oil FORD CAPRI 1974 Workshop Manual

, 22 Chapter 6 Manual gearbox and automatic tran smissio n
17 Fllult dingllosis -IlH IIlU<l I gCMboll
Symptom
Weak or in effec tive synch romesh
Jumps out of gem
Excessive noise
Exces~ivo difficliity III enonU ing (]0,11
P ART 2: AUTOMATIC TRANSMISS IO N
18 Gen eral description
Thc aulOma llC l,an~nHss&#39;on ,;rkl:~ lhe JlI&#34;Ct~ uf the clutch and Hcmhox. wh,ch ,"c. of cow se . mounte(1 heh,nd lhe enu;ne . The unil has a 1"'{lO nluminl"'" content which helps to .elluc" liS
overall weinhl and 11 IS o f compact dimenSions. All 0,1 coole. 's filled ,IS
Reilson (s )
Sy nchronising cones worn, spilt Of dmnaU ed O~ulk rin g sy nch romes h dogs worn, or dmnagcr!
Broken gcarc h,lnUC fOfk rod spring Selector fo rk rod !IIOOye h.ldly worn
Inen!!cc! 9(,1(10 of oil in gc,llhox 0' 0,1 level 100 low Bu sh or ncc(tie roller hC<lrlng s WOUl or dnlllill)cd
GeM welh exce ssively WOrtl 0' (l;Ullll!Jcd
l;'lync:u 1hru st W;'\ShCfS w or n ililowing excessive cndplilV (folll,spC<ld only)
C lu tc h cilhle .1(tjllsllllcnl in corrcr. l
Sliln da.d .. nd ensules cooler OI)(lI.lI1Qn of the \.,lnSUlISSlon lind!)! l.a>l." lowinU ;lnd sunlla. conrll1i0l15 . A VaClIl,Hll conncctlon 10 lhe IIII~I manifold p,ovldes smoO lh cr anrl morc conSI$1r.1l1 clownstlll,S IIndc. load than IS the case Wilh IIn,lS nOl !IlcOlI)Or.11U1IJ lh,s f,,(:Illly The sysle m cotlllJltses lWO tIl.lin com(lonenrs.
(.1) A /"ree e/c'mcnl "v,/lokinc/ic IOUIIIII I:Ollvcrler cOII/,lmy 1:;'I'.1h1(.' o f /orqu c 1II1I!lIplicii /iorr ;, 1 .1/1 irr"mldv Villl;,hle r.1/1O (h) A /unluC/Sln'cd respOlIsiv~ .md IWdwlllrI:illlv IIIIL'f.1lCr! cp'· qL"fie f/c.1rbox COIIII}liSIilf/ pl.wel.l/V m:.lISII/S /IIovidmy tlllf:C forw.l/d 1.1/ios "llff OIlC Icvcrsc ril/'O
Fig . 6.24 C utllw ay view of th e a utomatic transmission (Sec 18)
1 GovelllUi ,'ssemblv 6 rop/leve/sc clu/e h 10 FlOn/ SCIVO 2 GOVlIIJI OI IIlIb 7 FIOIII blilkc bil/Jd /I Valve botlV 3 Olle ·w/lV cfalclt 8 rorquc convenor 1 2 V/lcuum diaplu/lym 4 IlCill bfiJ~C baml 9 Hvdraufic pump 1 J Re/ll servo 6 Forwlllfl cia/eli
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Chapter 6 Manual gearbox and automatic transmission 123
When towing a vehic le wIth automl11ic uansmission it is impoltllllt to observe the precautIons gIven til ,he 'Jading and Towing' se<:,ion at the Iront 01 the manual. Due to the complexity of the au'oma',c tran smission unit. If performance IS not up 10 s tandard, or overhaul is necessary, it IS impera tive that this be left to the locallllain agents who will have the special equipment for fault diagnosis and rectiflcallon. The content of the following sections is thereforc confined to supplying gener", Informl11ion 1'Ind any service information and ins t.uc tion tha i cnn be used by the owner.
19 Routine Illilinte,wno
At the i!lle.vnls SI)CClfiecllll Iho ROllllne Milintennnce seCIlOll in the I.onl 01 th e Illanllal cnllY Oul Ihe follOWIng p'ocp.dwe
Luuricow selector link'1[}() , Applv the h;rrldh.,lke th(:n J,lck \lp the front of Ihc Cill ,'lid Support
,n nxle Slnnds
2 Orlthe Irnkn!JCs at cndl end 01 Ihe genrsh ,h rml on the Icfl·hnnd "le 01 Ihe Iransnll~s,on lowel the cnr \0 Iho wound,
Check /mn.Wllissioll fluid level 4 Elrlll!! the engIne and trnnsnllSSlon to nOllllal ope.IlIUl!IIp.llIperillllfe
and I)alk tho vehlchl on le vel grOllnd 5 Wi,h Ihe engIne idllll(l. move tht: 1.,lnsnllSj"on St:leclt>r lev!]r through ill! pOSlllons 1!lIee lImes. Ihen onuaue '1" ,11111 wall for ;rt lea~t one minute. 6 With ,he engine 51111 idling, wllhd.ilW Ihe lr.1nSnllSSIOll d,psllck.
Wipe it dean, reinsert II, wilhd •• 1W 11 for Ihe second !line nnd read off the levol. 7 Two tv pes 01 automatic transnllssion fluid a.e nvarlilblc (sec SpccifiCiltions 10' tv,>c numbe.s) .1nd It is ImpO,I,ln , Ihilt IheV 'lIe nOI mixed. The colour 01 the dipstick. 10' flUId level checklllg denotes which fluid tvpe to use , 8 If a tlr1nsnllssion requlII"U 1,1ter tvpe fluid IS I'lled 10 " to'<lue COIlVOIlr!r preViously used w<lh oarl.er tVI}e fluid, or vice vr:&#39;.~iI, the compollellt~ shOuld Ire Ilushed 10 ,1IIoi(1 mlxinu o f the two Ill/Ids
COllsult your I'ord dealer rI thIS cond,t ron arIS&#34;~ 9 If III)r.CS~.1rv IOp·up with til'.! spec.rlled orl, thr ough tire drpSlrck tube. 10 tire MAX m, uk, The '1"<rlllrty leqlm ed 10 r,IIS!] tile level !rOllr 'V1IN In MAX IS approxlmatt:lv 0 3 Illre (05 pIIIl)
Adjust Iront brake /)(In(/ '" ApplV Iho handb."ko tholl lack 1'1) th'.! ',ollt 01 the ca. and sUPPO.I axlo stands 11 D,sconnoC t the downshIft ca!)le at Iho t'.1nsmISSlon 12 Slacken Iho brnke band adJusto, sClew locknut and unSClew the
adjus'or screw n lew h,fIlS . 13 Tlghlolllhe adJuslo, sOcw to 14 Nm (10 Ihl II) IISIilU a SUItable lo,que wrcnch From Ih,s poSlllon slaCken the adJusle r screw bv exact Iv I'll \Urns (pre·1983 models) or 2 Iwns ( 1983 and late,
model), Ihen tighten Ihe locknut Wllhoul diSlUrblllg Ihe pOsition of Ihe adjuster sc,ow .
14 R econnec t the downshift cable and lowe' Ihe car 10 Ihe ground.
20 Automalic transmission -removal (HId refining
If l)Osslble, ,aise the car on a hOlsl o. place it over an inspectIon pit. Alternatively, it WIll ho necessary 10 Jack up Ihe car to obtain the Illaximum possible amount of wOlking room undernealh. 2 Place a large d.ain pan benealh the transmiss.on sump (011 pan)
Ihen. working horll the ,car, loosen the a!laching boilS and allow ,he lIuld to drain. nemove all thO bohs excep t tho two I.onl ones to draIn as mIlch fluid as pOSSIble, th on temporarilV .efit Iwo bolls at th e re,1I 10 hold it in place . 3 Remove tho Slilrte. moto. as desc.ibed in Chapter 12 . • jWhero apphcable, rernove the access cover Dnd ad3pto, plale bolts,
Ie the engine untrl the to.qu e converter drain plug is visible, then
unsc.ew Iho plug and d.ain Iho Ihud Into a suit3ble con winer. Refl! and l'Uh ten Iho plug.
Fig. 6 .25 Checkill{J tho au tomatic transmission lIuid lovel (Soc 19)
Fig. 6.2 6 FrQ,1 bn'ko band adjustment (Sec 19)
A Arllf/SICI sc/t'w a Locknut
C Downslu/t Icvel D Downs/u/t c.lblc
Fig. 6.27 Torquo convorter to driveplato boll -arrowod (Sec 20)
'I
.' i
!
,
{ ,
I , .::
.1 , I, , i:
i 'i; ; I
:1
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Chapter 6 Manual gearbo x and auto m atic transmission
5 Unsc rew and remove the tolque conve rter·to·driv eplme b ol ts
t h rough the stader mot o r openrng. turning the engine ,1S neces sary to position the holts rn the opening.
6 Rem ove the propel ler s h alt. reI erring 1 0 Chap te r 7 as necess,u y.
Place a po ly thene bag over the end of t he transmiss io n to preven t dirt Irom ente ring. 7 Detach the sp eedome te r cable from I he extension housing .
8 D iscon nec t the shIft rod althe trans miss ion manual lever. an d the downshift c<lble at the tl a nsmission d ow nshi ft le v er. If necessar y, the
sh if t r od may be completely r emove d by d isconnec ting il frOIl1 t he
selec to r level.
D D isconnect the downshift ouler cable hom the support bracket. 10 D,SCOI1l10Ct th e StMter rnhlbilOr (noullal Start) switch leads. II Disconnoctthe vacuum lines from the vacuunl unll. 1 2 POSItion a Irolley lac k bcne<lt h Ihe Iransmiss ion and raise II 10 /US{ I"ko the transmiSSIo n weig ht. 13 Remove the engme rllar suppor t 10 crossmember nll t <lnd Iho tlanSI111S 510n extenSion housing r.rossmember 14 DIsconnect bOlh eKhaus t pIpes at the m anrfolrfs (Ch<tpter 3) ,111(1 support them ilW<ty from the transmission ! 5 Lowe r the lla ns rll1ssion and also support Ihc 11011 cnd of the ~11!lille 16 D,s coll,lect the 0 11 cooler hnes <It the lranSIlHSSIOn and pili!) thel1110 lev el)! dut from entering . 17 R~move "II the corlVf&#34;t~r hO\l5111g to·onUII1O hott s. and Ihe tl;1I1~I1HSSIOll fIller lube
Fig . 6.29 Downshifl cahle locknut A. Ir[lnsmission lover B
<llld st<lrter inhihitor switch C (Sec 20)
F ig . 6.3 1 O il coole r pipes (Sec 20)
Fig. 6 .2 8 C onnecting d ips A ,m d shift ro d B (SIlC 20)
-=<
~:=~~3
-: _~e~~-=--'
Fig . 6.30 V ilCUUI11 line connection to the vilcuum unit ­arrowed (Sec 20)
.... ,' ,',.<.
~
&#34;i&#39;i.
~&#39; ..
F ig . 6.32 Oil fil ler tube - arrowed (Sec 20)
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Chapter 6 Manual gearbox and automatic transmission 125
18 Carefully ~ove the lrilnsmission reilrwards ilnd downwmds, and
away from the car. Make sur e that lhe torque conver ter rema ins fully in
the transmission. 19 Refilling is the reverse of remova l but ensure that the torque converter drain plug is In line wIth the hole in the driveplate . To check
that the torque converter is positively engaged. measure the distance A between the converter housing to engine mJting fJce and the end of the $llIb ShilfL This should be al leilsl 10 mm (0.4 in) (Fig. 633). Adjust the selector cilble i1nd inhlbilOr switch i1S deSCribed later ill this Chapter. Reftll the 1riln smission unit with lhe specified flu,d before StDrlll1g the ennine i1nd check lhe level i1S describe(f in Section 19.
21 Selecto r mechililism -removnl. overhnlll ilud refitting
Apply the hnndbr,lke then Inek up the front of the car ilntl suppo'1
on ilxle stands. 2 Insi(fe the cm. prose off th e selector lever escutcheon. ,md wothrhaw
!he Illumillnt,on 1ll0U1l1l1l\J from the selec tor lever Oeneilth the CM. remove the Spr<fl\l chp and dewch the selector rod
.1 the selector lever.
r(
®---i
A
6 .33 Checking torque converter engagement with trnnsmission oil pump (Sec 20)
Alle,1S1 100111111 (0.4 ill) 8 O(.1ill (lluy
:-----­
--
6 .34 Selector mechanism (Secs 2 1 and 22)
A SclcclOf pawl B SClccrof cabie
C Pusllbu/loll
o Natld/c
f Connccting clip F Shill (od
.'
. 1 , ;
I
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)
Chapter 7 Propeller shaft
Contents
Cenl,C be"wl(J rCl1<,w,,1 !':HlII d'''!I(lOSIS 1',01'"11,,, Shill, Gel,..,,;!1 li('SCIIIIIIO"
Specifications
Type
Torque wrench settings C{:II(,,, I,/!,,, ,,,! )
(',op"lll:r shall (" "',II i,xlc I I,moO]
Cello!',,1 duscriptioll
3 , ..
o"V() IS lI&#34;Il~&#34;&#34;w,d 110m III!: HP.;uh<)x 10 thCIVill ,"xlc hy mpdns "r " r",,!ly 1)"I,lIlted two 1''',Co) tuhul;1I p,opcli.:r ~hafl The u 'Hv""Si,1 JOlin ;" 1he 1'0111 of tile ,hilh IIH:()rpOI,lICS;) sphno"r yoke winch IS,' ~hd&#34;&#39;!II&#39;1 Oil Iliu \lUilllJu x "''''''SIHlft A (w Illel lIIuvcrs"r lUll)! ,11 11'0 leill uf the f.Il,1f1 IIl(;orpOr;\I(!s iI [lill1lter! yoke which IS holled to the Ie", ,1xle drive !lilll\IC The honl ,111<1 "."" sh"hs illU cOIll"'cl(,d vIa a COI1~1<I1lt vulo(;lIy )'''''1. ;lIlt! ~ ccntre bC.,roll(J IOC<lICd 011 11,,~ ICHI 01 the 110111 shalt sl1ppnllS lit,! nsscnlllly on the \. nriCII>ody .
!'wpldlc, ~h;!h ,ctl1()v;)1 ,md rcf,UIIlU l)n,v,,,,,,II'''''IS '""pectln!) 2 .,
TWO'IHCCll tl1l>\lI., •. w llh lwo HMdy,Splcer type uillvelsitl 10lols an d 01'(' COIISWII1 V"loc,ly (CV) ccnl.e 10"'1. CC"lIC SUppO' 1 IUI;II">!)
NIIl 1 B 10 23 (;0 hI tj~
'1)111 13 10 17 114 10 48
II", 1110) ",11." ,hol!1 ,,,uv,,,s;r ) )OUlls C;IP"lOl hc ICllewed wllhoul ,purloll "'l"'Pllh:ll1 hcciI",e Ihe )01111 s pldels ;IIC sl"ke(1 11110 Ihe yokes ,n i> I'OSl1l011 dUWln)lnud dUlln9 elccl ,olHC h;>l;lI1cin\j When 101111 we;u IS dd,'Cit,d (seu SectIon 11). "ilher .1 new IHopelh;. sh~1t should he ohl;"""d. 01 lilt) cOlllpl{,tc plopelle. shah shQuld he p;rss~d to;> SIIII.IUly
equI pped el1!).necIIt>\j wOlkshop lor I~pn&#34;
2 Propeller sh<lll ~ rClllov<l) nnd relitling
Chock hOlh IIonl wheels Ihen )<lck up Ihc IC<1l 01 the citr .111(1
F
ig. 7. 1 Two-piece propeller shaft showing tubular section (Sec 1)
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Cllilpter 7 Propeller shaft 129
suppOrl 011 ... 1" ~ta&#34;ds P'>'>II'''IIo:d Oil Ihe wldr,hudy m<llll d"I1"",1>; 2 M<l,k 1111' pH,p"lIcf ~h;dt a"d ",;11 .,.Ie drove fl"nlles 111 ,,~I;ll&#34;lIl to
each Olhe' Il'holU) 3 UnscIPw Ihe 10lll 1Ia"!I" I,oits willie hol(hn(llhc shall willi <l Im:l,,1 bM insc.wd Ih"'''!lh Illu "nlv,!,,;,,1 IOllll 0' hy apply,,,\) Ih.) h,mdh.;,kc 4 Unsc,,~w llu. <;,;1\1(<) 1",;1111\(1 rnOlllHUlO bolls (pi1olO). h"l notl' Ill(! locauon (,1 .lIly ~llIms (,Ih:d 1'"lwC(:11 the he,lll!lO hl;H&#34;~ &#34;l ;lIul un(h:rhody flu. ~hll&#34;s III11st he Icf'lh'd III Ihell OllOll1al ID':"!!"",; 10 Jl\ilint"lI! \1", ,:o",:1:1 shall ;,h(plll1&#39;~1\1 5 Place;1 0:0111;11111" h(!lI !lalli tl&#34;~ ,,~&#39;&#34; 01 the !I" ,,,hox 100:.11 •. 10 "llY 0.1 whiCh 11l;IY I,·.I~ .IS Ih e prop"lie, Sh,lf1 IS r+mloVflfl 6 Push 110,-... h •• 11 IUlw.lld :,I'!lhlty In ~(&#39;I&#39;;)I&#34;llJ lI,e IWO 1I."HI"h .11 Ih" re;)r. Ihell 1,,,,1,"" Ih" "'HI ollh" hh.oIl .md pull ,I ,,·.uwo,ds 10 d"""!I'''1'' il lro'" 11,,, \1,·.HIII'x n,.II",h,,11 hl)I&#34;H:~ II,I'()"'I 7 Ref'II",\! Ih" 1'101',,111:, ,.h.0I1 's ;, ",v",s.,1 o f Ih" ;,I,IlV" I'"" ,,'hH" Ensu,e ,h,'1 Ih" ,,,,,In'!1 "'.IIks hO:,:I1<:1l1'd on Ihe 1""1',·11,,, ~h,oll ,,,,, I ,,,.11 ~xlc 11;,,,!i"" 10"" "I', ,,,,<1 Ih,'1 ;"'Y &#34;I&#34;Ill~ .01 Ill<: '.""III! I .... "H'!I .11" ,ehlll,d I" ,'"'.''''' II;" "(1" .. <:1 p'",<I""""!! III Ih,~ ,,,,,.I,,' 1"·, .. ,,,'1 , .. ," cO"SI,nll 1,'.·1", oty 1011'1. [""I hI th" """1,,, I .... 'II"!I holls ['"!!''' I'!II<I Ih"11 '"hlt:1I Ih,' "'.0, lI,u'!I" 1,,,It~ III tI .. , '1"·",1,,,01 1""11'" WlIh Ih" It'.o, .'AI" 1l\)'''H 1".,.ly 1'"1111,,, I,,,,,, ,.h,.h .,,,01 ","11,,: 1"',"""1 [",w.l,,1 ""I,llh" c0l1sl",,1 v"I"<.1ly 1')1111 ,~ 1,,11 10 h".11 "!I.,u'sl Ih" """ 01 Ih" """1,,,
1<ll1!J W,th II", [","1 ~h.d\ 1,,:1<1 "' IIII~ POs'I '('" (I<lh",,, II", ""IIIII!
"",H111!1 1",(1', 10 th .. ~1&#34;&#39;&#39;&#39;&#39;&#39;&#39;&#39;:l1 IIl'q,,",. &#39;&#39;&#39;&#39;&#39;~&#39;&#34;0 ~11&#39;&#34; th,,1 Iii" h"''''''!1 hous'''\1 ""I \10 10 II", ~h;oll .",01 Ih" Iw.""'!1 ~l1ppoi! ,,,1,1,,,, ,~ ",,(
=----­~~.--,--.-,-
)
>
2,6 W 'lhdr<lW"'\i the l"Opl.dlc, ~hah hom tile !)eD,llox m"mshJlI splincs
(ioslorlcd F'I1i1l1y ch(:ck illld ,I IH&#39;C&#34;~&#34;y lOp up Illfl !I&#34;&#34;,lIo~ od levfll
3 Ccntre h C <lrin9 -rC llcwill
1 Removc III" pr()IlI:lle, ~h<lll .oS de,,"I,,·oI 111 $<:(;1I0n 2 2 M<I,k Ihe COliS""'! veluc,ly loml IlOU""'O.o"d III" II. "'!)!) Oil Ihc trO,lt
sh<llt in ,P.iill 'OIl 10 (,,,cll 0111,,, Abo &#34;,~,k Iho: frOIl! ~h,,11 "' ,el"ill,1I 10
Ihc Ii<lll!lc 3 Unsc,cw (h,) C&#39;&#34;1~1.111! ",·h"·,I. 1,",,1 11<1I&#39;~&#39;I1!1 I ",lh ;0,111 ~&#34;I&#39;~&#39;&#39;&#39;I&#39;&#39; IllI! tr()nt illI<i 'e." ~I,,,lls (pholo) 1 Unscrew Illn C"III,P' 101111. "" "01,'" til" w,,,.I1,,, , awl w,lhd,;,w Ih" II<lnge 1'011' (h" ~phll&#34;,s nil Ih,~ [")111 ~h.ill 5 RCIllOv" 110" rf'I'I" .. ,lud':I, lollowo:rll,v 1110: 0:,,,11,,, 1&#34;&#39;;H11l~lllOlI~IfIO wllh il s '(11111':1 II,~&#34;I,I\O< No(" (iI.,( II", &#34;&#34;&#39;&#39;&#39;~~ orl tit" 1&#34;&#39;(J~&#34;&#34;ll;rc&#34;s III" fronl of IIII! ~h&#34;fl () US'Il!j ,IIwII I"!I!I",I pulh, ', '" ~&#39;&#39;&#39;I.,bl&#34; I"v",", . W&#39;lhd&#34;,,~ II,,: I!I&#39;.II&#34;&#39;~I folluwfld lIy II", 1111"" dlJ~1 "x, h"I",
., P"se npo:n II", ""'I.d I.,I,~ a"d ",,,,ov,, II,, : ,ul,I,," ,,,~,,I.&#39;I&#39;&#34; I""" til"
1,0US&#34;\~1 8 elc,," Ih" r.&#34;&#34;&#39;P()&#34;&#34;&#34;(~ II",,, 1'1 II", Il"W ,ul,\\,' , 11,,,,,1,11,11 II) II,.,
hOIlSIfl\) so 11r.11 III" Ij(,~s,~ LlPI&#39;,,&#34;&#34;I)~1 B""d th" "",1., 1 1.1i1" down I" 5,!CWe tho IIlSul,H<H 9 Re[n the ,,111':1 d&#34;~1 ,~xo:l()(k&#39;
3.3 The conSlanl veloc'l y loint houslllg boilS
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130 Chapte r 7 Pro pelle r sh aft
14
. 12 ~
"> ., I>
" 10 11
9 a
·6)6f
. -r 3
~I&#34;&#34;)~ 2
Fig. 7 .2 CCllIre bearing and CV joint cOIll I)onenls (Sec 3)
1 FIO,,/ sll,1// 2 Inncr (/(IS/ cJ(cfudm 3 Cemrc bC.1riny 11 Rubber in$u/.l/(J'
5 1f00wl/f/ 6 Du/!)( rlusl cXl;/mh'I 7 AIlYflml'lJ/ shim 8 flull
FiU · 7.3 T ho recess (;ufo\l\lcd) in the <:orllre bearing housing m ust la ce forw(.rd (Soc J)
10 To lI~fll the bearing. first f,lI the 51)<lCO between the bC<I,iny and dust e~clu(tcrs with 11 general purpose urease . Selec t 11 piece of piping or tubing that is just 11 hnclion smaller in (h;lInctcr than the bCilring. place the sphncd p,HI of the shill I upright in a vice, position the bCiI.ing 011 Ihe shaf t and, using a soft hilrlHn cr o n the end of the piece of lubing. drivc\ho bearing firmly and squarely OntO the shalt . 11 Slido lhc con Ire bearing housing and fubber insulalof Ollef the bearing. milking sure lhallhe prelliously nOled recess faces lhe IrOnl 01 lhe shalt. Relil lhe Outef dUSl cxcludCl . 12 loca1O the l1anyc on the splmes of lho frOIll shal l. making SUfe th,l1 tho PfOlliously made marks are aligned . Rel it the cenue bolt and
washOf and tig h10n the boll. 13 Assemble thc two shahs togothCl with lho previously made marks
alrgned. Ihen refit and tighten the constanillclocity joint housing bolts. 14 Refit the propeUef shalt With ,efefcnce to Section 2.
4 U nillorsal joints in sp ectio n
) Weaf in the
needle rollef heafings is Ch,Uoclefi sed by vibfalion in the tfan srnission. 'clonks' on takrng up the drille. and in e~treme cases 01 tack 0 1 lubficat ion. mOlalhc squoaking. and ultimately grating and
shrie king sounds as the bOilflngs breiJk up.
9 Fl.",!!.: /0 C('/IIf<.' 1",11 /1 Cllcllf'S 12 CV /01111 ilssl:mbly
13 Sprillg c.lf' 14 Boll
Fig. 7.4 Using.~ plillor 10 withdraw the centre bClI ring (Sec 3)
Fig. 7.5 Bendi" g the metal tabs to secure the insulator (Sec 3)
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Chapter 8 Rear axle
Contents
Axle rear cover .. lemoval and .etliling Axlosha!! bearing -renewal Adcshah -removal and refltllng . Fnul1 diilgllosis -re3. ,1xle Gcncr<ll description. Limited-slip difterenlial -generill
Speci fic", iOl1s
Gel \cra' Axle dcsI\)n<lIoOIl _ Type
Hallo . uhllei'ml C"llilClly •• I>IIC;1I11 type. O ,lIcnmll.1I sIde 90;u ('"dllo;u 1'''''011 turning torque (~ell&#34;llJ) Crown wheel and pill 1011 backlilsh
Torqu e w re nch settings Bc,uinu (31) \0 axle Cilsing Cover \0 axle caSing CrOWllwheel Axlcshalt bearmg retainer /backplate . Drove pinion nut ....... ....... .. Rear 51),ing U·boh Stabilise. bar clamp boll _. Propeller shnfl 10 lear <Jxlo drive flange
General descrilHion
6 !i ,
11 1 10
The rear axle IS of the hypol(f seml·floallnO tYI)oO and is located hy semi·elliptic ro~d springs, In conjunction with a smhlliser har. The dilJerel11inl is intogral Wllh the axle hOUSing and Ihe rear axlo
InuSt he removed to carry out ilny rePil" S to the dll1erellt,,,, wh,ch milY hecorne necessary . J The drive pinion runs in two lapered roller UeiltlllgS, which are "reloaded by a spacer . Early a.l"s have a ',xed lengltl Slh'lcer and I<lter ones a collal>sible spacer (F'{ls 8.1 and 8 2). Both IYlleS of SI>aCer are InlOrchangeable. but c<lre mUSI be taken to ensure th<ll the appropriate
nle lhO<J of delerm ining drove p'nion bcarrng preload is used
The COrfeCI deplh of me~h 0 1 the p,nion in the crownwheel is
PUlIon 0.1 so,, , renew"l . fie;]! .1x10 ove.h;wl Ilear axle ,emOYil. and refIlling f1ollll!w 1ll00intCIHlIlCC • Wheel siud renewal,"
() (Sahshury)
7 8 3 2 ,
Ilypo,d. sem,·flo,lIU1!), onteorill dolle/ent",', limited-slip dollelenl,')1 on 28 Speciill 300.1
I I loire (1.0 l)il11) SAE 90 015 mill (0006 'n) 2510 2 7 N,,, (I 8 to 2.0 IIlI tt) 010 to 020 ,nm (0004 to 0008 in)
Nm 60 10 68 35 to 45 801087 27 10 31 100tol20 25 to 36 401050 60 to 65
Ibl It 44 to 50
26 1033 501064 20 to 23 74 to 89 18 to 27 301037 44 10 48
obwined by Ihe use of selected shims inserted belween Ihe pin ion and rear t<lpered loller bearing. The crownwheel is boiled 10 Ihe dilferen lial c ase, w hich is mounled on IWO lapered rolle r bearings . These bearings ilre preloaded by selec tive· fil shims, positioned on eilher side 01 the dlfferenti<ll housing The d'fferential <l55embly is 01 Ille two pinion Iype, 28 Special models ;lre filled with IIlimiled'slip d<llerential. Th e adesh<lfls are splmed co ehe dlHeren eial side gears <lnd supponed at ehe oule. ends by b<lll· bea.ings . 011 seals <lre filled .11 each
end 0 1 Ihe axle housing . Ove.hauling ehe lear axle requires a variely of spedallools and it is no! recommended Ihal any allernpl should be made tfJ do Ihis unless these lools ~re <II hand,
d
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1 Chapter 8 Rear axle 133
Fig. 8 .1 CrOSS-Sl!ction o f cnrlv rCilr ;1xlo (Sec 1)
A Fixed /ellglh SIJ.1C(!f B Pinion slum
2 Routino mnintcnoncc
C Dd1clCII1.11 S/II"'$
At lhe uHerv"ls specIfIed 111 the HOlltmc M.111l1cn;mc c SCCllon III the 110111 0 1 the mnnu;1I c""y oul the following p,uccdw(!.
Check fcar axle oil level 1 Jilek lIlllhc IvaI of the Cil! ;uHf suPPOtl on axle ~I&#34;nds T o C!lSI'''') li1,'l Ihe Cilr is lellel ;,150 I<lo k III) Ih e IrOnl of th e cm Allefll;. \,vcly . OSI110n Ihe en, ovcr ;m IIlSIJO:ction ,)11 or all .;)mps J. Usmg;J 51111<11110 sqll1lrO key, llrlSe.cw the hiler plu\) I.om Ihe 't·h;md Side 01 tho d'lfcruntinl housmu. USIng a 'mger Or., )llceO 01 bent mowl .otl. check Ihat the OlliS level WIth the b0110111 01 tho f ,lIe . 1)lug hole O f il n>i!xnmun ul 100 mill (0 39 Ill) belo w the holo 4 II necessmy top Ull wllh I he euoree! \)I;lde 01 011 ;IS !Jlvcn '" 'Rceommcmlt'd !"brle,',,'s ImrllhUfls' 00 no! ovcllill thc .em ,nle. o th e.wise thc 011 will ove.he;ll ;111(1 he IO~1 Ihl oUll h Ih e b.e;Ith e. vent 5 Rcht ilnd tiuhten thu hUu. plu\1 Ihen lowe. Ihe eM 1 0 the lJ'ound
3 R e<lr <1)(10 - relllov,,1 ,\Il d refilting
Jack up the le,lI olth e cm ;Jnd sUPPOl1 wllh axl a stan ds 0' hl oc ks
posi tioned lIancnlh the sid(Hllemhe.s . Cho ck thc tronl wheels and rcmove the .ear wheelS . 2 Mark thc p.ol>elle. sh;J1! ilnd .eil' <ule drivc ft3!111cs in .elallon .0 ench olhcr. 3 Unscrew the Iou. fI,lIlge boilS while holding the sh M , wilh a mewl
ha. insc<led through the universal 10Ini. o r by applylllg lhe hJ'ldhrake lower the 'eM 01 th e p.opelle. shafl.
4 D is connect the h,mdlllilkc ti.lIle and. whe.e .1pphC;Jblc. tha
t'ansverse ,od from the .ea. (Ide wl,h refalCnce 10 Chal >!el 9
5 CI<lmp Iha fle~lble hr<lke hosa t o the re<lr a~lc then unsc.ew 'he nuts and disconnec t II /.om the IIgid tJ'ilke pipe all(i ;J~le hrnckel. It a ho se clamp is not av allahle. lig hlen a piece of polythene sheel lIenealh the laSle r cyl inde f till> 10 reduce any fl u id loss and also plug the disco nnecte d hose 6 Jack up the ,ca. ilxle a few Inc heS Ihen unsc.ew and rem ove the sh oc k ab so,be, lowe. moun.,n g lIo115. Prise Ihe shock abso,lIers horn lhe b.ack (lIS on Ih e rca. aKle.
COUAPS'8ll -----i--i!~e&#34;&#39;.!i SPACH'
,
Fig. 6 .2 Cross·sc ction of I"ter rear Ilxle (See 1)
Fig. 6.3 Removing the rear ax le fillo r 1)lug (Sec 2)
Fig. 8.4 Flexible brake hose connection to the .ear axle­arrowed (Sec 3 )
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1
134 Chapte r 8 Rea r axl e
FiO. 8.5 Discorlllccti!l9 the rcar sI"biliser Iwr (Sec 3)
7 U~&#34;&#39;!I u"ps (FlU 8 5) I)UU rile s1.1h,l,s(lI b.ll 10 lilt:! lCol. while unstocwIIlIJ the mOlllllnlU I)oIIS from the Ie;)' ;l~II!. flcl110vc the C!JIllI'S 8 W,lh the rC:II Ildc sUlt,lbly SUIlI>o.ICd. lIIlSCICW rhe nulS hom the hallom 01 the U-bolts i1rld reOlOlle rhe lowel S I)llrlU p l;lrcs .. ",t! 1115 .. 1<11015. 9 Wllh rhe help of an asslSlilnt. hft the rem a~lc over the &#34;~<lr ~p&#39;!I1\1s iUld withdraw i t from undcr the CilL 10 To refit the ICtllr axle, lirst cher.k Ihal the upper insul<l ,ors ;lnd 1",lCkclS a.e correctly located on the springs. 11 Wllh rhe help of an assistant hft the rear ;'!Kli! into 1)05'1'011 on the W:1r 5Il flrl!JS. 17. COIIIWC l rhe IUOI)clle. shall 10 Ihe dflllc flanUc with rile IlfClllous ly 111;1,1 " "'o1rks :11111110<1. ,1nd loosely fll the four bOl ts. tOljclhe. W Ith new hl':kw;,s he.s
13 I O.:.lt!"! the ul~&#34;&#39;&#39;&#39;&#39;o.s 1m!! lowe. SP""1J pl~ws all the sp rin!jS thclI "1 Ihn 1)·llo\1s. W!IClhc. wilh Il/!W sld/.locklll\) lIutS T'!Jhlf:l1 thc IHII S l"o!Jlnsslvuly 10 Ihe spo{;lf ,/!(IIOIQUC. III 1')<;,lIe Ihc CI;1I1IP~ 011 liIe Slilhd,scr bilr "'0\I1111\1 tubhers tlrCII pull 1 hili IlltO poslllon WIllI thl) grips <l1l(1 fIt the mountlllll bolts. TIUhtell .Il hl>l1~ 10 the S IICclllI .. '(l toIlIUI) . • ,. j<lck up the reM a~l{l ,1S neceSSilry and push the shock <lhso<be .s
, Ihe" I/.ac ket s. In se'l Ihe nloum"lU bolts and tlghlel1 the nUI S. H i Ilelll Ihe lIexll/le b.,lko hose and lIuhten the nuts. 17 Rel1lovc the hoso cl,lrn p or polythene sh eet then blcL,{/ Ihe hr<lke s n~ d(!sCllhed ill Ch<lpWr 9
t 8 nelll t he h<llldhr<lke c,1blc and. where <lpphcllhle. the tr~&#34;sverse lad II) thfl ICi"lI n K le WIth referen ce to Chapter 9 . 19 T,ohtell Ihe dllve ""nne·to·propeller shall holls to lhe speCIfI ed to.que. 20 R el'l the .ear wheels "nd lowe. the car to the ground. 21 Check Ihe .en. aKle 0,1 level <lnt! top up II 'Hlcessi"lIy .
1 AxleshMt -removal ilnd refilting
Chock Ihe front wheels then jack up the re,lr of the c~r ilnd support with onle stilnds. Remove the .ear wheel 2 Ilelea se the hilndb.nke and .emove Ihe brake drum.
3 USIng a socket through the special holes in the drive lI.::tnge. unsc'ew the bollS secu.ing the b.::tckp late and bearing ,el.::tinor to tho a~le cilSln g (pholo). 11 Withdraw tho a~leshnft. together with the bearing. " it is tight due 10 tho oulor Ir<lc k seizing in the casing tcmporarily refil Iho wheel .::tnll Iwll on the wheel. If Ihis is unsuccessfu l. use n slide hammer allached
1 0 the dtive lIange. or ,1Iternil1ively sc rew two long baits th.ough Ihe jng al diametlicaUy opposite pOInts (FIg. 8 .7) and lighten them I,·...r<jressiv ely un!11 the be.::tring is freo . 5 To .e"l the a~leshafl. IU$I w ipe clean Ihe bcallng .(!(:ess in the casing and al>ply a liule Illhium based glease both 1 0 the casing and bear ing outer !rack . F
ig. 8
.6 RelHoving t h o Mdeshalt .e l'l ining hoits (Soc 4)
If
I
/1
II
I
\,
Fig 8 .7 U sing long bolls to ""ithdra"" tho a~leshaft (Sec 4)
cd
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