Can you post some photographs of the rotor and spindle? Maybe something may appear with visual documentation of the assembly, but probably leave the grease out for the pictures.

From the last description it alsmost sounds like the spindle is too long for the rotor. So the washer is bottoming on the shoulder of the spindle before the bearings are fully seated preventing enough preload on the bearings. The parts seem to be mismatched, so you may require a spacer that clears the spindle shoulder. Get another washer and enlarge the hole and see if when that is placed under the washer it makes any difference. I don't know if it is a problem to run shims in that location, but at least you'd know if that is the problem.

Last edited by 70XL (August 12, 2016 10:55 am)

dan_6776 wrote:

 The more time I spend on this, the more I am confused.

You and me both!  I'm not sure what I was thinking when I said to measure to the inside of the outer bearing... I meant outside, as you have wisely done. Good thinking!

Okay, let's look at your measurements.

Spindle measurement from shoulder to inside of washer at stopping point: 3-3/8"

Measurement from outside to outside of both bearings installed in rotor: 3-5/8"

Since the second measurement is greater than the first, theoretically there should be room to squeeze the bearings once the rotor is installed. However, the difference is only 1/4", which is a reasonable allowance for error considering you're doing the best you can with only a tape measure. Also, it's possible that the bearings could compress that much upon tightening (1/8" each), therefore preventing drag on the rotor due to the washer coming to a stop at that shoulder. 

So I guess the next thing I would do is follow 70XL's advice and try a washer with a hole big enough to go past
that shoulder, and see if you can get drag on the rotor.

Also, from looking at your pics there's one little thing that bothers me - this is the shoulder where the washer stops, correct?:



I don't know why, it just doesn't look right to me for some reason. Probably nothing, but... ?

You mean we have to wait two weeks before any further investigation into this mystery? Damn. Any chance of postponing your vacation?

Just kidding! Have a great trip!


 

Alright Boogyman! Just for you, I will postpone my vacation cause I just don't want to leave you hanging! Really, I am heading out the door as I type. Lol
To answer your concern, the circled area you are questioning is the end of the spindle taper. What you see is the gap between the inside of the washer and the outside edge of the outside bearing. The reason a gap exists, is because I pushed the outer bearing as far inwards as I could until the spindle taper prevent further movement. I was trying to simulate what would happen if I used another larger washer that would slide over the shoulder of the spindle to move the bearing further inward to further increase preload.
JWSpeed: As mentioned earlier, I have already cross referenced the bearings I have with new ones and they are a match. I also checked the current bearing part numbers for a 78 Cougar and everything seems to be correct. Perhaps you may see something that doesn't jive? Part numbers are:
Donor bearings: Inner-Timken JL69349, Outer-Bower LM12749, seal-CR19221
New bearings:    Inner-Timken BR11,     Outer-Timken BR12,     seal-CR19221
You mentioned that from the picture you thought that the rollers look like they are only running on part of the race. I believe you are correct. From the wear pattern on the rollers(dull, flat appearance) most of the rollers are making contact with the outer races. There is small shinny area on both bearings towards the outside of each roller that would indicate no contact. I wonder if this is just a result of the preload and how the rollers sit in the races when they are correctly tensioned up? It appears they hang out of the races slightly.
Posting pictures of the donor parts as I bought them. The salvage guy told me they were from a 78 Cougar, maybe someone can confirm. They looked correct and intact to me. OK...good bye everyone, talk to you in a couple of weeks! Hope we can figure this out...I really don't want to put the drums back on. LOL

Last edited by dan_6776 (August 13, 2016 9:48 am)

dan_6776 wrote:

"....... The reason it stops at that point is because the washer hits a shoulder. The shoulder is the start of the taper on the spindle.

 
If the washer is stopping against the shoulder, then you have the wrong washer, or the wrong bearing.  Most likely the wrong washer.  This issue has come up on the VMF several times, and the washer was at fault.


Z

Last edited by zray (August 21, 2016 6:30 am)

Hi Dan, just wondering if you're back from vacation yet...