Werkstatthandbuch Book 1 · Seiten 401–500

15-02-9 Integral Carrier Axle-conventional 15-02-9 A new ring gear and pinion should always be installed in an axle as a matched set never separately. Be sure the same identifying matching number, pointed in white, appears on the bolt hole face of the ring gear and on the head of the drive pinion Fig. 21. 4. After determining the correct shim thickness as

15-02-10 Integral Carrier Axle-Conventional 15-02-10 should hold it flatly to the gauge block when the 8. Inspect the pinion gear that will be used for this shoulder screw is fully bottomed. buildup. It will have ONE of THREE markings: 6. Securely attach a standard indicator Toot-4201-C, a.plus + marking -4-.002 Tool 6565 or equivalent to the indicator arm. Set b.minus - marking ..001 the indicator to zero while the indicator pointer is on the gauge block. c. or no marking Subtract the plus marking from the reading7. Place the gauge block on the dummy pinion head

15-02-11 Integral Carrer Axle-Conventional 15-02-11 ADJUSTING NUT FIG. 22 Pinion Depth Gauge Application T7OP-4020-A FRONT PINION EEARING HANDLE ci SCREW,.JV. GAUGE/ ALIGNING REAR BLOCK ADAPTER PINION BEARING U

15-02-12 Integral Carrier Axle-Conventional 15-02-12 GAUGE TUBE E2615-IA FIG. 24 Using Pinion Depth Gauge Tool T75P-4020-A 6. If the replacement pinion gear is marked with a plus 3. Install the bearing caps and adjusting nuts as + reading, the amount shown as a plus must be outlined in Steps 11 thru 14 under Differential Case subtracted from the thickness dimension obtained and Drive Pinion Installation. in Step 5. 4. Tighten the right nut two notches beyond the 7. If the replacement pinion gear is marked with a

15-02-13 Integral Carrier Axle-Conventional 15-02-13 ASSEMBLY OF AXLE Refer to Part 15-01 for Cleaning and Inspection PAESS HAM before starting assembly operations. DIFFERENTIAL CASE TOOL-4222-L DETAIL 7 Assembly 1. Lubricate all the differential parts with axle lubricant, before they are installed in the case. 2. Place the side gears and thrust washers in the case. 3- Place the two pinion gears and thrust washers exactly opposite each other in the case openings, and in mesh with the side gears. 4. Turn the pinions and thrust washers until the holes in the pinion gears align with the pinion shaft holes in the case.

15-02-14 Integral Carrier Axle-Conventional 15-02-14 T?OP-4 067-A 1 INSTALL DIAL ENDICATOR E218Q-1 FIG. 26 Typical Gear Set Timing Marks FIG. 27 Backlash and Bearing Preload When installing the hunting-type gear set no Adjustment timing marks, place the differential case and ring gear assembly in the carrier without regard to the 16. If the adjusting nuts do not turn freely as the cap matching of any particular gear teeth.

15-02-15 Integral Carrier Axle-Conventional 15-02-15 SPECIFICATIONS DRIVING AXLE IDENTIFICATION INTEGRAL CARRIER -CONVENTIONAL Ident. Ring Gear Diff. Went. Ring Gear Duff. Tag Ratio Die. Inches Type Tag Ratio Dia. Inches Type WI3F-K1 3.18:1 63/4 C2 WGF-AA 3.18:1 63/4 C2 WGF-LJ1 3.18:1 63/4 C2 WGF-AJ 2.73:1 63/4 ADJUSTMENT TORQUE SPECIFICATIONS INTEGRAL CARRIER - CONVENTIONAL

15-02-16 Integral Carrier Axle-Conventional 15-02-16 SPECIAL TOOLS Tool Number Description Tool Number Description T5OT-100-A Impact Slide Hammer T7OP-4O67-A Differential Bearing Adjuster Nut Wrench TOOL-i 175-AC Grease Seal Remover Use with Slide Hammer TSBP-46O2-AB Vial or TOOL-il 75-AE TSOT-1 00-A T68P-46O2-AC Magnet T65F-1 177-A Axle Shaft Oil Seal Replacer TOO L-461 5-G Drive Pinion Front Bearing Cup Remover T6OK-1177-B Hear Wheel Bearing Oil Seal Replacer T6OK-4616A Pinion Bearing Cups Replacer Inner and Otter TJOP-40

11 Integral Carrier Axle-Ford WER 15-034 PART - - Integral Carrier Axle Ford WER 15-03 Applies To Ford/Mercury, Granada/Monarch SUBJECT PAGE SUBJECT PAGE DESCRIPTION 03-1 REMOVAL AND INSTALLATION - Axle Housing 03-6 DISASSEMBLY AND ASSEMBLY Drive Pinion Oil Seal 03-3 Assembly Of Axle

15-03-2 Integral Carrier Axle-Ford WER 15-03-2 The hypoid gear set consists of an 8.7-inch diameter casting. The brake backing plate retainer is welded ring gear and an overhung drive pinion, which is inboard of the outer edges of the tubes, and allows supported by two opposed tapered roller bearings. A assembly of the backing plate, independent of the axle drive pinion pilot bearing is not used in this axle. shafts. The differential carrier is the nonremovable type, The roller-type wheel bearings have no inner race,with a stamped bolt-on cover. The filler hole is tapped and contact the bearing journals of the axle shafts.in the front portion of the carrier casting and uses a 1/2-14 tap

15-03-3 Integral Carrier Axle-Ford WER 15-03-3 on the bearing lournal of the shaft is normal and 7. Position the differential pinion gears and thrust the shaft need not be replaced. Slight pitting and washers 180 degrees apart to the differential side wear is also normal. gears. Revolve the gear assembly until the holes in the differential case are aligned with the pinion gears.Installation 8. Position the differential pinion shaft through the1. Lightly coat the wheel bearing rollers with ax

15-03-4 Integral Carrier Axle-Ford WER} 15-03-4 Replacement of the pinion oil seal involves 3. Install an in-lb. torque wrench on the pinion nut Fig. removal and installation of only the pinion shaft 9. Record the torque required to maintain rotation nut and the universal joint flange. However, this of the pinion shaft through several revolutions. operation disturbs the pinion bearing preload, and this preload must be carefully reset when assembling. Removal 1. Raise the vehicle and install safety stands. Remove the rear wheels and brake drums. 2. Make scribe marks on the drive shaft end yoke and the axle U.joint flange to insure proper position of the drive shaft at assembly Fig. 8. Disconnect the drive shaft from the axle U-joint

1543-5 Integral Carrier Axle-Ford WER 15-03-5 52182W FIG. 13 Typical Drive Pinion Flange Seal Installation 4. Align the punch or scribe mark on the U-joint flange with the mark on the end of the pinion shaft, and install the flange. 5. Install a new in

15-03-6 Integral Carrier Axle-Ford WER 15-03-6 INSTALLATION OF A NEW UNIVERSAL 3. Disconnect the upper suspension arm from the axle JOINT FLANGE housing by removing the pivot bolt, nut, Jock washer, and two eccentric washers. Use procedure as outlined under Drive Pinion Oil 4. Lower the rear axle to the floor with the jack andSeal Replacement, omitting replacement of the seal. remove the axle from under the vehicle, along with AXLE HOUSING the right and left rear springs and ins

NUT - 382828.5100 LOCK WASHER - 34785.52 - 9716-12 CLIP 100.130 LB. FT. 3534/3-58 UPPER HOSE - 4AOOI

15-03-8 Integral Carrier Axle-Ford WER 15-03-8 4. Slide the axle shafts into place in the axle housing. EHAME E401M/’Ef? Exercise care that splines or any portion of the SCREWREAR axle shafts do not damage the oil seals and that they engage with the splines of the differential side gears. 5. Install the axle shaft C.lock on the inner end of each shaft, and push the shafts outward so that the shaft lock seats in the counterbore of the differential side gear. 6. Position the pinion differential gears and thrust washers 180 degrees apart to the differential side

15-03-9 Integral Carrier Axle-Ford WER 15-03-9 DIFFERENTIAL SIDE GLAR AXLE SHAFT C-WASHER 4N237 4236 THRUST WASHER-. 4228 DIE F ERENTIAL PINION SHAFT DIFFERENTIAL PINION GEAR -4215 421I e BEARING ADJUSTING NUT4067 DIFFERENTIAL LOCK WASHER PINION aSHAFT LOCK BOLT SEARING ADJUSTING 424I NUT LK-4I43 LOCK WASHER

15-03-10 Integral Carrier Axle-Ford WER 15-03-10 DIFFERENTIAL SIDE GEAR AXLE SHAFT C.WASHER.4N237 4236 THRUST WASHER- 4228 DIFFERENTIAL PINION SHAFT DIFFERENTIAL PINION GEAR -4215 4211 NUT 4067 LOCK WASHER DIFFERENTIAL PINION aSHAFT BEAR ING ADJUSTING LOCK BOLT NUT LOCK-4143 4241 LOCK WASHER

15-03-11 Integral Carrier Axle-Ford WER 15-03-11 FIG. 18 Checking Backlash and Runout-WER Axle FIG. 19 Drive Pinion Shaft Nut Removal DISASSEMBLY OF DIFFERENTIAL CASE 81814-lb 1. If the two differential side bearings are to be removed from the differential case, use the tool FIG. 20 Drive Pinion Flange Removal shown in Fig. 22. 2. Remove and discard the bolts that attach the ring PINION BEARING CUPS gear to the differential case. Press the ring gear Do not remove the pinion bearing cups from the from the case or tap it off with a soft-faced carrier costing unless the cups are wor

15-03-12 Integral Carrier Axle-Ford WER 15-03-12 PRESS RAM T71 /P4621-S E1914-1C FIG. 21 Pinion Rear Bearing Removal TOOL- TS7L-4220,A FIG. 23 Pinion Bearing Cup Installation-Typical change is necessary, it will be indicated in the tooth pattern check.

15-03-13 Integral Carrier Axle-Ford WER 15-03-13 DRIVE PINION AND GEAR SET ALTERNATE 7. Place the gauge block on the dummy pinion head PROCEDURE and rotate the indicator over the crossbar. The 1. Using pinion depth gauge set, Tool 170P-4020.A, correct reading will be obtained when the indicator select the correct aligners they ore marked to is at top dead center over the crossbar readings correspond with the correct axle to fit the front and are usually 0.020-0.040. Because 0f the necessary rear pinion bearing 1.0. Screw these on the dial indicator position the use of a mirror will threaded shaft to the correct position Fig. 25 and simplify rea

15-03-14 Integral Carrier Axle-Ford WER 15-03-14 front bearing into the bearing cap and assemble DIFFERENTIAL CASE. BEARINGS AND RING the tool handle onto the screw and tighten to 20 GEAR ft-lbs Fig. 27. If the ring gear runout check before disassembly 3. Center the gouge tube into the differential bearing exceeded specification, the condition may be caused bore. Instali the bearing caps and torque the bohs by a warped gear, a detective case, or excessively worn to specification Fig. 27. differential bearings. 4. U

15-03-15 Integral Carrier Axle-Ford WER 15-03-15 GAUGE TUBE E2615-IA FIG. 27 Using Pinion Depth Gauge Tool T75P-4020-A exceed specifications, install a new ring gear. If the runout still exceeds specifications, the ring gear is true and the trouble is due to either a damaged casting or worn bearings. 7. Remove the differential case from the carrier and remove the side bearings from the case. SEARI’IGAND ROLLERCONE 8. Install new bearings on the case hubs, and again install the differential assembly in the carrier

15-03-16 Integral Carrier Axle-Ford WER 15-03-16 REAR BEAR-G CONE nut. Hold the flange with the tool shown in Fig. AND ROLLER 20 and tighten the pinion shaft nut. As the pinion shaft nut is tightened, the pinion shaft is pulled into the front bearing cone and into the flange. As the pinion shaft is pulled into the front bearing N cone, pinion shaft end play is r

15-03-17 Integral Carrier Axle-Ford WER 15-03-17 When installing the hunting-type gear set no 12. Slide the case assembly along the bores until a timing marks, place the differential case and ring slight amount of backlash is felt between the gear gear assembly in the carrier without regard to the teeth. Hold the differential case in place. matching of any particular gear teeth. 13. Set the adjusting nuts in the bores so that they just contact the bearing cups. 14. Carefully position the bearing caps on the carrier casti

15-03-18 Integral Carrier Axle-Ford WER 15-03-18 SPECIFICATIONS DRIVING AXLE IDENTIFICATION INTEGRAL CARRIER -WER blent. Ring Gear Duff. Tag Ratio Dia. Inches Type ® WER-AA 2.47:1 8.7 C2 WER-AB 2.47:1 8.7 C2 WEB-AC 2.47:1 8.7 C2 Type: C2 - Conventional Differential - 2 Pinion ADJUSTMENT TORIJE SPECIFICATIONS INTEGRAL CARRIER -WER Torque Torque Description

15-03-19 Integral Carrier Axle-Ford WER 15-03-19 SPECIAL TOOLS Tool Number Description Tool Number Description TSOT- 100-A Impact Slide Rammer T7OP-4067-A Differential Bearing Adjuster Nut Wrench TOOL-i 175-AC Grease Seal Remover Use with Slide Hammer TB8P-4602-AB Vial orTOOL-1175-AE TS0T100-A TB8P-4602-AC Magnet T78P-1 171-A Axle Shaft Oil Seal Replacer TOOL-4615-G Drive Pinion Front Bearing Cup Remover T6OK-1 177-B Rear Wheel Bearing Oil Seal Replacer T60K-4616-A Pinion Bearing Cups Replacer Inner and

15-06-1 Integral Carrier Axle-Ford WGX 15-06-1 PART Integral Carrier AxIe-Ford--WGX 15-06 Applies To Fairmont/Zephyr SUBJECT PACE SUBJECT PAGE CLEANING AND INSPECTION 06-3 MAJOR REPAIR OPERATIONS Cont’d. Pinion Bearing Cups 06-10 DESCRIPTION 06-1 Lubricant Checking Procedure 06-16 REMOVAL AND INSTALLATION MAJOR REPAIR OPERATIONS

-a 91 149951 HOUSING ASSEMBLY 4209 RING AND PINION 4211 DIFFERENTIAL PINION SHAFT 4204 DIFFERENTIAL CASE 14251 DIFFERENTIAL PINION GEARS 387246-SI PFNION SHAFT LOCK BOLT 146

15-06-3 Integral Carrier Aide-Ford WGX 15-06-3 CLEANING AND INSPECTION damaged gears cannot be rebuilt to correct a noisyINSPECTION BEFORE DISASSEMBLY candition. OF CARRIER BEARING CUPS The differential case assembly and drive pinion should be inspected before they are removed from the Check bearing cups for deep scores, galling, or carrier casting. These inspections can find the cause of spalling. If a .0015" feeler gage can be inserted the complaint and determine the resolution needed. between a cup and the bottom of its bore at any 1. Wipe the lubricant from the internal working parts

15-06-4 Integral Carrier Axle-Ford WGX 15-06-4 5. Push flanged end of the axle shafts toward the SOWER ILOOSE Fill center of the vehicle and remove the C - lock from the button end of the axle shaft. Fig. 3 6. Remove axle shaft from the housing, being careful nat to damage the oil seal. TORRINOTON SNUG FIll AXLE SHAFTS

15-06-5 Integral Carrier Axle-Ford WGX} 15O6-5 Install the axle shaft seal using tool T7BP-1 177-A as shown in Fig. 7. NOTE: INSTALLATION OF THE BEARING OR SEAL ASSEMBLY WITHOUT THE PROPER TOOL MAY RESULT IN AN EARLY BEARING OR TOOL NO- T78P-ll71-A SEAL FAILURE. IF SEAL BECOMES COCKED IN THE BORE DURING INSTALLATION, REMOVE IT AND INSTALL A NEW ONE. INSTALLATION AXLE SHAFT 1. Carefully slide the axle shaft into the axle hous ing, without damaging bearing assembly. Stan the splines into the side gear and push firmly until the button end of the axle shaft can be seen in the differential case. CAUTION: Care must be token so as not to let the axle shaft splines damage the

15-06-6 Integral Carrier Axle-Ford WGX 15-06-6 SCRIBE MARKS. F2SB-1A FIG. 9 Drive Shaft to Axle U-Joint Connection COMPANION FLANGE HOLDING TOOL T77P-4676 B F2610 IA FIG. 11 Companion Flange Holding Tool T77P-4676-B MARK THE FLANGE IN F2669.1A FIG. 10 Checking Pinion Bearing Preload

15-06-7 Integral Carrier Axle-Ford WGX 15-06-7 76. Tighten the pinion nut; rotating the pinion occa sionally to insure proper beorirt9 seating. AA50, take frequent pinion bearing torque preload readings until the original recorded preload reading is obtained. 17. If the original recorded preload is less than speci

15-06-8 Integral Carrier Axle-Ford WGX 15-06-8 11. Disconnect the vent from the rear axle housing. 15. Install the wheels and tires. NOTE: THE AXLE VENT IS SECURED TO THE 16. Install the carrier cover using the new silicone HOUSING ASSEMBLY THROUGH THE sealant gasket material and torque to specifica BRAKE JUNCTION BLOCK. AT ASSEM tion. Fig. 8 BLY, LOCTITE OR EQUIVALENT IS 17. Fill the axle to 1-1/4" below the bottom of the APPLIED TO THE THREAD TO INSURE RE filler hole with the specified lubricant. Be sure TENTION. UPON INSTALLATION, LOC that the axle is in its operating position. TITE COMPOUND PART NUMBER C3AZ-

15-06-9 Integral Carrier Axle-Ford WGX 15-06-9 385252 SEDANS! 384485-32 14-26 FT-LB 18198

15-06-10 Integral Carrier Axle-Ford WGX 15-06-10 ARROWCAST INTO PRESS RAM F2675-IA F20fl-1A FIG. 17 Differential Bearing Cap Markings FIG. 19 Pinion Rear Bearing Removal 13. Remove the companion flange with the tool shown in Figure 13. opposite side of the cups during removal to prevent 14. With a soft-faced hammer, drive the pinion out of cups from cocking in the casting. the front bearing cone and remove it through the

15-06-11 Integral Carrier Axle-Ford WGX 15-06-11 7. Remove the differential case from the carrier and remove the differenflal bearings from the case Fig. 22. - 8. Install new differential bearings on the case hubs and install the differential assembly in the carrier without the ring gear Fig. 23.

15-06-12 Integral Carrier Axle-Ford WGX 15-06-12 bearing cup and case Fig. 24. Install the 178P- 9. Use aback and forth motion of the ring gear using 4136-82 .300 gauge disc spacer on the pinion your right hand, while tightening the rod with the gear side R.H.. Install the bearing caps and left hand until zero backlash is obtained. torque to 30 in-lb. NOTE: BEARING CAPS TO BE INSTALLED WITH TOOL-TI8P-4136-A ARROWS IN THE SAME DIRECTION AS THEY WERE WHEN REMOVED. F 2684-lA

15-06.13 Integral Carrier Axle-Ford WGX 15-06-13 TOO L-T7SP-4000-A P2686-lA F2687-IA FIG. 28 Installation of Differential Bearing FIG. 29 Installation of Differential Carrier Preload Disc Spreader Adapters EXAMPLE - Step 4 - Feeler Gauge Reading .040 in. Add .500 in. Total Clearance .540 in. EXAMPLE - Step 11 - Feeler Gauge Reading .086 in. Plus .200 in.

15-06-14 Integral Carrier Axle-Ford WGX 15-06-14 22. Determine backlash readings at service teeth around the ring gear. Specification .O08..012. However, the variance of the read ings must not exceed .004 Fig. 31. P2690-lA FIG. 32 Checking Ring Gear Runout F 2889-lA FIG. 31 Checking Ring and Pinion Gear Backlash 31. Add the amount of specified lubricant to rear

_____ 15-06-15 Integral Carrier Axle-Ford WGX 15-06-15 PART NO. PAINT STRIPES ARE APPROx. NUMBER OF SUFFIX DIM. A 25 WIDE AND .25 APART STRIPESAND BASIC PART NO. OF COLOR CODE DBBW-4067-I 5- BLU AH1A/AH2A -3030 ---3035 4 BLU AG1A/AG2A .3010 - .3015

_____ ___________ 15-06-16 Integral Carrier Axle-Ford WGX 15-06-16 NOTE: THE SAME REAR PINION BEARING USED T76P.4b2O-A1 I IN THIS PROCEDURE MUST BE USED IN FINAL ASSEMBLY OF THE AXLE. 8. Place the selected shims on the pinion shaft and press the pinion bearing until firmly seated on the shaft. NOTE: A TOOTH PATTERN C

_____________ 15-06-17 Integral Carrier Axle-Ford WGX 15-06-17 SPECI FICATIONS DRIVING AXLE IDENTIFICATION INTEGRAL CARRIER - CONVENTIONAL Identification Tag Ratio Ring Gear Diameter Inches - Differential Type r j WGXA 2.73:1 71/2 C2 J WGX-B 3.08:1 7-1/2 C2 WGX-C 2.47:1 7-1/2 C2 ADJUSTMENT TORQUE SPE

_______________________________ 15-06-18 Integral Carrier Axle-Ford WGX 15-06-18 SPECIAL TOOLS Tool Number Description ISOT-100-A Impact Slide Hammer TOOL-I 175-AC or Grease Seal Remover Use with Slide Hammer T5OT-100-A 175-AE -- T76P-4020-A Pinion Depth Gauge TOOL-4201-C Differential Backlash and Runout Gauge with Universal Bracket Dial Indicator and Bracket -4201-U TSIL-4220-A Differential Bearing Assembly Remover T51L-4221-A Differential Side Bearing Remover TOO L-4221-C Differential Side Bearing Remover T7OP-4221-A Differential Side Bearing Remover

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

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15-40-1 Traction-bk Limited Slip Differential-Ford 15-40-1 Traction -Lok Limited PART 15-40 Slip Differential-Ford Does Not Apply to Vehicles with Integral Carrier Axles SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS 40-3 REMOVAL AND INSTALLATION 40-3 DESCRIPTION 40-1 SPECIFICATIONS 40-7 DISASSEMBLY AND ASSEMBLY 40-3 OPERATION 40-3 TESTING 40-3

UI a0 tO PINION SHAFT 2 PINION DIFFERENTIAL RING GEAR

15-40-3 Traction-bk Limited Slip Differential-Ford 15-40-3 OPERATION In operation, the clutch will transfer power to On a totally icy surface, both wheels can be made whichever wheel is not dipping in cases where one to rotate together by lightly applying the hand brake. wheel is on ice or a slippery surface. In other words, Once again, resistance to rotation increases the clutch resistance to rotating increases the clutch action. action. TESTING Test procedures for the Traction-Lok differential are given in Part 15-01. ADJUSTMENTS Mo in-vehicle adjustments are possible on this unit. Refer to Part 15-10 for adjustments to the axle in which it is installed. REMOVAL AND INSTALLATION Refer to Part 15-10 for removal of this differential, wh

15-40-4 Traction-Lok 1.imited Slip Differential-Ford 15-40-4 RAM FIBER BLOCK BEARING OR WOOD BLOCK FIG. 2 Installing Differential Bearing E1B932A FIG. 3 Center Block and Pre-load Springs Installation center block should be positioned so the long 6. With a suitable drift, install the shaft lock pins. shaft is driven through the rough side and Make sure the pinion and side gears move freely.

15-40-5 Traction-Lok Limited Slip Differential-Ford 15-40-5 8. Position the pre-load plate over the four springs, between the shim tool and the cover-to-case mating making sure the springs are properly seated. The surface. Using a feeler gauge, determine the preload plate straddles the center block over its exact amount of clearance. The shim pack narrower or machined width. thickness chart will indicate the correct amount of 9. Mount the differential cover in a soft jawed vise shims to subtract from the 0.050 shim originally or holding fixture. installed. In order to correctly select the proper shims, th

15-40-6 Troction-Lok Limited Slip Differential-Ford 15-40-6 CLEARANCE CHECK AREA SHIM TEMPLATE ElB952A FIG. 5 Shim Template Tool Application while the other is held stationary. The initial break 100-250 ft-lb. The rotating torque required to keep away torque, if the original clutch plates are used, the side gear turning with new clutch plates may should be no less than 40 ft-lb. If new clutch plates fluctuate up to 40 ft-lb. are used, the break-away torque should run from "This pub

15-40-7 Traction-Lok Umited Slip Differential-Ford 15-40-7 SPECIFICATIONS GRANADA, MONARCH, VERSAILLES FORD, MERCURY IdentIfication Ring Gear Differential identIficatIon Ring Gear Differential Ta Ratio Oiameter Inches Tag Ratio Diameter Inches Type U/l-B-G 1501 9 T4 WFG-AL 3.00:1 9 T4 VFB-K 250.1 9 T4 WFG-AA 275:1 9 14

15-60-1 Drive Shaft-Single Cardan Type U-Joint 15-60-1 Drive Shaft - 1 Single Cardan Type U-Joint Applies To All Models Except Lincoln Continental and Versailles SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION 60-5 Drive Shaft Balancing 60-2 TESTING DESCRIPTION 60-1 Drive Line Angle Check 60-2

15-60-2 Drive Shaft-Single Cardan Type U-Joint 15-60-2 DRIVE LINE ANGLE CHECK DRIVE SHAFT RUNOUT CHECK Vibration or shudder which is noticeable either on Using a dial indicator, check the runout at each end fast acceleration, when coasting, or when using the and in the middle of the drive shaft. The rear check engine for braking, may be caused by the rear axle should be made on the small tube section of the shaft housing being loose on the rear springs or by improper between the balance weights and the yoke welds. Drive pinion angle. Refer to Group 14, for pinion angle shaft runout should not exceed 0.035 inch at any one checking procedures. If the rear axle U-bolts Pinto! point. aobcat!Mustang, Granada!Monarch/ only are loose, to

15-60-3 Drive Shaft-Single Cordon Type U-Joint 15-60-3 DRIVE SHAFT BALANCING 5. Stop the vehicle and rotate the driveshaft so that the chalk line is in the same location as it was noted Using Special Equipment under the strobe light. Road test the vehicle. Evaluate and record road 6. Install two screw-drive stainless steel hose clamps speed at which vibration occurs. on the driveshaft. Position the clamps 180 degrees 2. Raise vehicle on a frame contact hoist, and re from the transducer and tighten Step 3, Fig. 5. evaluate, by accelerating to the indicated speeds 7. Run the vehicle t

15-60-4 Drive Shaft-Single Cardan Type U-Joint 15-60-4 TRANSDUCER CHALK LINE SCRIBE AN AXIALC CHALK LINE SUPPORT EDOF/AND POSITION APPROXIMATELY 4 LONC OF TRANSDUCER CLAMPS ROTATINGCCLAMPS INSTALLATION OF SCR[W-IJHIVE CLAMPS AND POSITION OF TRANSDUCER

15-60-5 Drive Shaft-Single Cordon Type U-Joint 15-60-5 REMOVAL AND INSTALLATION STANDARD DRIVE SHAFT Removal 2. Lubricate the yoke spline with B8A-19589-A 1. To maintain drive line balance, mark the rear drive lubricant or equivalent. This spline is sealed so shaft yoke and the drive pinion flange of the axle that the transmission fluid does not wash away if the yellow alignment marks ore not visible, in the spline lubricant. Remove the tool from the relation to the shaft, so that they may be installed extension housing. Install the yoke on the in their original positions. transmission output shaft. Do not al

15-60-6 Drive Shaft-Single Cordon Type U-Joint 15-60-6 8. Position the slip yoke on the spider and install two new bearings and snap rings. 9. Check the joint for freedom of movement. If bind has resulted from misalignment during the foregoing procedures, a sharp rap on the yokes with a brass hammer will seat the bearing needles and usually provide freedom of movement. Take care to support the shaft end during this operation, and do not strike the bearings themselves. Be sure the universal joints are free to move easily without binding before installing the drive shaft. OTC 7025-A 09

15-66-1 Drive Shaft-Double Cardan Type U-Joints 15-66-1 Drive Shaft - 16 Double_Cardan_Type_U-Joints Applies To Lincoln Continental and Versailles SUBJECT PAGE SUBJECT PAGE DESCHIPTION 66-1 TESTING Drive Line Angle Check 66-2 DISASSEMBLY AND ASSEMBLY Drive Line Balance Check 66-2 Double Garden Joint - Versailles 66-3 Drive Shaft Runout Check

15-66-2 Drive Shaft-Double Cordon Type U-Joints 15-66-2 TESTING DRIVE LINE BALANCE CHECK a brake, may be caused by the rear axle housing being or by improper pinion angle. If detailed parts of the drive shaft are replaced and loose on the rear springs far pinion angle checkingshaft vibration is encountered after installaion, Refer to Part 14-01 disconnect the shaft at the slip yoke. Rotate the slip procedures. yoke 180 degrees; then, reconnect the shaft to the slip yoke. If the vibration persists, disconnect the sha

15-66-3 Drive Shaft-Double Cardan Type U-Joints 15-66-3 disconnected from the axle, rotated 180 degrees and reinstalled. 0-RING 3. Install the bolts and nuts that attach the yoke to the drive pinion flange. Torque the nuts to 70 to 90 ft-lbs. YOKE EZiOl lB FIG. S Output Shaft Spline Seal DISASSEMBLY AND ASSEMBLY DOUBLE CAROAN JOINT-VERSAILLES 3. Using a suitable tool,

15-66-4 Drive Shaft-Double Cardan Type U-Joints 15-66-4 FLANGE YOKE BEARING TOOL-CJ91 B F2544-IA F25?1-lA FIG. 4 Partially Pressing Bearing From Center FIG. 5 Punching Alignment Marks Yoke 7. Remove all of the remains of the sheared plastic CENTER YOKE retaining rings from the grooves in the yokes. The sheared plastic may prevent the bearing cups from being pressed into place and thus

15-66-5 Drive Shaft-Double Cardan Type U-Joints 15-66-5 CENTER YOKE INSERT THE SPIDER INTO THE YOKE SO THAT JOURNAL SEATS FREELY IN THE BEARING CUP. S F’ IL C fl F2563-14 P2564-lA FIG. 7 Removing Bearings FIG. 8 InsertIng Spider into Yoke 10. Thread nut on tool, Part No. J-23996-4, and draw 2. Lubricate the seal lip and install the seal flush into the ball off the stud using wr

15-66-6 Drive Shaft-Double Cardan Type U-Joints 15-66-6 INSTALL THE OPPOSITE BEARING CUP PART WAY SPIDER JOURNALS STRAIGHT IN BOTH BEARING CUPS F2S652A FIG. 9 Aligning Bearing Cups and Journals 4. Install the opposite bearing cup part way. Be sure that both spider journals are started straight and true into both bearing cups.

15-66-7 Drive Shaft-Double Cardan Type U-Joints 15-66-7 J- 239 96-4 PLACE FINGERS OP TOOL OVER BALL F25701A FIG. 11 Relieving Binding Condition-B FIG. 14 Installing Ball-Remover Tool PLACE CYLINDER OVER THE OUTSIDE or BALL

15-66-8 Drive Shaft-Double Cardan Type U-Joints 15-66-8 J-23996-I DRIVE ON THE BALL P25741 A FIG. 18 Driving BalI Into Position THREAD NUT ON TOOL F 2572-lA

16-00-1 Clutch And Manual Transmission 16-00-1 - GROUP Clutch and Manual Transmission -16 PART TITLE PART NO. PART TITLE PART NO. Clutch 16-02 General Manual Transmission Service 16-10 Ford Three-Speed Transmission 16-11 Mechanical Clutch Linkage 16-03 Ford Four.Speed Overdrive Transmission 16-30 Model RAD Four-Speed Transmission . . 16-28

16-01-2 General Clutch Service 16-01-2 CLUTCH DIAGNOSIS COMPLAINT POSSIBLE CAUSE RESOLUTION * Clutch squeaks’ or ‘scrubs" when the * Clutch release linkage and/or cable - * Lubricate, repair or replace as required. pedal is in motion lack of lubrication, binding, interfer ence, worn or kinked * Lack of lubrication on the clutch release * Remove transmission and release

16-01-3 General Clutch Service 16O1-3 ADJUSTMENTS - - - DIAL INDICATOR ASSEMBLY FLYWHEEL HOUSING ALIGNMENT SPECIALTOOL NO, 4201-C DIAl, INDICATOR

16-01-4 General Clutch Service 16-01-4 bore runaut Fig. 4. The rubber band shown attached to the lever Figs. 1 and 4 must be TOOPOSTL-T1SL-6392-AASSEMBLY installed as indicated, prior to installation of the lever, to preload the dial indicator for bore readings. UNIVERSAL BRACKET PART OF TOOL-42Ol r POST ASSEMBLY TOOL TIBL E302 A 4 SUPPORT BAR. INDICATOR BUTTO TOOL-T7EL-4201’I