The Ford Barn

wga · 05-14-2022, 11:50 AM

Need some help on front suspension rebuild.
According to the 49 service manual, to remove the spindle, the upper expansion plug is removed. Then drive the spindle out, which removes
the lower expansion plug.

How do you remove the upper expansion plug? My plan was to make a hole with a punch and enlarge it, get a small pry bar into it, and remove the plug. So far that approach is not working.

Suggestions?

Thanks

19Fordy · 05-14-2022, 12:41 PM

Look here:
https://www.jalopyjournal.com/forum/...issue.1076031/

Hopefully, your service manual has pictorials with instructions.

TAKE PHOTOS OF EACH STEP.

Your approach will work. Remove the expansion plug by first loosening it with a a sharp pointed prick punch with the point of the punch facing inward towards the center of the plug. Make a series of "prick punch indentations" around the perimiter of the plug. This loosens the fit of the plug by forcing the metal plug inward away from its edges. Then carefully pry the plug up and out.

Then remove the spindle lock pin that holds the king pin (spindle pin) in place. Then drive out the spindle pin through the spindle support to remove opposite expansion plug on the bottom. Then, take photos and remove spindle bearing assembly.

My 49-51 Mercury Service Manual has detailed info. if you need it.

51 MERC-CT · 05-14-2022, 03:28 PM

Quote:

Originally Posted by wga

Need some help on front suspension rebuild.
According to the 49 service manual, to remove the spindle, the upper expansion plug is removed. Then drive the spindle out, which removes
the lower expansion plug.

How do you remove the upper expansion plug? My plan was to make a hole with a punch and enlarge it, get a small pry bar into it, and remove the plug. So far that approach is not working.

Suggestions?

Thanks

Remove by drilling holes as required to pry off cap.
Then remove the horizontal tapered lock pin to drive out kingpin.

Until you remove the horizontal pin you are not going to be able to remove the kingpin.

Frank Miller · 05-15-2022, 08:37 AM

Try drilling a few holes and install hex headed sheet metal screws to push it up.

wga · 05-15-2022, 09:36 AM

The Ford service manual has no pictures, diagrams only. Always take pics prior and during the process. The horizontal pin was removed.
Will drill a few holes and also use the hex head sheet metal screws.

Thanks for all the suggestions, will advise as progress continues.

19Fordy · 05-15-2022, 11:10 AM

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wga: The deep recess at the top of your spindle support in your photo suggest that the expansion plug has fallen out or already been removed and never replaced. That expansion plug is very soft metal and easily deformed for removal. I suspect you are looking at the top of your hardened spindle pin (king pin).
Notice the "U" groove for a punch. Could also be hammer marks. Here's some info. from the 49-51 Mercury Repair Manual that may help. The design of the ford and merc suspension is similiar except the Ford components are not interchangeable with the Mercury as the Ford are smaller. More photos follow.

19Fordy · 05-15-2022, 12:02 PM

More spindle removal photos. NOTICE spindle support does not have to be removed to replace spindle. Hope this helps.

wga · 05-15-2022, 01:34 PM

19Fordy - wow, many thanks. My Ford manual has the descriptions, though most of the photos were not included.
I had the same thought yesterday afternoon that the expansion cover was missing. My impression is that this suspension was never overhauled since new.

Heading out to the shop after typing this message - stay tuned.

Very much appreciate your assistance.

wga · 05-15-2022, 08:29 PM

Success this afternoon, friend dropped by who suggested drilling more holes around the circumference might help. Five minutes later.....

Spindle is stubborn, letting it soak with penetrating oil over night. If this does
work, will remove as an assembly.

Onward....

many thanks.

19Fordy · 05-16-2022, 09:44 AM

wga: That's good news indeed. Glad you got it removed.

rotorwrench · 05-17-2022, 09:33 AM

Ford used some type of a rotating burnishing tool to roll the edge of the boss over a bit. This helped keep the plugs in place but it required a counter bore tool to remove the lip if a person wants a new plug to go back in. Some heavy handed mechanics get carried away with staking the edge of the bore around the plug as well after new king pin kits are installed. It's always something with these old cars.

05-14-2022, 11:50 AM	#1
wga Senior Member Join Date: Jul 2010 Location: Yorba Linda, CA Posts: 897	49 spindle removal Need some help on front suspension rebuild. According to the 49 service manual, to remove the spindle, the upper expansion plug is removed. Then drive the spindle out, which removes the lower expansion plug. How do you remove the upper expansion plug? My plan was to make a hole with a punch and enlarge it, get a small pry bar into it, and remove the plug. So far that approach is not working. Suggestions? Thanks __________________ Henry Ford designed the flathead without the aid of a computer.

05-14-2022, 12:41 PM	#2
19Fordy Senior Member Join Date: May 2010 Location: Coral Springs FL Posts: 10,925	Re: 49 spindle removal Look here: https://www.jalopyjournal.com/forum/...issue.1076031/ Hopefully, your service manual has pictorials with instructions. TAKE PHOTOS OF EACH STEP. Your approach will work. Remove the expansion plug by first loosening it with a a sharp pointed prick punch with the point of the punch facing inward towards the center of the plug. Make a series of "prick punch indentations" around the perimiter of the plug. This loosens the fit of the plug by forcing the metal plug inward away from its edges. Then carefully pry the plug up and out. Then remove the spindle lock pin that holds the king pin (spindle pin) in place. Then drive out the spindle pin through the spindle support to remove opposite expansion plug on the bottom. Then, take photos and remove spindle bearing assembly. My 49-51 Mercury Service Manual has detailed info. if you need it. Last edited by 19Fordy; 05-14-2022 at 12:48 PM.

05-15-2022, 08:37 AM	#4
Frank Miller Senior Member Join Date: May 2010 Location: Auburn, MA Posts: 2,106	Re: 49 spindle removal Try drilling a few holes and install hex headed sheet metal screws to push it up. __________________ “The technique of infamy is to start two lies at once and get people arguing heatedly over which is true.” ~ Ezra Pound

05-15-2022, 01:34 PM	#8
wga Senior Member Join Date: Jul 2010 Location: Yorba Linda, CA Posts: 897	Re: 49 spindle removal 19Fordy - wow, many thanks. My Ford manual has the descriptions, though most of the photos were not included. I had the same thought yesterday afternoon that the expansion cover was missing. My impression is that this suspension was never overhauled since new. Heading out to the shop after typing this message - stay tuned. Very much appreciate your assistance. __________________ Henry Ford designed the flathead without the aid of a computer.

05-16-2022, 09:44 AM	#10
19Fordy Senior Member Join Date: May 2010 Location: Coral Springs FL Posts: 10,925	Re: 49 spindle removal wga: That's good news indeed. Glad you got it removed.

05-17-2022, 09:33 AM	#11
rotorwrench Senior Member Join Date: Jun 2010 Location: San Antonio, Texas Posts: 16,425	Re: 49 spindle removal Ford used some type of a rotating burnishing tool to roll the edge of the boss over a bit. This helped keep the plugs in place but it required a counter bore tool to remove the lip if a person wants a new plug to go back in. Some heavy handed mechanics get carried away with staking the edge of the bore around the plug as well after new king pin kits are installed. It's always something with these old cars.