preload.

PINION RETAINER-REMOVABLE CARRIERTYPE AXLE ONLY

Be sure that the pinion bearingcups are seated. Remove any chipsor burrs from the mounting flange.Clean the groove for the O-ring sealand all lubricant passages. If the cupswere removed, examine the borescarefully. Any nicks or burrs in thesebores must be removed to permitproper seating of the cups.

CARRIER HOUSINGMake sure that the differential

beariniZ bores are smooth and the

threads are not damaged.Remove any nicks or burrs from

the mounting surfaces of the carrierhousing.

DIFFERENTIAL CASEMake sure that the hubs where the

bearings mount are smooth. Care-fully examine the differential casebearing shoulders, which may havebeen damaged when the beatingswere removed. The bearing assem-blies will fail if they do not seat firm-ly against the shoulders. Check thefit (free rotation) of the differentialside gears in their counterbores. Besure that the mating surfaces of thetwo parts of the case are smooth andfree from nicks or burrs.

LIMITEO-SLIP DIFFERENTIALPARTS

Inspect the clutch plates for un-even or extreme wear. The dog-earedclutch plates must be free from burrs,nicks, or scratches which could causeexcessive or erratic wear to the bond-ing material of the internally splinedclutch plates. The internally splinedclutch plates should be inspected forcondition of the bond, bonding ma-terial, and wear. Replace the bondedplates if their thickness is less than0.085 inch or if the bonded materialis scored or badly worn. Inspect thebonded plate internal teeth for wear.Replace them, if excessive wear isevident. Bonded plates should be re-placed as a set only.

Examine all thrust surfaces andhubs for wear. Abnormal wear onthese surfaces can contribute to anoisy axle.

Inspect the Belleville spring fornroner free hei2ht of 1/4 inch.

4-11

REAR AXLES

Section Page1 Description and Operation. . . . . . . . . . . . . . . . .4-11

Conventional Axles-Description. .. . .. . . . . .4-11Operation 4-12Limited-Slip Differential Axle-Description. . .4-12Operation 4-12

2 In-Car Adjustments and Repairs. ... .. .. . .. .4-13Rear Axle Shaft, Wheel Bearing and Oil Seal

Replacement 4-13Drive Pinion Oil Seal Replacement. . . . . . . . . .4-14Universal Joint Flange Replacement. .. .4-16

3 Removal and Installation. . . . . . . . . . . . . . . . . .4-17Rear Axle Housing-Integral Carrier Type. . .4-17Differential Carrier-Removable Carrier

Type 4-18Rear Axle Housing-Removable Carrier

Type 4-184 Major Repair Operations-Integral Carrier

Type Axle 4-19Disassembly 4-19Removal of Differential Case and Drive

Pinion 4-19Disassembly of Conventional Differential Case 4-19Disassembly of Limited-Slip Differential Case. 4-19Parts Repair or Replacement. .. . ., . . . . . . . . .4-19

Page

.4-19

.4-22

.4-22

.4-24.4-24

4-24

4-25

. .. .4-25

... .4-26

. ., .4-26

.. . .4-26

.. . .4-27

,4-27

SectionPinion Bearing Cups Differential Case, Bearings and Drive Gear

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .Installation of Drive Pinion and Differential

Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Major Repair Operations-Removable

Carrier Type Axles Disassembly. . . . . . . . . . . . . . . . . . . . . . . . .

Removal and Disassembly of ConventionalDifferential Case , Removal and Disassembly of Limited-Slip

Differential Case Removal and Disassembly of Drive Pinion

and Bearing Retainer Parts Repair or Replacement. . . . . . . . . . .

Pilot Bearing Pinion Bearing Cups ..., Drive Pinion and Gear Set. . . . . . . . . . . .

Assembly and Installation of Drive Pinionand Bearing Retainer Assembly and Installation of Conventional

Differential Case ..,..""",.,...,.Assembly and Installation of Limited-Slip

Differential Case. . . . . . . . . . . . . . . . . . . 4-30

below the centerline of the ring gear(Fig. 2).

The integral pinion gear and shaftand the pinion bearings are assem-bled in a pinion retainer, which isbolted to the carrier. In this axle, thepinion is straddle mounted; that is,the pinion is supported by bearingsboth in front of and to the rear ofthe pinion gear. Two opposed taperedroller bearings support the pinionshaft in front of the pinion gear. Astraight roller (pilot) bearing sup-ports the pinion shaft at the rear ofthe pinion gear. Pinion and ring geartooth contact is adjusted by shims be-tween the pinion retainer and the car-rier housing.

The differential assembly ismounted on two opposed taperedroller bearings, which are retained inthe carrier by removable caps. Theentire carrier assembly is bolted tothe axle housing.

Ball bearing assemblies (rearwheel bearings) are pressed onto theouter ends of the axle shafts and setin the outer ends of the axle housing.These bearings support the semi-float-

D DESCRIPTION AND

IDENTIFICATIONA metal tag stamped with the

model designation and gear ratio issecured to all Ford-produced axlesunder one of the rear cover-to-hous-ing bolts (integral carrier type) or thecarrier-to-housing bolts (removablecarrier type). The first five spaces onthe top line are reserved for themodel designation letters such asWCY-E, WDJ-C, or WEA-B. Theseletters indicate a specific combinationof the following factors: convention-al or limited-slip axle; diameter ofring gear; small or large wheel bear-ings; and the gear ratio. It is impor-tant, therefore, to use the model des-ignation for obtaining the correct re-

placement parts.

CONVENTIONAL AXLES

DESCRIPTION

Integral Carrier Type AxleThe rear axle assembly is an inte-

gral-type housing, hypoid design,with the centerline of the pinion setbelow the centerline of the ring gear(Fig. 1).

OPERATIONThe semi-floating axle shafts are

retained in the housing by ball bear-ings and a bearing retainer at theaxle housing outer ends.

The differential assembly ismounted on two opposed taperedroller bearings. The bearings are re-tained in the housing by removablecaps. Differential bearing preload anddrive gear backlash is adjusted bynuts located behind each differentialbearing cup.

The drive pinion assembly ismounted on two opposed taperedroller bearings. Pinion bearing pre-load is adjusted by a collapsible spac-er on the pinion shaft. Pinion andring gear tooth contact is adjustedby shims between the rear bearingcone and pinion gear.

j\ cover on the rear of the differ-ential housing provides access for in-spection and the removal and instal-lation of the differential assemblyand drive pinion.

Removable Carrier Type AxleThe rear axle is of the banjo-hous-

ing, hypoid gear type, in which thecenterline of the pinion is mounted


PINION GEAR4215

~

DIFFERENTIAL/ :: CASE ("

X j "",f ~

;" "/ ~

LEFT-HANDAXLE SHAFT

4735I

~

RIGHTAXLE SHAFT

4234

~'!i&i'!i&~

~

.~ PINION

4209 SEAL4859

FLANGE4851

~

DRIVE PINIONBEARINGS

4630.4621 . ,SEAL

'177BEARING

1225E1212.D

FIG. 1-Typical Rear Axle Assembly-Integral Carrier Type Axle

ing axle shafts at the outer ends. Theinner ends of the shafts spline to thedifferential side gears. Bearing re-tainer plates hold the shafts in thehousing. The left and right axle shaftsare not interchangeable, because theleft axle shaft is shorter than the

right.

OPERATION

The rear axle drive pinion receivesits power from the engine throughthe transmission and drive shaft. Thepinion gear rotates the differentialcase through engagement with thering gear, which is bolted to the caseouter flange. Inside the case, thereare two differential pinion gearsmounted on the differential pinionshaft which is pinned to the case.These pinion gears are engaged withthe side gears, to which the axleshafts are splined. Therefore, as thedifferential case turns, it rotates theaxle shafts and rear wheels. When itis necessary for one wheel and axleshaft to rotate faster than the other,the faster turning side gear causes thepinions to roll on the slower turning

ferential action to take place. Underadverse weather conditions, whereone or both wheels may be on a low-traction surface such as snow, ice ormud, the friction between the clutchplates will transfer a portion of theusable torque to the wheel with themost traction. Thus, the wheel thatis on ice or snow will not spin, butwill have a tendency to operate withthe opposite wheel in a combineddriving effort.

When performing the followingprocedures, refer to Part 4-1, Section3 for cleaning and inspection proce-dures.

CARE OF AXLEThe lubricant level should be

checked every 6000 miles, with ve-hicle in normal curb attitude. The lu-bricant level should be at the loweredge of the filler plug hole. It is un-necessary to periodically drain theaxle lubricant. The factory fill shouldremain in the housing for the life ofthe vehicle, except when repairs aremade. The specified lubricant shouldbe installed when the axle is over-h""lplj

side gear to allow differential actionbetween the two axle shafts.

LIMITED-SLIP DIFFERENTIALAXLE

The locking differential is providedas optional equipment in both the in-tegral and the removable carrier typeaxle.

DESCRIPTIONThe axle assembly, except for the

differential case and its internal com-ponents, is identical to the conven-tional axle.

A constant-friction locking differ-ential, which employs automatictransmission-type clutch plates tocontrol differential action, is avail-able as optional equipment (Fig. 3).

Four steel clutch plates are lockedinto the differential cover. Threebronze, bonded clutch plates aresplined to the left-hand axle shaft. ABelleville spring washer maintains aconstant pressure between the steeland bonded clutch plates so that theclutch is always engaged.

OPERATIONThe pressure between clutch plates

opposes differential action at alltimes. When the car turns a cornerthe clutch slips allowin2 normal dif-

PART 4-2 - REAR AXLES 4-13

~

LEFT-HAND AXLE SHAFT

~~~

",: .),

,,1RING GEAR

DRIVE PINION

RIGHT-HAND AXLE SHAFT

I[J11

TAPERED ROLLERBEARINGS

~~

.:

~

PINION PILOT BEARING

PINION BEARING RETAINERE1304-B

FIG. 2-Rear Axle Assembly-Removable Carrier Type Axle

FIG. 3-Typical Limited-Slip Differential

the drum from the flange.3. Working through the hole pro-

vided in each axle shaft flange, re-move the nuts that secure the wheelbearing retainer plate. Then pull theaxle shaft assembly out of the axle

REAR AXLE SHAFT, WHEELBEARING AND OIL SEALREPLACEMENT

The rear axle shafts, wheel bear-ings, and oil seal can be replacedwithout removing the differential as-

sembly from the axle housing.1. Remove the wneeI and tire

from the brake drum.2. Remove the Tinnerman nuts

that secure the brake drum to theaxle housing flange, and then remove


FIG. 4-Removing AxleShaft-Integral CarrierType Axle

-'---"" E1O32-D

FIG. 5-Removing Axle Shaft-Removable CarrierType Axle

housiQg (Fig. 4 or 5). The brake car-rier plate must not be dislodged. In-stall one nut to hold the plate in placeafter the axle shaft is removed.

4. If the rear wheel bearing is tobe replaced, loosen the inner retainernick by nicking it deeply with a coldchisel in several places (Fig. 6). Itwill then slide off easily.

side of the brake carrier plate, andthen carefully slide the axle shaft in-to the housing so that the roughforging of the shaft will not damagethe oil seal. Start the axle splines intothe side gear, and push the shaft inuntil the bearing bottoms in the hous-ing.

15. Install the bearing retainerplate on the mounting bolts at theaxle housing, and install the attach-ing nuts. Torque the nuts to specifi-cations.

16. Install the brake drum and thedrum attaching nuts.

17. Install the wheel and tire on~he drum.

~

1.)Qi'~!,

':.:-_c - E1420-A

FIG. 6-Removing Rear WheelBearing Retainer Ring

REMOVAL AND REPLACEMENTOF DRIVE PINION OIL SEAL

Replacement of the pinion oil sealon either type axle involves removaland installation of only the pinionshaft nut and the universal jointflange. However, this operation dis-turbs the pinion bearing preload, andthis preload must be carefuUy resetwhen assembling.

1. Raise the car and install safetystands. Remove the rear wheels andbrake drums.

2. Make scribe marks on the driveshaft end yoke and the axle V-jointflange to insure proper position of thedrive shaft at assembly (Fig. 14).Disconnect the drive shaft from theaxle V-joint flange. Be careful toavoid dropping the loose universaljoint bearing cups. Hold the cups onthe spider with tape. Mark the cupsso that they will be in their originalposition in relation to the flange whenthey are assembled. Remove the driveshaft from the transmission exten-sion housing. Install an oil seal re-

5. Remove the bearing from theaxle shaft with the tool shown in Fig.7 or 8. If the push-puller operationshown in Fig. 8 is used, be sure thatthe puller arms contact the flat sur-fate of the axle shaft flange ratherthan the bolt heads. Also with thismethod, be careful not to damage orburr the oil seal journal as the bear-ing breaks loose.

6. Whenever a rear axle shaft is

removed, the oil seal must be re-placed. Remove the seal with thetools shown in Fig. 9. Soak new oilseals in SAE 10 oil for 1/2 hour be-fore installing.

7. Inspect the machined surface ofthe axle shaft and the axle housingfor rough spots or other irregularitieswhich would affect the sealing actionof the oil seal. Check the axle shaftsplines for burrs, wear or damage.Carefully remove any burrs or roughspots. Replace worn or damagedparts.

8. Lightly coat wheel bearingbores with ball joint grease (C3VY-19586-B).

9. Place the retainer plate on theaxle shaft, and press the new wheelbearing on the. shaft with the toolshown in Fig. 7 or 8. The bearingshould seat firmly against the shaftshoulder. Do not attempt to press onboth the bearing and the inner re-tainer ring at the same time.

10. Using the bearing installationtool, press the bearing inner retain-er ring on the shaft until the retainerseats firmly against the bearing.

11. Wipe all lubricant from the in-side of the axle housing in the areaof the oil seal before installing thenew seal.

12. Wipe a small amount of oilresistant sealer on the outer edge ofthe seal before it is installed. Do notput sealer on the sealing lip.

13. Install the new oil seal withthe tools shown in Fig. 9. Installationwithout use of the proper tool willdistort the seal and cause leakage.Be sure the new seal has been soakedin SAE 10 oil for 1/1; hour.

14. Place a new gasket on each

Tnn/_A?~,,_r /~


Tool-60K-1177-Borl177-BorC

INSTALLATION E1214.DREMOVAL

FIG. 9-Removing and Installing Axle Shaft Seal

placer tool in the transmission exten-sion housing to prevent transmissionleakage. Refer to the transmissiongroup for the appropriate tool.

3. Install an in-ib torque wrenchon the pinion nut. Record thetorque required to maintain rota-tion of the pinion shaft through sev-eral revolutions.

4. While holding the flange withthe tool shown in Fig. 10, remove theintegral pinion nut and washer.

Too/-T53T.485!.Aor 4851.A

,

f,.~c'~L

E1223-8

FIG. ll-Typical Drive PinionFlange RemovalFIG. 10-Typical Drive Pinion

Shaft Nut Removal

5. Clean the pinion bearing retain-er around the oil seal. Place a drainpan under the seal, or raise the frontof the car higher than the rear.

6. Using the tool shown in Fig.11, remove the pinion U-joint flange.

7. Using the tool shown in Fig.37, remove the drive pinion oil seal.

8. Clean the oil seal seat.9. Coat the outer edge of the new

seal with a small amount of oil resis-tant sealer. Do not put any of thesealer on the sealing lip. Install theseal in the retainer, using the toolshown in Fig. 12 on integral carriertype axles. With removable carriertype axles, use tool T62F-4676-A or4676-H on all except cars equippedwith high performance engines. Oncars equipped with high perform-

E1227-B

shaft to be sure they are free of burrs.If burrs are evident, remove themby using a fine crocus cloth, workingin a rotational motion. Wipe the pin-ion shaft clean.

11. Apply a small amount of lubri-cant to the V-joint splines.

12. Align the punch mark on theV-joint flange with the mark on theend of the pinion shaft, and installthe flange. With removable carriertype axles, it will be necessary to usethe tool shown in Fig. 50 to installthe flange.

13. Install a new integral nut andwasher on the pinion shaft. (Applya small amount of lubricant on thewasher side of the nut.)

14. Hold the flange with the toolshown in Fig. 36 while tightening thenut.

15. Tighten the pinion shaft nut,rotating the pinion occasionally to in-sure proper bearing seating, and takefrequent preload readings until thepreload is at the original recordedreading established in step 3.

16. After original preload hasbeen reached, tighten the pinion nutslowly, until an additional preloadhas been placed on the bearings, asshown below:

Removable Carrier: 8 to 14 in-ibs.Integral Carrier: 6 to 12 in-ibs.The preload should not exceed the

amount indicated above, or bearingfailure may result. Under no circum-stances should the pinion nut bebacked-off to lessen preload. If thisis done, a new pinion bearing spacermust be installed. In addition, theV-joint flange must never be ham-mered on, or power tools used.

17. Remove the oil seal replacertool from the transmission extensionhousing. Install the front end of thedrive shaft on the transmission out-put shaft.

18. Connect the rear end of thedrive shaft to the axle V-joint flange,aligning the punch marks made onthe drive shaft end yoke and the axleV-joint flange (Fig. 14).

19. Check the lubricant level.Make sure the axle is in running po-sition. Add whatever amount of spec-ified lubricant is required to reachthe lower edge of the filler plug hole.mSTALLATION OF A NEWUNIVERSAL JOINT FLANGE

1. Raise the car and install safetystands. Remove both rear wheelsand brake drums.

2. Disconnect the drive shaftfrom the axle V-joint flange. Becareful to avoid dropping the loose

FIG. 12-Typical Drive PinionFlange Seal Installation

ance engines, use tool 58L-4676-A or4676-F.

10. Check splines on the pinion

PART 4-2 REAR AXLES 4.17

7. Check splines on the pinionshaft to be sure they are free of burrs.If burrs are evident, remove them byusing a fine crocus cloth, workingin rotational motion, then wipe clean.

Apply a small amount of lubricantto V-joint splines.

8. Install the V-joint flange usingthe tool shown in Fig. 50.

9. Install a new integral nut andwasher on the pinion shaft. (Apply asmall amount of lubricant on thewasher side of the nut.)

10. Hold the flange with the toolshown in Fig. 35 while the nut is be-ing tightened.

11. Tighten the pinion shaft nut,rotating the pinion occasionally to in-sure proper bearing seating, andtake frequent preload readings untilthe preload is at the original recordedreading established in step 3.

12. After original preload hasbeen reached, tighten the pinion nutslowly, until an additional preload of8 to 14 in-ib over the original reading

is reached. (The preload should notexceed 8 to 14 in-lb over the originalreading, or bearing failure may re-sult.)

Under no circumstances should thepinion nut be backed off to lessenpreload. If this is done, a new pinionbearing spacer must be installed. (Inaddition, the V-joint flange must nev-er be hammered on, or pneumatictools used.)

13. Remove the oil seal replacertool from the transmission extensionhousing. Install the front end of thedrive shaft on the transmission out-put shaft.

14. Connect the rear end of thedrive shaft to the axle V-joint flange,aligning the scribe marks made onthe drive shaft end yoke and the axleV-joint flange (Fig. 14).

14. Check the lubricant level.Make sure the axle is in running posi-tion. Add whatever amount of spec-ified lubricant is required to reachthe lower edge of the filler plug hole.

universal joint bearing cups. Holdthe cups on the spider with tape.Mark the cups so that they will bein their original position in relationto the flange when they are assem-bled. Remove the drive shaft fromthe transmission extension housing.Install an oil seal replacer tool in thetransmission extension housing toprevent transmission fluid leakage.Refer to the transmission group forthe appropriate tool.

3. Install an ip-lb torque wrenchon the pinion nut. Record the torquerequired to maintain rotation of thepinion shaft through several revolu-tions.

4. While holding the flange withthe tool shown in Fig. 36, removethe integral pinion nut and washer.

S. Clean the pinion bearing retain-er around the oil seal. Place a drainpan under the seal, or raise the frontof the car higher than the rear.

6. Using the tool shown in Fig.36, remove the V-joint flange.

REMOVAL AND INSTALLATION

REAR AXLE HOU5ING-INTEGRAL CARRIER TYPE AXLE

can be installed. On a Comet or Fair-lane position the spring upper insu-lators and retainers between the axlehousing and springs and install thelower insulators. Torque the springclip nuts to specification.

2. Place the brake carrier platesin their normal position on the axlehousing. Use new gaskets on eachside of the brake carrier plates.

3. Install new axle shaft oil sealswith the tool shown in Fig. 9. Soakthe new seals in light weight engineoil (SAE 10) for 1/2 hour before in-stalling them. Installation without use

10. Support the rear axle housingon a jack, and then remove the springclip nuts. Remove the spring clipplates (Fig. 13).

11. Lower the axle housing andremove it from under the car.

11. If the axle housing is beingreplaced, transfer all the differentialand pinion parts to the new housing.See Section 4, Major Repair Opera-tions.

INSTALLATION1. Raise the axle housing into po-

sition so that the spring clip plates

REMOVAL1. Raise the car and support it

with safety stands under the rearframe member.

2. Drain the lubricant from theaxle.

3. Disconnect the drive shaft atthe drive pinion flange.

4. Disconnect the lower end of theshock absorbers.

5. Remove the wheels, brakedrums and both axle shafts as out-lined in the foregoing Section 2.

6. Remove vent hose front venttube (Corbin clamp) and removevent tube from brake tube junctionand axle housing.

7. Remove the hydraulic brake T-fitting from the axle housing. Do notopen the hydraulic brake systemlines. Remove the hydraulic brakeline from its retaining clip on theaxle housing.

8. Remove both axle shaft oil sealswith the tools shown in Fig. 9.

9. Remove both brake carrierplates from the; axle housing and sus-pend them above the housing withmechanic's wire. The hydraulic brakelines and the parking brake cablesare still attached to the brake car-rier plates.

E 1231-A

FIG. 13-Rear Axle Installation-Integral Carrier Type


axle. Remove the carrier assemblyfrom the axle housing.

INSTALLATION1. Clean the axle housing and

shafts using kerosene and swabs. Toavoid contamination of the grease inthe sealed ball bearings, do not allowany quantity of solvent directly onthe wheel bearings. Clean the matingsurfaces of the axle housing andcarrier.

2. Position the differential carrieron the studs in the axle housing usinga new gasket between carrier andhousing. Install the copper washersand the carrier-to-housing retainingnuts, and torque to specifications.

3. Remove the oil seal replacertool from the transmission extensionhousing. Position the drive shaft sothat the front U-joint slip yoke splinesto the transmission output shaft.

4. Connect the drive shaft to theaxle U-joint flange, aligning thescribe marks made on the drive shaftend yoke and the axle U-joint flangeduring the removal procedure (Fig.14). Install the U-bolts and nuts andtorque to specifications.

7. Install the bearing retainers onthe attaching bolts on the axle hous-ing flanges. Install the nuts on thebolts and torque to specifications.

8. Install the two rear brakedrums and the drum retaining (Tin-nerman) nuts.

9. Install the rear wheel and tireassemblies.

10. If the rear brake shoes werebacked off, adjust the brakes as out-lined in Part 2-1.

11. Fill the rear axle with speci-fied lubricant.

AXLE HOUSING-REMOVABLECARRIER TYPE AXLE

of the proper tool will distort theseal and cause leakage. Coat the out-side edges of the new oil seal with ahardening type of sealer such as Per-matex No.2 or its equivalent.

4. Install the axle shafts, brakedrums and wheels as outlined in theforegoing Section 2.

5. Attach the hydraulic brake lineT fitting to the axle housing, and se-cure the hydraulic brake line in itsretainer on the axle housing.

6. Install vent tube to brake tubejunction and install vent hose to venttube.

7. Raise the axle housing and con-nect the shock absorbers.

8. Connect the drive shaft at thedrive pinion shaft.

9. Fill the axle with the propergrade and amount of lubricant.

10. Road test the car.

DIFFERENTIALREMOV ABLE (AXLE

DRIVE SHAFT END YOKE,AXLE FLANGE

.U-BOLT

..SCRIBE MARKS E 13 51 -A

FIG. 14-Drive Shaft-to-AxleU-Joint Connection

5. Soak two new rear wheel bear-ing oil seals in SAE 10 oil for Ihhour before installation. Wipe asmall amount of an oil resistant seal-er on the outer edge of each seal be-fore it is installed. Do not put any ofthe sealer on the sealing lip. Installthe oil seals in the ends of the rearaxle housing with the tool shown inFig. 9.

6. Install the two axle shaft assem-blies in the axle housing. The shortershaft goes into the left side of thehousing.

When installing an axle shaft,place a new gasket on each side ofthe brake carrier plate and carefullyslide the axle shaft into the housing sothat the rough forging of the shaftwill not damage the oil seal. Startthe axle splines into the differentialside gear, and push the shaft in untilthe bearin2 bottoms in the housin2.

REMOVAL1. Remove the carrier assembly

from the axle housing as outlined inthe foregoing procedure.

2. Position safety stands under therear frame members.

3. Disengage the brake line fromthe clips that retain the line to theaxle housing.

4. Disconnect the vent tube fromthe rear axle housing.

5. Remove the brake carrier plateassemblies from the axle housing,and support them with wire. Do notdisconnect the brake line.

6. Disconnect each rear shock ab-sorber from the spring clip plate andposition out of the way.

7. Lower the rear axle slightly toreduce some of the spring tension. Ateach rear spring, remove the springclip (V-bolt) nuts, spring clips, andspring clip plate. Remove the springlower insulator and retainer. SeePart 3-2.

8. Remove the rear axle housingfrom under the car.

INSTALLATION1. Position the rear axle housing

on the rear springs. On a Comet orFairlane, position the spring upperinsulators and retainers between theaxle housing and springs, and installthe lower insulators.

2. Install the spring clips (U-bolts), spring clip plate, and nuts.Torque the spring clip nuts evenly tospecifications.

3. If a new axle housing is beinginstalled, remove the bolts that retainthe carrier plate and bearing retainerfrom the old housing flanges. Posi-tion the bolts in the new housingflanges to hold the brake carrierplates in position. Install the carrierplates with new gaskets to the axlehousinl! flanl!es.

REMOVAL1. Raise the car on a hoist and

remove the two rear wheel and tireassemblies.

2. Remove the two brake drums(3 Tinnerman nuts at each drum)from the axle shaft flange studs. Ifdifficulty is experienced in removingthe drums, back off the brake shoesas explained In Part 2-2.

3. Working through the hole pro-vided in each axle shaft flange, re-move the nuts that secure the rearwheel bearing retainer plate~ Pulleach axle shaft assembly out of theaxle housing (Fig. 5). Install a nut onone of the brake carrier plate retain-ing bolts to hold the plate to the axlehousing after the shaft has been re-moved. Whenever a rear axle shaftis removed, the wheel bearing oilseal must be replaced. Remove bothseals with the tools shown in Fig. 9.

4. Make scribe marks on the driveshaft end yoke and the axle V-jointflange to insure proper position at as-sembly. Disconnect the drive shaft atthe rear axle V-joint, remove thedrive shaft from the transmission ex-tension housing. Install an oil seal re-placer tool in the housing to preventtransmission leakage. Refer to thetransmission group for the appro-priate tool.

5. Place a drain pan under thecarrier and housing, remove the car-rier retaininv; nuts. and drain the

CARRIER-:ARRIER TYPE


the rear shock absorbers to the springclip plates. Connect the lower stud ofeach shock absorber to its springclip plate, and install the bushing,washer, and nut on the stud. Be surethe spring clip plate is free of burrs.Tighten the nut to specified torque.

7. Install the carrier assembly andthe two axle shaft assemblies in theaxle housing as outlined in the In-stallation procedure under Differen-tial Carrier-Removable CarrierType Axle.

4. Connect the vent tube to theaxle housing.

5. Position the brake line to theaxle housing, and secure with theretaining ciips.

6. Raise the rear axle housing andsprings enough to allow connecting

CARRIER TYPE AXLE

attaching bolts. This procedure willcontain the spring pressure betweenthe differential case and cover untilafter the bolts are removed, andthereby prevent stripping of thethreads.

2. Release the hydraulic pressram, and remove the differentialcase cover.

3. Remove the Belleville spring(Fig. 21).

4. Remove the steel and thebonded clutch plates.

5. Remove the differential clutchhub, outer side gear, and thrustwasher.

6. Remove the ring gear from thedifferential case.

7. Drive out the differential pin-ion shaft lock pin.

8. With a brass drift, drive outthe differential pinion shaft. Then re-move the pinion gears, inner sidegear and thrust washers.

PARTS REPAIR ORREPLACEMENT

Clean and inspect all the parts asoutlined in Part 4-1, Section 3. Be-fore assembling the carrier, repair orreplace all parts as indicated by theinspection.

The principal replacement opera-tions are covered in the followingprocedures. All other repair or re-placement operations are performedduring Cleaning and Inspection Part4-1, Section 3, or during the Assem-bly in this section.

adjusting nut locks (Fig. 15).10. Mark one differential bearing

cap and the case (Fig. 16) to helpposition the parts properly during as-sembly.

11. Remove the differential bear-ing cap bolts and bearing caps. Holdthe differential case assembly in thehousing after the caps are removed.

12. Remove the differential caseand bearing cups (Fig. 17).

13. Hold the drive pinion flangeand remove the pinion nut (Fig. 10).

14. Remove the pinion flange(Fig. 11).

15. With a soft-faced hammer,drive the pinion out of the front bear-ing cone and remove it through therear of the carrier casting.

16. Drive against the pinion frontbearing cone, and drive the pinionflange seal and the bearing cone outof the front of the carrier casting.

17. To remove and install the pin-ion rear bearing cone use the toolsin Fig. 18.

18. Measure the shim which isfound under the bearing cone witha micrometer. Record the thicknessof the shim.

DISASSEMBLY OFCONVENTIONALDIFFERENTIAL CASE

1. If the differential bearings areto be removed, use the tools shownin Fig. 19.

2. Remove the bolts that attachthe ring gear to the differential case.Press the ring gear from the case ortap it off with a soft-faced hammer.

3. With a drift, drive out the dif-ferential pinion shaft lock pin (Fig.20.

PINION BEARING CUPSDo not remove the pinion bear-

ing cups from the carrier casting un-less the. cups are worn or damaged.

If the pinion bearing cups are tobe replaced, drive them out of thecarrier casting with a drift. Installthe new cups with the tool shown inFig. 22. Make sure the cups areproperly seated in their bores. If aO.OO15-inch feeler gauge can be in-serted between a cup and the bottomof its bore at any point around the

4. Drive out the pinion shaft witha brass drift. Remove the gears andthrust washers.

DISASSEMBLY OF LIMITED-SLIP DIFFERENTIAL CASE

1. Place the differential case in ahydraulic press, and apply about oneton pressure across the case bearinghubs while removing the drive gear

DISASSEMBLYAll service operations on the dif-

ferential case assembly and the drivepinion assembly can be performedwith the housing in the car.

REMOVAL OF DIFFERENTIALCASE AND DRIVE PINION

1. Raise the car and support it onthe underbody, so that the rear axledrops down as far as the springs andshock absorbers permit.

2. Remove the cover from the car-rier casting rear face, and drain thelubricant. On a Mustang, the mufflerassembly must be removed to provideclearance for removing the cover.

3. Perform the Inspection BeforeDisassembly of Carrier in Part 4-1,Section 3.

4. Remove both rear wheels.5. Remove the brake drums.6. Working through the hole pro-

vided in the axle shaft flange, removethe nuts that attach the wheel bear-ing retainers to the axle housing.

7. Pull the axle shafts with thetool shown in Fig. 4. Install a nut onone of the brake carrier plate attach-ing bolts to hold the plate to the axlehousing after the shaft has been re-moved. Whenever a rear axle shaftis removed the wheel bearing on sealmust be replaced. Remove both sealswith the tool shown in Fig. 9.

8. Make scribe marks on the driveshaft end yoke and the axle V-jointflange to insure proper position of thedrive shaft at assembly (Fig. 14).Disconnect the drive shaft from theaxle V-joint flange. Be careful toavoid dropping the loose universaljoint bearing cups. Hold the cups onthe spider with tape. Mark the cupsso that they will be in their originalposition in relation to the flange whenthey are assembled. Remove the driveshaft from the transmission extensionhousing. Install an oil seal replacertool in the transmission extensionhousing to prevent transmission leak-age. Refer to the transmission groupfor the appropriate tool.

9. Remove the differential bearing


DiffERENTIAL PINION SHAfT

DiffERENTIAL PINION GEAR --.61 181. ~ a \0AND THRUST WASHER~V ~ N

rg 0 ; @ (9 DiffERENTIAL SIDE GEARCOVER AND GASKET SHAfT RETAINER AND THRUST WASHER

E1216-E~--FIG. 1 5-Disassembled Rear Axle

m"""",~v"" ---"'" E1257-A

FIG. 16-Typical DifferentialBearing Cap Marking

~

E1258-A

FIG. 1 7 -Differential CaseRemoval or Installation

FIG. 1 a-Pinion Rear Bearing (one Removal and Installation

cup, the cup is not properly seated. set, each pinion gear is marked withWhenever the cups are replaced, an adjustment number such as the

the cone and roller assemblies should + 2 marking in Fig. 23.also be replaced. When replacing a ring gear and

pinion it should be noted that theDRIVE PINION AND GEAR SET original factory installed shim is of

Individual differences in machin- the correct thickness to adjust foring the carrier casting and the gear individual variations in both theset require a shim between the pin- carrier casting dimension and in theion rear bearing cone and the pinion original gear set dimension; there-gear to locate the pinion for correct fore, to select the correct shim thick-tooth contact with the ring gear. In ness for the new gear set to be m-order to adjust the shim pack to the stalled, follow these steps:correct thickness for a given gear 1. Measure the thickness of the


FIG. 21-Locking Differential Assembly

FIG. 19-Differential BearingRemoval

FIG. 22-Pinion Bearing Cup Removal or Installation

MATCHED GEAR-SET

IDENTifiCATION

MARKING FORSHIM SELECTION

E 1226-8

FIG. 20-Differential PinionShaft Lock Pin Removal

FIG. 23-Gear Set Markings

the correct amount of shim thicknesschange. The amount shown in Table1 under the old pinion shim adjust-ment number and in line with thenew pinion number is the amount ofchange that should be made to the

oriwnal shim thickness.If the old pinion is marked +4,

for example. and the new pinion ismarked - 2, the table indicates that

0.006 inch of shim stock should beadded to the original shim pack.

original shim with a micrometer.2. Note the shim adjustment num-

ber on both the old pinion and thenew pinion.

3. Refer to Table 1 to determine

4-22

TABLE 1

GROUP 4 REAR AXLE

.Drive Pinion Adjusting Shim Thickness Changes (Inch)

New Pinion MarkingOld PinionMarking -4

+0.008

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-3

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-2

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-0.002

-1

+0.005

+0.004

+0.003

+0.002

+0.001

0

-0.001

-0.002

-0.003

0

+0.004

+0.003

+0.002

+0.0010

-0.001

-0.002

-0.003

-0.004

+1

+0.003

+0.002

+0.0010

-0.001

-0.002

-0.003

-0.004

-0.005

+2

+0.002+0.001

0-0.001-0.002- 0.003- 0.004

-0.005-0.006

+3

+0.0010

-0.001-0.002-0.003- 0.004

-0.005-0.006-0.007

+4+3+2+1

0-1-2-3-4

+4

0-0.001-0.002 i-0.003-0.004-0.005-0.006-0.007-0.008 I

gears align with the pinion shaftholes in the case.

5. Start the pinion shaft into thedifferential case. Carefully align theshaft lock pin hole with the pin holein the case. Drive the shaft into placeand install the lock pin (Fig. 20).

6. Place the ring gear on the dif-ferential case and install the bolts.Torque the bolts to specification.

7. If the differential bearings havebeen removed, press them 01) asshown in Fig. 24.

5. Again loosen the right nut torelease the preload. Check to seethat the left nut contacts the bearingcup. Using the dial indicator set-upshown in Fig. 13, Part 4-1, adjustthe preload to 0.012 case spreadfor new bearings or 0.005 to 0.008for the original bearings, if re-used.

6. Check the runout of the dif-ferential case flange with a dial indi-cator. If the runout does not nowexceed specifications, install a newring gear. If the runout still exceedsspecifications, the ring gear is trueand the trouble is due to either adefective case or worn bearings.

7. Remove the differential casefrom the carrier and remove the sidebearings from the case.

8. Install new bearings on the casehubs, and again install the differentialassembly in the carrier without thering gear.

9. Check the case runout againwith the new bearings. If the runoutis now within limits, the old bearingswere excessively I worn. Use the newbearings for assembly. If the runoutis still excessive, the case is defectiveand should be replaced.

ASSEMBLYRefer to Part 4-]

Inspection beforeoperations.

If the original shim pack was lostor if a new carrier casting is beinginstalled, substitute a nominal 0.018inch shim for the original, and fol-low the foregoing procedure for atrial build-up. If any further shimchange is necessary, it will be indi-cated in the tooth pattern check.

A new ring gear and pinion shouldalways be installed in an axle as amatched set (never separately). Besure that the same matching numberappears on both the drive pinion andthe ring gear. Note the number 818in Fig. 23.

4. After determining the correctshim thickness as explained in theforegoing steps, install the new pin-ion and ring gear as outlined underAssembly.DIFFERENTIAL CASE,BEARINGS, AND DRIVE GEAR

If the ring gear runout check (be-fore disassembly) exceeded specifi-cations, the condition may be causedby a warped gear, a defective case,or excessively worn differential bear-ings.

To determine the cause of exces-sive runout proceed as follows:

1. Assemble the two halves of thedifferential case together without thering gear, and press the two differen-tial side bearings on the case hubs.

2. Place the cups on the bearingsand set the differential case in thecarrier.

3. Install the bearing caps and ad-justing nuts as outlined in steps 11thru 14 under Installation of DrivePinion and Differential Case in thissection.

4. Tighten the right nut twonotches beyond the position whereit first contacts the bearing cup. Ro-tate the differential case severalrevolutions in each direction whilethe bearings are loaded to seat thebearings in their cups. This step isimportant.

ASSEMBLY OFCONVENTIONALDIFFERENTIAL CASE

1. Lubricate all the differentialparts with axle lubricant, before theyare installed in the case.

2. Place the side gears and thrustwashers in the case.

3. Place the two pinion gears andthrust washers exactly opposite eachother in the case openings and inmesh with the side gears.

4. Turn the pinions and thrustwashers until the holes in the pinion

FIG. 24-DifferentialBearing Installation

ASSEMBLYOFLIMITEO-8LIPDIFFERENTIAL CASE

1. Place the side gear and thrustwasher in the differential case (Fig.24). Lubricate all parts liberally withaxle lubricant during assembly.

2. With a soft-faced hammer,drive the pinion shaft into the caseonly far enough to retain a pinionthrust washer and pinion gear.

3. Place the second pinion andthrust washer in position, and drivethe pinion shaft into place. Carefullyline up the pinion shaft lock pinholes.

4. Install the pinion shaft lock

l for Cleaning andstarting assembly


BELLEVILLE SPRINGpin. The lock pin must not extendbeyond the surface of the case.

5. Insert two 2-inch 7/16 (N. F.)bolts through the differential caseflange, and thread them three or fourturns into the ring gear as a guidein aligning the ring gear bolt holes.Press or tap the drive gear into posi-tion.

6. Clamp the differential case ina soft-jawed vise. Install the otherdifferential side gear on the differ-ential pinion gears. Place the clutchhub on the side gear. Place the thrustwasher on the hub (Fig. 25).

FIG. 26-Belleville SpringInstallation

FIG. 25-Clutch PlateInstallation

FIG. 28-DifferentialTorque Check

5. Coat the outside edge of a newoil seal with an oil resistant sealerand install it in the carrier casting(Fig. 12).

6. Insert the drive pinion shaftflange into the seal and hold it firmlyagainst the pinion front bearingcone. From the rear of the carriercasting, insert the pinion shaft intothe flange.

7. Place the flat washer on thepinion shaft and start the nut. Use anew nut. Hold the flange with thetool shown in Fig. 10 and tighten thepinion shaft nut. As the pinion shaftnut is tightened, the pinion shaft ispulled into the front bearing coneand into the flange.

As the pinion shaft is pulled intothe front bearing cone, pinion shaftend play is reduced. While there isstill end play in the pinion shaft, theflange and cone will be felt to bot-tom. This indicates that the bearingcone and flange have bottomed onthe collapsible spacer.

From this point, a much greatertorque must be applied to turn thepinion shaft nut, since the spacermust be collapsed. From this point,also, the nut should be tightenedvery slowly and the pinion shaft endplay checked often, so that the pin-ion bearing preload does not exceedthe limits.

If the. pinion shaft nut is tight-ened to the point that pinion bear-ing preload exceeds the limits, thepinion shaft must be removed and anew collapsible spacer installed. Donot decrease the preload by loosen-ing the pinion shaft nut. This will re-move the compression between thepinion front and rear bearing conesand the collapsible spacer and may

13. Torque the case to ring gearbolts to specifications.

14. Check the torque required torotate one side gear while the otherside gear is held (Fig. 28). Ignorethe torque required to start the sidegear turning. The torque required tokeep it moving steadily should bebetween 100 and 125 ft-lbs, if newclutch plates were installed. Thetorque should be at least 50 ft-lbs,if the original clutch plates were in-stalled. If the required torque is notwithin these limits, check for im-proper assembly.

15. If the differential bearingshave been removed press them on asshown in Fig. 24.

INSTALLATION OF DRIVEPINION AND DIFFERENTIALCASE

1. Place the shim and pinion rearbearing cone on the pinion shaft.Press the bearing and shim firmlyagainst the pinion shaft shoulder(Fig. 18).

2. Place a new pinion bearing pre-load spacer on the pinion shaft.

3. Lubricate the pinion rear bear-ing with axle lubricant.

4. Lubricate the pinion front bear-ing cone and place it in the housing.

7. To align the clutch plates dur-ing assembly, insert two 3/16 X 2dowel pins into the differential case.Place a steel plate on the differentialcase so that the slots in the earsstraddle the dowel pin (Fig. 25).Lubricate all the limited-slip differ-ential parts with axle lubricant sothat an accurate torque check can bemade.

8. Place a bonded plate on thesteel plate. Make sure the bondedplate inner spline teeth properly en-gage the hub spline. Assemble theremaining plates: a steel plate, abonded plate, a steel plate, a bondedplate, and lastly a steel plate.

9. Place the Belleville spring onthe top steel plate. The Bellevillespring is assembled with the concaveside down (Fig. 26). Carefully cen-ter the Belleville spring so that itwill fit into the cover.

10. Place the differential casecover on the case (Fig. 27). Startthe ring gear bolts.

11. Tighten the bolts evenly andalternately across the diameter of thedrive gear. As the bolts are tightenedthe Belleville spring is compressedand the differential case and coverare pulled together.

12. Remove the dowel pins.


permit the front bearing cone to turnon the pinion shaft.

8. As soon as there is preload onthe bearings, turn the pinion shaftin both directions several times toset the bearing rollers.

9. Adjust the bearing preload tospecification. Measure the preloadwith the tool shown in Fig. 29.

,_c ~",. ...~""..,~ ., ~.~- . ~,. IN WHICH GEARS WERE LAPPED

FIG. 30-Typical Gear Set Timing Marks

E1335-A

FIG. 29-Checking PinionBearing Pre-load

Too/-T60K-4067-A or4067-f E1262-C

FIG. 31-Backlash andBearing Pre-load Adjustment

threads or incorrectly positionedcaps. Tightening the bolts to thespecified torque is done to be surethat the cups and adjusting nuts areseated. Loosen the cap bolts, andtorque them to only 5 ft-ibs beforemaking adjustments. Refer to part4-1 for backlash and bearing pre-load adjustment procedures.

gear set (no timing marks), assemblethe differential case and ring gearassembly in the carrier without re-gard to the matching of any partic-ular gear teeth.

12. Slide the case assembly alongthe bores until a slight amount ofbacklash is felt between the gearteeth. Hold the differential case inplace.

13. Set the adjusting nuts in thebores so that they just contact thebearing cups.

14. Carefully position the bearingcaps on the carrier casting. Matchthe marks made when the caps wereremoved.

15. Install the bearing cap boltsand lockwashers. As the bolts aretightened, turn the 'adjusting nut withthe tool shown in Fig. 31.

16. If the adjusting nuts do notturn freely as the cap bolts aretightened, remove the bearing capsand again inspect for damaged

10. Wipe a thin coating of lubri-cant on the bearing bores so that thedifferential bearing cups will moveeasily.

11. Place the cups on the bearingsand set the differential case assemblyin the carrier casting (Fig. 17).

If the gear set is of the non-hunt-ing or partial non-hunting type, as-semble the differential case and ringgear assembly in the carrier so thatthe marked tooth on the pinion in-dexes between the marked teeth onthe ring gear as shown in Fig. 30.

In almost every case of improperassembly (gears assembled out oftime), the noise level and probabilityof failure wiD be higher than theywould be with properly assembledgears.

When installing the hunting type

DISASSEMBLYAfter removing the carrier from

the axle housmg as described insection 3, mount the carrier in aholding fixture and perform the In-spection Before Diassembly ofCarrier as explained in Part 4-1,Section 3. Then disassemble the car-rier as outlined in the followingprocedures.

REMOVAL AND DISASSEMBLYOF CONVENTIONALDIFFERENTIAL CASE

1. Mark one differential bearingcap and the mating bearing supportwith punch marks to help positionthe parts properly during assemblyof the carrier. Also, mark one of thebearing adjusting nuts and the car-rier with scribe marks for proper

location during assembly (Fig. 45).2. Remove the adjusting nut

locks, bearing caps, and adjustingnuts. Then lift the differential assem-bly out of the carrier.

3. If the differential bearings areto be removed, use the tool shown inFig. 19. On cars equipped with highperformance engines, use tool T57L-4220-A.


4. Mark the differential case, cov-er, and ring gear for assembly inthe original position.

s. Remove the bolts that attachthe ring gear to the differential case.Press the gear from the case or tapit off with a soft-faced hammer.

6. With a drift, drive out thedifferential pinion shaft lock pin(Fig. 32) and separate the 2-piecedifferential case.

DIFFERENTIALCASE

E1174-ADIFFERENTIAL PINION SHAFT --

FIG. 32-RemovingDifferential Pinion ShaftLock Pin

FIG. 34-Assembly of Differential

bearings from the differential as out-lined in steps 1 through 4 in theforegoing procedure.

2. Place the differential case in ahydraulic press, and apply about oneton pressure across the case bearinghubs while removing the ring gearattaching bolts. This procedure willcontain the spring pressure betweenthe differential case and cover untilafter the bolts are moved, and there-by prevent stripping of the threads.Loosen alternate bolts an equalamount so that the spring pressurewill release evenly.

3. Release the hydraulic pressram, and remove the differentialcase cover.

4. Remove the Belleville spring(Fig. 21).

5. Remove the steel and thebonded clutch plates.

6. Remove the differential clutchhub, outer side gear, and thrustwasher.

7. Remove the ring gear from thedifferential case.

8. Drive out the differential pin-ion shaft lock pin.

9. With a brass drift, drive outthe differential pinion shaft. Thenremove the pinion gears, inner sidegear, and thrust washers.

7. Drive out the pinion shaft witha brass drift (Fig. 33).

FIG. 33-Driving OutDifferential Pinion Shaft

8. Remove the gears and thrustwashers. (Fig. 34).

Tool- T57l.4851.A or 4851.K - .

FIG. 35-Removing PinionShaft Nut

REMOVAL AND DISASSEMBLYOFLIMITED-8LIPDIFFERENTIAL CASE

1. Remove the differential casefrom the carrier and remove the

2. Remove the seal (Fig. 37) andthe slin2er.

Case

REMOVAL AND DISASSEMBLYOF DRIVE PINION ANDBEARING RETAINER

1. Turn the carrier case upright,and remove the pinion shaft nut(Fig. 35). Then remove the V-jointflange (Fig. 36).


E1307-B

FIG. 36-RemovingU-Joint Flange

FIG. 38-Removing PinionFront Bearing (one

Too/-T62F-4625-Aor 4625-AC- J and 2

FIG. 39-Removing PinionRear Bearing (one -R

The principal replacement opera-tions are covered in the followingprocedures. All other repair or re-placement operations are performedduring Cleaning and Inspection Part4-1, Section 3, or during the As-sembly in this section.

FIG. 41-lnstallingPilot Bearinguse handle adapter 753L-200-A withtool 757L-4625-A, or 4625-K, or4625-KA.

3. Using the same tool, install anew pilot bearing retainer with theconcave side up.PINION BEARING CUPS

Do not remove the pinion bearingcups from the retainer unless thecups are worn or damaged. Theflange and pilot of the retainer aremachined during manufacture bylocating on these cups after they areinstalled in their bores. If the cupsare worn or damaged, they shouldbe removed and replaced as shown

FIG. 37-RemovingPinion Seal

3. Remove the pinion, bearing,and retainer assembly from the car-rier housing (Fig. 48). Measure theshim thickness with a micrometer.Record this original shim thickness.If a new gear set is installed duringassembly, a new shim will have to beinstalled. The original shim thicknessis one of the factors necessary in cal-culating the new shim thickness.Extreme care must be taken not todamage the mounting surfaces of theretainer and carrier.

4. Place a protective sleeve (hose)on the pinion pilot bearing surface.Press the pinion shaft out of the pin-ion front bearing cone (Fig. 38).

5. Press the pinion shaft out ofthe pinion rear bearing cone (Fig.39).

PARTS REPAIR ORREPLACEMENT

Clean and inspect all the parts asoutlined in Part 4-1, Section 3. Be-fore assembling the carrier, repairor replace all parts as indicated bythe inspection.

PILOT BEARING1. Remove the pilot bearing as

shown in Fig. 40. Drive out the pilotbearing and the bearing retainer to-gether. On cars with high perform-ance engines, use handle adapterT53L-200A with tool 757L-4625-Aor 4625-K.

2. Drive the new bearing in untilit bottoms as shown in Fig. 41. Oncars with hiv.h performance env.ines.

PART 4-2 REAR AXLES 4-27

in Fig. 42. On cars equipped withhigh performance engines, use thefollowing tools: T57L-46l4-A withT57L-46l6-A for front cup removalexcept Comet; tool 46l5-D forComet front cup removal; T57L-46l4-A with T57L-46l6-A2 for frontcup installation and T57L-46l4-Awith T55P-46l6-A2 for rear cup in-stallation.

the correct shim thickness for thenew gear set to be installed, followthese steps:

1. Measure the thickness of theoriginal shim with a micrometer.

2. Note the shim adjustment num-ber on both the old pinion and thenew pinion. Each pinion gear ismarked with an adjustment numbersuch as the + 1 marking in Fig. 44.

FIG. 42-Removing PinionBearing Cup

After the new cups are installed,make sure they are seated in the re-tainer by trying to insert a 0.0015-inch feeler gauge between the cupand the bottom of the bore.

Whenever the cups are replaced,the cone and roller assembliesshould also be replaced.

Toof-T60K-4616-A"""

Defoi/3

or 46 J 5-HF

Press Ram

""-./..

~TooI-

T57L.4614-A

~

- "-

~

MATCHED GEAR SETIDENTIFICATION E1178-A

FIG. 44-Pinion and RingGear Markings

3. Refer to Table 2 to determinethe correct amount of shim thick-ness change. The amount shown inthe table under the old pinion shimadjustment number and in line withthe new pinion number is theamount of change that should bemade to the original shim thickness.

If the old pinion is marked + 4,for example, and the new pinion ismarked - 2, the table indicates that

0.006 inch of shim stock should beremoved from the original shimpack.

If the original shim pack was lostor if a new carrier housing is beinginstalled, substitute a nominal 0.020-inch shim for the original, and fol-low the foregoing procedure for atrial build-up. If any further shimchange is necessary, it will be indi-cated in the tooth pattern check.

A new ring gear and pinionshould always be installed in an axleas a matched set (never separately).Be sure that the same matching num-ber appears on both the drive pin-ion and the ring gear. Note the num-ber 170 in Fig. 44.

4. After determining the correctshim thickness as explained in theforegoing steps, install the new pin-ion and ring gear as outlined underAssembly.

DIFFERENTIAL CASE,BEARINGS AND RING GEAR

If the ring gear runout check (be-fore disassembly) exceeded specifi-cations, the condition may be caused

-,~.~vu-~

FIG. 43-lnstalling PinionBearing CupDRIVE PINION ANDGEAR SET

When replacing a ring gear andpinion, note that the original fac-tory installed shim is of the correctthickness to adjust for individualvariations in both the carrier hous-ing dimension and in the original gearset dimension. Therefore. to select

by a warped gear, a defective case,or excessively worn differential bear-ings.

To determine the cause of exces-sive runout proceed as follows:

1. Assemble the two halves of thedifferential case together without thering gear, and press the two differ-ential side bearings on the case hubs.

2. Place the cups on the bearingsand set the differential case in thecarrier.

3. Install the bearing caps and ad-justing nuts as outlined in step 11thru 14 under Assembly and In-stallation of Conventional Differen-tial Case in this section.

4. Tighten the right nut fwonotches beyond the position whereit first contacts the bearing cup.Rotate the differential case severalrevolutions in each direction whilethe bearings are loaded to seat thebearings in their cups. This step isimportant.

5. Again loosen the right nut torelease the preload. Check to seethat the left nut contacts the bear-ing cup. Using the dial indicator set-up shown in Fig. 13, Part 4-1, adjustthe preload to 0.012 case spread fornew bearings or 0.005 to 0.008 forthe original bearings, if re-used.

6. Check the runout of the dif-ferential case flange with a dial indi-cator. If the runout does not nowexceed specifications, install a newdrive gear. If the runout still exceedsspecifications, the ring gear is trueand the trouble is due to either adefective case or worn bearings.

7. Remove the differential casefrom the carrier and remove theside, bearings from the case.

8. Install new bearings on the casehubs, and again install the differ-ential assembly in the carrier with-out the ring gear.

9. Check the case runout againwith the new bearings. If the runoutis now within limits, the old bear-ings were excessively worn. Use thenew bearings for assembly. If therunout is still excessive, the case isdefective and should be replaced.

ASSEMBLYRefer to Part 4-1 for Cleaning

and InslJection before starting as-sembly operations. Fig. 45 shows thedisassembled parts.

ASSEMBLY ANDINSTALLATION OF DRIVEPINION AND BEARINGRETAINER

1. Install the drive pinion rear


TABLE 2 - DRIVE PINION ADJUSTING SHIM THICKNESS CHANGES (Inches)

Old Pinion Marking

-3

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-2 -1 +1

+0.003

+0.002

+0.0010

-0.001

-0.002

-0.003

-0.004

-0.005

+2

+0.002

+0.0010

-0.001

-0.002

-0.003

-0.004

-0.005

-0.006

+4

0-0.001-0.002-0.003

-0.004

-0.005

-0.006

-0.007

-0.008

-4

+0.008

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

NewPinion

Marking

+4

+3

+2

+10

-1

-2

-3

-4

+0.006

+0.005+ 0.004

+0.003

+0.002

+0.0010

-0.001

-0.002

+0.005+ 0.004

+0.003

+0.002

+0.001

0

-0.001

-0.002

-0.003

0

+0.004

+0.003

+0.002

+0.001

0

-0.001

-0.002

-0.003

-0.004

+3

+0.0010

-0.001

-0.002

-0.003

-0.004

-0.005

-0.006

-0.007

FIG. 45-Rear Axle-Disassembledbearing cone and roller on the pinionshaft (Fig. 46). On cars equippedwith high performance engines usetool T57L-4621-B along with tool757L-4614-A as shown in Fig. 46.Place a new spacer on the pinionshaft (Fig. 47).

2. Place the bearing retainer onthe pinion shaft, and install the frontbearing cone and roller in the re-tainer. Press the front bearing coneand roller into position with thesame tools as used in Fig. 46 forfront bearing installation. On carswith high performance' engines, use

T57L-462l-B along with tool T57L-46l4-A.

3. Lubricate the a-ring with axlelubricant and install it in its groovein the pinion retainer. Be careful notto twist it. Snap the a-ring into po-sition.

4. Place the proper shim on thecarrier housing and install the pinionand retainer assembly being carefulnot to pinch the a-ring (Fig. 48).

5. Install the pinion retainer bolts.Torque bolts to specifications.

6. Place the slinger on the pinionshaft.

7. Coat the outside edge of a newoil seal with a small amount of a newoil resistant sealer. Do not put anyof the sealer on the sealing lip. In-stall the seal in the bearing retainer(Fig. 49). On cars with high per-formance engines, use tool T58L-4676-A or tool 4676-F.

New seals should be soaked inSAE 10 oil for V2 hour before use.

8. Install the V-joint flange (Fig.50).

9. Start a new integral nut andwasher on the pinion shaft.

10. Hold the flange (Fig. 35) and

PART 4-2 REAR AXLES 4.29

pound torque wrench is not availabletool 4209-C may be used in combi-nation with tool 4209-CI2. Correctpreload will be obtained when thetorque required to rotate the pinionin the retainer is as specified in Part4-3. If the torque required to rotatethe pinion is less then specified,tighten the pinion shaft nut a littleat a time until the proper preload isestablished. Do not overtighten thenut. If excessive preload is obtainedas a result of overtightening, replacethe collapsible bearing spacer.

Do not back off the pinion shaftnut to establish pinion bearing pre-load. If the torque on the pinionshaft nut is less than 175 ft-lbs. afterbearing preload is established, a newcollapsible spacer must be used.ASSEMBLY ANDINSTALLATION OFCONVENTIONALDIFFERENTIAL CASE

1. Place a side gear and thrust

line up the pinion shaft lock pinholes.

4. Place the second side gear andthrust washer in position (Fig. 34),and install the cover on the differ-ential case. Install the pinion shaftlock pin. A pinion or axle shaftspline can be inserted in the sidegear spline to check for free rotationof the differential gears.

5. Insert two 7/16 (N. F.) bolts twoinches long through the differentialcase flange, and thread them threeor four turns into the ring gear as aguide in aligning the ring gear boltholes. Press or tap the ring gear intoposition.

6. Install and tighten the ring gearbolts and washers evenly, and torquethem alternately across the gear to

specification.7. If the differential bearings have

been removed, press them on asshown in Fig. 52.

FIG. 46-lnstalling PinionRear Bearing (one

LOCK NUT

'1' " I~', c

i, ,j

SEAL

FIG. 47-Pinion and Bearing Retainer

nI

FIG. 50-InstallingU-Joint Flange

8. Wipe a thin coating of lubri-cant on the bearing bores so that thedifferential bearing cups will moveeasily.

9. Place the cups on the bearings.If the gear set is of the non-huntingor partial non-hunting type, assemblethe differential case and ring gearassembly in the carrier so that themarked tooth on the pinion indexesbetween the marked teeth on thering gear as shown in Fig. 30.

In almost every case of improper

E1474-A

FIG. 49-lnstalling Oil Sealwasher in the differential case boreFig. 34). Lubricate all differentialparts liberally with axle lubricantduring assembly.


3. Place the second pinion andthrust washer in position, and drivethe pinion shaft into place. Carefully

FIG. 48-lnstallingPinion and Retainer

tighten the pinion shaft nut to 175ft-lbs. Do not exceed 175 ft-lbs atthis time. As the pinion shaft nut istightened, rotate the pinion shaftfrequently to allow the bearing toseat.

11. Check the pinion bearing pre-In:lrl :I~ ~hnwn in Fill. 51. If an inch-


~~,

Inch.PoundTorque Wrench

E1330-B

FIG. 51-Checking PinionBearing Pre-load

engaged about the same number ofthreads on each side.

12. Carefully position the bearingcaps on the carrier. Match the marksmade when the caps were removed.

13. Install the bearing cap boltsand alternately torque them to 70-80ft-ibs.

14. If the adjusting nuts do notturn freely as the cap bolts are tight-ened, remove the bearing caps andagain inspect for damaged threadsor incorrectly positioned caps. Tight-ening the bolts to the specifiedtorque is done to be sure that thecups and adjusting nuts are seated.Loosen the cap bolts, and torquethem to only 25 ft-ibs. before mak-ing adjustments.

15. Adjust the backlash betweenthe ring gear and pinion as outlinedin Part 4-1, Section 2.

16. Be sure to make a final toothpattern check before installing thecarrier assembly in the axle housing.

FIG. 52-InstallingDifferential Bearing

assembly (gears assembled out oftime), the noise level and probabilityof failure will be higher than theywould be with properly assembledgears.

When installing the hunting typegear set (no timing marks) assem-ble the differential case and ring gearassembly in the carrier without re-gard to the matching of any particu-lar gear teeth.

10. Slide the assembly along thebores until a slight amount of back-lash is felt between the gear teeth.

11. Set the adjusting nuts in thebores so that they just contact thebearing cups. The nuts should be

pinion gears. Place the clutch hub onthe side gear. Place the thrust washeron the hub (Fig. 25).

7. To align the clutch plates duringassembly, insert two 3/16 X 2 dowelpins into the differential case. Placea steel plate on the differential caseso that the slots in the ears straddlethe dowel pin (Fig. 25). Lubricateall the locking differential parts withaxle lubricant so that an accuratetorque check can be made.

8. Place a bonded plate on thesteel plate. Make sure the bondedplate inner spline teeth properly en-gage the hub spline. Assemble theremaining plates: a steel plate, abonded plate, a steel plate, a bondedplate, and lastly a steel plate.

9. Place the Belleville spring onthe top steel plate. The Bellevillespring is assembled with the concaveside down (Fig. 26). Carefully centerthe Belleville spring so that it will fitinto the cover.

10. Place the differential case cov-er on the case (Fig. 27). Start thering gear bolts.

11. Tighten the bolts evenly andalternately across the diameter of thering gear. As the bolts are tightenedthe Belleville spring is compressedand the differential case and coverare pulled together.

12. Remove the dowel pins.13. Torque the case to ring gear

bolts to specifications.14. Check the torque required to

rotate one side gear while the otherside gear is held (Fig. 28). Ignorethe torque required to start the sidegear turning. The torque required tokeep it moving steadily should bebetween 155 and 195 ft-Ibs, if newclutch plates were installed. Thetorque should be a least 75 ft-Ibs, ifthe original clutch plates were in-stalled. If the required torque is notwithin these limits, check for im-proper assembly.

15. Install the side bearings on thedifferential case, and install the casein the carrier as described in steps 7through 16 under Assembly and In-stallation of Conventional Differen-tial Case.

ASSEMBLY ANDINSTALLATION OF LIMITED-SLIP DIFFERENTIAL CASE

1. Place the side gear and thrustwasher in the differential case (Fig.21). Lubricate all parts liberally withaxle lubricant during assembly.


3. Place the second pinion andthrust washer in position, and drivethe pinion shaft into place. Carefullyline up the pinion shaft lock pinholes.

4. Install the pinion shaft lock pin.The lock pin must not extend beyondthe surface of the case.

S. Insert two 2-inch 7/16 (N. F.)bolts through the differential caseflange, and thread them three or fourturns into the ring gear as a guidein aligning the ring gear bolt holes.Press or tap the ring gear into po-sition.

6. Clamp the differential case in asoft-jawed vise. Install the other dif-ferential side gear On the differential

4-31

SPECIFICATIONS

REAR AXLE LUBRICATION

For temperatures above -25°F use SAE 90 Grade lubricant.For temperatures below -25°F use SAE 80 Grade lubricant.

REAR AXLE-INTEGRAL CARRIER TYPEDRIVE PINION ADJUSTING SHIM THICKNESS CHANGES-INCH

New Pinion MarkingOld PinionMarking +3

+0.0010

-0.001

-0.002

-0.003

-0.004

-0.005

-0.006

-0.007

-4

+0.008

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-3

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-2

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-0.002

+2

+0.002

+0.0010

-0.001

-0.002

-0.003

-0.004

-0.005

-0.006

+4

0-0.001-0.002-0.003

-0.004

-0.005

-0.006

-0.007

-0.008

-1

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-0.002

-0.003

0

+0.004

+0.003

+0.002

+0.001

0

-0.001

-0.002

-0.003

-0.004

+1

+0.003+0.002+0.001

0-0.001

-0.002

-0.003

-0.004

-0.005

+4+3+2+1

0-1-2-3-4

REAR AXLE RATIOS, GEAR AND CODEIDENTIFICATION

Ring GearDiameterUnches)

Identification Tag Axle RatioTypeof

Differential

ConventionalLimited-Slip

ConventionalConventional

Limited-Slip

2.88:171/4

N71/4-r1/iN

, WCY.R~WCY-AA WCY-E

WCY-AJ

WCY-L

3.20:1

CONTINUED ON NEXT PAGE


REAR AXLE-INTEGRAL CARRIER TYPE (Continued)

ADJUSTMENTS TORQUE LIMITS

CDlnch-pounds

REAR AXLE-REMOVABLE CARRIER TYPE

REAR AXLE RATIOS, GEAR AND CODE IDENTIFICATION

Type ofDifferential

Axle Ratio Identification TaR Ring GearDiameter(Inches)

Type ofDifferential

Axle RatioIdentificationTag

Ring GearDiameter(Inches)

WDE-B

WEB-C

WED-C

WED.A

WDY-B

WDY.C

WEA-B

WDY.A

WEA-F

WEA-A

WEC-A

WEC-B

WEE-A

WEE-C

9

9

9

9

8

8

8

8

8

8

9

9

9

9

WCZ-E

WDJ-B

WCZ-F

WDJ-C

WCZ-S

WCZ-R

WDZ-A

WDW-C

WDW-E

WDW-A

WDW-D

WDZ-C

WDW-B

WDC-B

73/4

73/4

Conventional

Limited-Slip

Conventional

Limited-Slip

Conventional

Conventional

Limited-Slip

Conventional

Conventional

Conventional

Conventional

Limited-Slip

Conventional

Limited-Slip

2.80:1

2.80:1

3.00:1

3.00:1

3.50:1

3.89:1

2.80:1

3.25:1

2.80:1

2.80:1

3.50:1

3.25:1

3.00:1

3.00:1

Conventional

Conventional

limited-Slip

limited-Slip

Conventional

Conventional

limited-Slip

Conventional

limited-Slip

limited-Slip

Conventional

Conventional

limited-Slip

limited-Slip

3.00:1

3.25:1

3.00:1

3.25:1

3.25:1

3.50:1

3.50:1

3.00:1

3.25:1

3.00:1

3.00:1

3.25:1

3.25:1

3.00:1

8

8

83/4

83/4

73/4

8

73/4

73/4

8

8

8

8

ADJUSTMENTS (Continued)

ADJUSTMENTS-Inch

I Backlash Between Ring Gear and PinionMaximum Backlash Variation Between Teeth

0.008-0.012 I0.003 1

-Maximum Runout of Backface of Ring Gear asAssembled 0.003

CONTINUED ON NEXT PAGE

PART 4-3 SPECIFICATIONS 4-33

REAR AXLE-REMOVABLE CARRIER TYPE (Continued)

TORQUE LIMITS SPECIAL TOOLS

Ford Tool No.

T50T-IOO-AT58L-IOI-AT62L-201-AT56L-400-AT57L-500-ATOOL-1175.ABT50T.IOO.A andTOOL-1175-ABT60K-1177-BT60K-1225-A

orTOOL-1225-CTOOL-1225.BT60K-4067-A

TOOL-4209-C

TOOL-4221-AL

Former No.

B-166

Description

-4851-A

1175-AB1175-AE

1177-B

4067-E

4209.C

4221.AL

T57L-4221-ATOOL.4222-HT60K.4234-A

T57L-4614-A

TOOL-4615-j

T60K-4616-A

T57L-4616-AT57L-4616-A2T55P.4616-A2TOOL-4621-K

T62F-4621-AT62F-4625-A

T55P-4676-AT62F-4676-AT53T-4851-A

T57L-4851-ATOOL-4858-E

T59L-4204-A

4222-K4222-H4235.0

4614

4615-J

4615-HF4625-HR4615-0

CDlf this torque can not be obtained with a used spacer, install anew spacer. 4621-K

REAR AXLES WITH LOCKING DIFFERENTIAL4625-AC-1 & 2

4676-G4676-H4851-A4858-04851-K4858-E

44211 and4421 I-A

T65K-4204-A

Impact HammerPuller AttachmentHandle AdapterPullerBench Mounted Holding FixtureGrease Seal Remover (Head Only)Seal Remover

Rear Wheel Bearing Oil SealAxle Shaft Bearing Remover

and Replacer.Axle Shaft Bearing RemoverAxle Shaft Bearil1g ReplacerDifferential Bearing Adjuster Nut

WrenchPinion Tension Scale with

TOOl-4209-C12 SocketDifferential Bearing Cone Remover

Pilot (Use with TOOl-4221-Cor TOOl-4851-A)

Differential Bearing Cone ReplacerDifferential Bearing Cone ReplacerRear Axle Shaft Assembly Remover

AdapterDrive Pinion and Drive Pinion

Retainer Assembly SupportDrive Pinion Front Bearing Cup

RemoverPinion Bearing Cup Replacer

Pinion Front Bearing Cup RemoverPinion Front Bearing Cup ReplacePinion Rear Bearing Cup ReplaceDrive Pinion Rear Bearing Cone

RemoverPinion Bearing Cone ReplacerDrive Pinion Pilot Bearing

Remover and ReplacerDrive Pinion Oil Seal ReplacerDrive Pinion Oil Seal ReplacerFlange (Universal Joint) Axle End

RemoverUniversal Joint Flange HolderCompanion Flange and Pinion

Bearing Replacerlocking Differential

Torque Check

locking DifferentialTorque Check Adapter

DRIVE PINION ADJUSTING SHIM THICKNESS CHANGES (inch)

Old Pinion Marking

0

+0.004

+0.003

+0.002

+0.0010

-0.001- 0.002

-0.003

-0.004

New PinionMarking -4

+0.008

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-3 -2

+0.006

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-0.002

+2

+0.002+0.001

0-0.001-0.002-0.003-0.004-0.005-0.006

+3

+.0010

-0.001-0.002-0.003-0.004-0.005- 0.006

-0.007

+4

0-0.001-0.002-0.003-0.004-0.005- 0.006

-0.007-0.008

+4+3+2+1

0-1-2-3-4

+0.007+ 0.006+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001

-1

+0.005

+0.004

+0.003

+0.002

+0.0010

-0.001- 0.002

-0.003

+1

+0.003+0.002+0.001

0-0.001-0.002

-0.003

-0.004

-0.005

group 4 rear axle

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