1977 Lincoln Versailles 9-inch - Installation
Tools required:
Floorjack
Jackstands
Hand Tools (wrenches, ratchet & socket sets)
Allen wrench (1/4")
Hammer
Prybar
Air Impact not required but makes the job much easier
Some things that must be done before installation:
1. Grind Flange off of wedges so that they lie flat on the leaf spring. Do NOT grind the two small raised circles, just the oval flange. The circles fit into the leaf spring perch on the rearend. See Pictures for more info.
2. Have bearings AND outer seals pressed onto axles by machine or mechanic shop
3. Have rearend gear assembly (chunk) rebuilt by competent rearend shop, seals & bearings replaced.
4. Make sure the "chunk" you use has correct flange for the u-joint on your driveshaft.
5. Make sure your "chunk" has a fill plug in it (if you are not using the original chunk housing)
6. Check my Part number list, making sure you have all the necessary parts.
7. Test fit bare axle, you may have to slightly relocate the mounting of the rear chassis brake hose (the Versailles hose bolts on farther to the outside because of its wider webbing)
Installation:
1. Install rearend gear housing with gears into axle housing. Be sure to use the gasket between the two as well as the copper washers under every nut.
2. Use vice-grips to hold your leaf springs together, then remove your leaf spring bolt. Bolt the Versailles bolt in place of it (you'll need the extra height the clear the "wedge.")
3. Using a floor jack, raise the rearend up and diagonally over the leaf springs. Have the wedges ready, set the rearend on the wedges and the bolt head, making sure it seats properly.
4. Use the U-bolts from the Versailles to bolt the rearend down. You will have to either use the Versailles shock mounts or weld and redrill the holes in your originals.
5. Again making sure that the leaf spring perches are seated properly on the wedge and bolt head, tighten the u-bolt nuts. Tighten them all snug and then equally in small amounts, like torqueing a head or intake manifold. Tightening one all the way will bend the u-bolt and cause loosening down the road.
6. Install inner seals in axle housing, using a big socket or piece of exhaust pipe. Be sure the seal is seated on its flange and is not cocked in the axle. Coat the seal rubber with axle lube to insure a seal.
7. Coat axle splines as well as the machined surface for the inner seal with axle lube, and install axles. Tighten four bolts well.
8. Use threadlocker (Permatex or Felpro) on the Caliper bracket bolts, and install caliper bracket.
9. Install Rotor
10. Compress caliper piston, install brake pads, retaining clip, and caliper.
11. Drive the wedge in from either side and secure with allen head bolt.
12. Attach brake lines, bleed.
The emergency brake will have to be fabricated. Use the back half of the Versailles unit and splice it with the front of your car's wherever is easiest using a cable connector.
That's it! You may need to change your Master Cylinder and proportioning valve to a four-wheel drum unit, if it is not already.