Rear Axles - Separate Housing: Description

CHANGES, CAUTIONS, CORRECTIONS 

• RING GEAR & PINION INSTALLATION CAUTION:  Some ring gear and pinion assemblies may be of the "non-hunting" type (pinion gear teeth mesh with the same ring gear teeth). It is important that marked tooth on pinion gear be meshed with marked tooth on ring gear if marks are found on the unit.
• 1967 MERCURY DIFFERENTIAL ASSEMBLY PRODUCTION CHANGE & PARTS USAGE CAUTION:  Parts for early and late type differential assemblies are not interchangeable except as indicated below. Later type have thicker side gears with distance between base of gear teeth and flange thrust face increased. Pinion gears to match side gears changed accordingly. Thrust surfaces in case (for thicker gears) moved outward.032". New type assembly identified by yellow paint mark. Always use two thrust washers (each side) when installing older type side gears in new type case to insure proper gear meshing.
• REAR AXLE VENT LOOSE OR LEAKING CORRECTION:  To correct, clean area around vent and remove vent, then thoroughly clean vent and vent hole with solvent. Apply small amount of sealer (Loctite available) around serrations of vent, then install vent and tap in place with soft faced hammer. Allow to dry for 15-20 minutes before using vehicle.
• FORD, MERCURY & LINCOLN "CHUCKLE" NOISE:  When removal and disassembly of the differential is required to correct a "chuckle" noise, differential case bore may be visually inspected for excessive wear. If the side gear hubs are phosphate coated (a dull black finish), they may have to be replaced with side gears having non-phosphate hubs (silver in color and relatively glossy).
• 1977-72 MAVERICK & COMET REAR AXLE NOISE:  Rear axle gear noise occuring between road speeds of 40-55 MPH can be reduced to an acceptable level by the installation of a turned damper slip-yoke, Part No. D1AZ-4841-A.
  NOTE: Installation of a turned slip-yoke assembly must be done before any attempt is made to minimize the rear axle noise by replacing rear axle components.
• 1972 MERCURY, THUNDERBIRD, MARK IV & LINCOLN IMPROPER AXLE MODEL TAG  - Some vehicles having 9" ring gear axle assembly may have been tagged with a 9 3/8" ring gear axle identification tag. Verify axle type on vehicles indicated before proceeding with overhaul or rework.

Banjo type housing, semi-floating hypoid gear type with "deep-offset" straddle mounted drive pinion, separate differential carrier, and Hotchkiss drive.