FORD CAPRI 1974 Workshop Manual

130 Chapte r 7 Pro pelle r sh aft
14
. 12 ~
"> ., I>
" 10 11
9 a
·6)6f
. -r 3
~I"")~ 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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)
Chapter 8 Rear axle 135
Fig 8 .8 Drilling the beMing rf!t<lining rino prior to splitl;l\g with ,1 eol ( 1 chisel (Sec 5)
6 ju sen the ilxlesh.1h "nd CIl!jol\JC the spl"u,d end of Ilu) ~h;,ft Wit I! the ulHcrcnliJI side gC;II, TilP tile shnft wllh <l mall,,( lIIl(,lltl(lI)C<lrill\j is
fully entered III the c .. sing. 7 Align the backplilW ,md be,1"'}!) rC1<lUHH holes with the C.1Sll1g holes. insert the bolts ilnd li\Jhwll them evenly 10 the spccllicd torque. S Relit the b'<Jke drum t1nd fCil' wheel <lnd lower the CM to the
ground. 9 Check the 'Cilt axle 0,1 level and lOp up II necess ary,
5 AxlcshiJft homing -renewal
Noto: A SfJL'CI.1f 1001 IS "Hlliller! /0 n&#39;III<!V~&#39; lilt' 1>1:''''''[1 (,0111 lilt' axles/mIl (s,:c Fly 89) 1 Remove the ;,xlushalt as ,h:sG"hcd 1(' St;CIl0n 1 2 Usin\J all 8 mill (0.31 In) dldl, 1Il;,kc a hole III the he,Hlnt! ,etauun\1 119 . t<lkllllJ CillO not to p,,"eto;Ito Into tlH~ .1xlesh"l!. 3 SupPOI1 the 1m\) 0" il v,ce thell spl>t 11 ;1{;II)SS tho hole with a sholp pllJ (;h,sel. RUlllove tlH~ ""9 hom the shafl ·1 PIC'SS th e l>earinIJ oH the shall lJSIIl\) " sUlt&#34;hl,~ jllJllcr or press. The specil1l Ford tool is shown '" FlU 89. 5 Remove lhe I>e,'''''o ,eiJll1e,
G Cleiln the l1xlcshnf1. be,non\) ,,,t;WlC' ,Hld "xle C.,1511l\) 7 Locl1le the loe1ll1ll9 HIWlIlel 011 the l1xleshl1lt. followed uy tho new uoa,ing wIth the 001 sel1l [l1CIll\) l1WilY ['om the l1~leshaft Hallge. 8 Slide on the new hea'lIl\) rcta"lIn\) '1119 and pr ess J fully 11\l111l1st tile hearing inner IWck. uSIng a slJItJIJle puller or J ICWlth oftuue. 9 Re fIt Ihe l1xleshalt wllh refe'ence to S ectIon <1
6 Axle reM cover relllov,,1 ilnd refitting
Chock the hont wheels then lilck up the re,l( o f the Cl1r il'l(l SOPPOI1 on axle stands.
2 Cl em1 the reM cover .Jnd surroundIng .Jre" (photo) 3 Remove the hllmlbr"ke relay le ver lind seco nd.Jry cable. or
transverse ,od (as ;;Jpplicilblc) with reletCnce to Ch"pter 9. <1 Place a suitable container helle~th the reM "x Ie to c~tch the oil as the rear cover is removed.
5 Undo and remove t he ten IJOlt s and sprinU washers lhilt securo the reill cover to the llIl,l l drive housillg LIlt aWilY th e re"r cover and its
\Jasko!. ~ Before refitting the ,oar cover Illilke sure thm the mating fJces ilre free of th() old Uaskct or 10nlting compound.
7 FIt a new uasket Jnd then the lea, cover and secure wIth the ten bolts and spring washers. The cover bolts protrude IntO the fillal drive hOUSor1U so it is important that a SUlwble oll·resist.Jr1t scaling
... __ ro*
Fig. 8.9 Usill(J the special Ford tool to removc the axlesllilfl henring (Sec 5)
r;olllpoulid IS SlIll:ilr() d onto lioe Ihro,'ds of each boll bef ore it IS [,twd. 8 TIUhwll tllr: cover secu,,"!.! holls 10 lhe spec,[,ed torque Wfl:IICh
se ttln\)
9 ReCOlillect
Iht! h,lndbr,l~e components with re ference to ChJp ter 9. 10 R efil l ti,e 1e;1I ,ule with the correct 9rJde 01 oil then lower the C,lr to
the UIOUIl(i
G
2 Axle reM cover
7
Pinion oil seal -re"cw,,1
This ope r,ltion may be performed WIth the rear axle in position or on
the benc h
2 Undo ~nd remove the two holts. sprinU Jlld plain washers that secure lhe centre bearing support to the under51(fe of the body (reler to
Chapter 7) 3 With a sc"ber 0' fde. Ill<lrk a 1000e across the propeller shalt alld rear ~xle drive fI~nu()s so thatlhcy Illay be ,cll ed \()gelloer ill thell o&#34;gin~1
positions <1 UndO ~nd remove the four bolts Jnd sprinu washers secu"n9 the propeller shalt and rear a~le dlivOllg flanges and carefully lower the
propeller sha h to ttt() flool I I
J m
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Chapter 8 Rear axle 136 )
5 C~rellJlly cle~n Ihe Ir Oll 1 01 the Im,ll d"ve housinU ~s there will Ilroll<lhly be a considerilble <!IllOUni 01 drll and orl rl Ihe se<ll has heen leilkillg lo r a willie (phO IO). 6 Remove Ihe wheels ,lilt! b.ake drums Ihen U Sing ellhe. <I sp"ng halance and a lenUth of co.d w'illlpcd .ound lho drove pUlion. 01 a
10lque w.ench. check and . ecor d the lurnrng IOrque of the pillion. On eally models lilted wllh ~ tl~ed longlh spacer (see SectIon 1) lI11S procedure is nOt neceSS<lry . HowevC/. unless the ',nill drive hilS beell conlplelely dismanlled prevIously. there is no WJy 01 delerminlng which spacer is !rued. 7 USIng a suilahle long·hilndled tool or large w.ench. g"p Ihe re", ,"xlf) p,nIOn flange and wllh il socket undo and . emove Ihe pillion lIan\Jo ,elainmg sell·lockmg nul. ThIS nUll11uSI be dIscarded ilnd il new Ollr. oblalned .e<ldy for rea ssembl y. 8 PI,lee il conWlIler undcr tho ir ani at tho lon<ll drove hOUSlllg to ciltch ""Y all Ih<ll rn<ly como out. then uSIng a unlvorSal puller and sUlt"llle thrusl p"d putt o ft tho 10 M <lxle pillion lIanUC from the alive pInion 9 USing a screwdrivcr 01 slllJl1 chlsol C<lrel\,lIy renlove the old all sl!,,1 It Will plOb"bly be necess<lry 10 p<llti;;llly destroy rt Note t he COIII~&#39;:1 way round is wrth the hp I;;ICnln ulw<lrds to Belo.o Iruill!1 a ne w so;;ll apply son'e !)re"s o 10 Ihe lillIe. 1.1I:e )I\\ICCII the two h,)S 01 the so,,1 11 AplllY;1 hule IOlnlon\! compo"nd 1 0 Ih,;! outer I,lce 01 tlie 50,,1 • USnlg a tuhuh .. drov o 01 :,ulwhle <I.;;III1<;tr:r. c;ucluliV dnvc the all
.,1 "\10 Ihe l ,n ,11 dllv!! hOllslnu unto! Ihl~h w'lh Ihe cas",o 13 Ilcfo1 Iho 1(';;1' "xlo p""nl1 fI.1IlUc ilnd on,:o "!I'"n hold sqll;,,,:ly wllh til" luol 0' wrench. 1~ SClew on " ncw s&#34;II·I()c~&#34;lll I1l1t IJIlIII Illl: (,ndllo,,1 ,s III~I dlll"n.llcd . II"", l'Uh h,n Iho nUL .1 1,;,,:11011 ill;r I"'h' whll" du":k"'!lII,,, prmO" lumlnu lor<ll'" wllh Ihe SI""'!I IJolrolllCU or 10r'l"0 wH;nd, COlltinuc tluhlen,"u untIl tho to '{ lue Cllu;rrs IIr<lt recnHle<l III l'a"'\I'''llh 6 1)lus <I furthel 02 1 0 04 Nm (015 to 030 Ihl It) to .1110w lo r tho ,l(ldruonallr,ct,on 01 tire new all se,,1. Do nOI trHhten the IIl1t lurtl"". olherwlse. rl a collapsible SllolCOf .s Illled. II Will he over·cornprr:sse<l and the assembl~ Will Ihell h,lVe 10 be drsnwntled to hi ;, new ~p;rcu&#39; Howover. il Ihe minimum speClfred torq uo wrench scWng lor th e pInion nut h"s not been re"ched. the sp"cer I'lle d IS p.olJi"lbly 01 Ihe
fixed ICllnth type "nd I he nul should be tIghtened lurthor WhIle domu Ih,s cheC k Ih"l Ihe pimon lurnrnn lorque doos not mcre;;lse. 15 flelll the h",ke <I"ml mId whee ls I G fl" co.mec i Ihe IlrOIl()lIe' ~h;llt ;rhlinmu thl,! p • ..,vlousty rllade fII;'lks 1)11 Ihe lIan!lf:S. '''III rc!lttlrll holts wuh new Splillg w.1"hels TIUhll!ll tel lire spec"'ed ta.que w.ench ~C1llll0 1 7 fle llt lir e r.:ellile I'c;un'!] ~&#34;I)P(Ht ,.ecllllI'(J l,olt5, ~I&#34;&#34;&#39;!J ;uHI pl.1111 w;r~lrerS ;;Inti t'lllrll'lI. 1 B FIIl.1l1y check IllI! (HI IlIvr:1 "' th" "';11 ,1>1" ,,"d l O p up II 1\&#34;,:eS~lIly
P ReM axle -o verh;;lul
Note: Mosl ymilycs wtlf Ilft'h" 10 If.'IWW Iflt' comfllelC IC,ll ,Jxfc ,15 .1 111111 d II IS WOII! ,.II/IC' I/Ioll! 10 rf,SllliI",fc Ille UII/I 10 lel/t·w '''IV r/;/11I.Jycd 01 WOIII poll Is ro do tlw ,ob correclly Icquires Ifle usc 01 spccial <111(1 cxpellsive loofs willch tin' "'",u/lly of y"WY"'S do 1/01 h,lVl' The P"n1<UY oh,eC I o f Ilrose speCIal lools is 10 e""hle Ille mesh 0 1 Iho crownwhcelto Ihe pIllIon 10 be very accur,1lely SCI "nd thus cnsuro that n o,se is kcpl 1 0 <I mm"num II illly lI,c ,e,lse In nOIse cmmot he 10loJHI\ed (p,ovlded Ih<ll the ,e,l, "de 'S nO t already na,sy due 10 "
, le lccl,v e Pol.l ) then IllS besllo Ilu.ch"se "II e~ch;lnHe bUIlt UJl le;;l. ilxl/! 01" Uoad secon (lh,lnd Uillt 1 Remove the rO;;lr "xle I,orn the ,:,1r (S(.'(;t,on 3) illld tha,oughly cleiln
,' . 2 Remove the a xlesh;;lhs (Sec lIon 4) "nd the;lxle ,e". covel (Secllon 6) . If rleceSS;;Jry remove lire !H" ke !liIckpl;,ws 3 WOlk,n!) inside IIlI! axle casUlU . undo .lnd .emove Ihe four bolts th" t hold Ihe IWO U'Shill>cd dlllerentl,ll be"rmg CilPS III the Cilsing. 4 W,lh a sc.iber. m<llk Ihe .e lilhve paSltlons ollhe Iwo be",,"U caps so Ih;uthey C,lll bo .elllled III therr o"g,nal poSItIons. LIlt away the twO end caps. the'e may ;rl .e"dy ho mallng numbe,s shown In FIg. 8 .1 1 . 5 OIJlaln Iwo,) JlIC'- OS 01 50 mm (2 in) squ",e woo d al le<lst 300 mill (12 in) long and. wrth a sharp knlle. !<Ipor the ends "iang J lenglh 01 150 mm (6 in) 6 Place Ihe tapered ends 01 the ..... ood..,o lr:vc lS rll the two cut'i1ways
i h a dlffl!renliiJl casrny (Illd. uS"'IJ the lea, cove. 1;;Jr.:e o f thl! Irnal drrvo asing as" lu lc ,um. CDielully leve , Ihe (Mle.entlal asS(!mbly I.om the Ilna l d"ve housrng.
15 Froni I'll Im<ll dflvo housing showIIlg pinIon n"nge ilnd nul
7 1I'lls IIfJcess,lIY la ",move th e Iwo (hffelenlral casc l1'-'alll'gs Ihese
",.IY I,,, ",move(1 Ih:xl uSlnU " ulllvers,,1 two·leuged puliCI and sui!<lhle
111111'.1 1,.ld C"rfully uase e;lch bca'"'IJ Irom liS local ron . necovor Ihe ~IIOIII p.IO:k s hom hehmll e"ch be"rrnu nOlmU from whIch SId e Ihey (.,rlOr'! 8 thou!] a sCflhcr. m;;lrk Iho relative positions of Ihe crawnwhee l ilnd ,hU",,"rtl.,llrousinu so that the oownwhcelmay be f,tte d on rts origin al p&#34;~H&#39;OII. unless ,t .s to be lenewed. 9 Undo ,11", r enlo ve the eruht holtS thai secure Ihe crownwheello the ,hl,,,""'11:11 hOllS"'II. U S1nll a solt·faced h"n""cl. I,ll! 0\11 Iho cllJwllwhuci Irom liS locillion on Ih e d,ffe,enl,,,1 housin!) I 0 lJ~III\1 ;r sU I\(Ih l{) (i"unete. parallel pIn pmch. lap 0\11 Ihe pin Ihal Iud , ... Ilu, rI,'lcrelll,;,1 Illnial1 gea. Shilll 10 the dlftmrmll.11 housrnlJ.
NOLI! : 1 hu h"le 11110 willch thc peu Irts IS shghlly "'I>c.ed. lind the I>pl''''.'I'! "",1 may he IrIJhLly peelH)d over ;'Iml should he r.:!e;rned with a ·.u,I.II,I" ,".11111;1". ,tr,ll 11 th'''!1 a ... "It IIlI;t.11 dllfl. "'i> out Ihe drllelenli"l p"uon Ue", slr"h. 1.011 .Iw.ly tlr" d,lh;u!Oltl;r1 pinian ue,us. sido {leMS "lid IhruSI was hers; IA"'!l':,"" 10 ell::ure Ih"t the th,usl washe.s ",e lell wllh Ihe ir relative
liP,"" 12 1&#39;&#34;,1&#34;~&#34;If)f .. ,1 Il1te.s (It Ihe <le<lle'5 usc a 51)OClal 1001 la r hlJldln(lthe pillion ,llIvl: lI;rllue StilIIOllil'Y wlulsl Ihe nul OIl Ihe cenl.e 01 rhe n"nge IS \l1I ... ".;w"d SI nce II IS ve,y \Oght ,I Wlllle(IUOfe sOllie lor ce 10 ullda il. ll,,! .IV\l,.IHe oWlle, w,1I not n O''''iJlIv hilV C the use 01 Ihls ~p(.&#39;C,.111001 so.,,~ .1" "11,,,11;lllve method. clamp the pnllon lIanU e in;r vic e "lid then unoi"lir" "ul Any (1'''''"\le cJused 10 I he edge of Ihe flail!] " hy the vice ~llIluld I,e calelully I lled smOOlh This nut must 1101 he u s1!1I .1\).111' SO II l1"w """ WIll he le' 11JUed durinU ,eilssem!)ly 1 J lJ.."'!I ,1 ullive rs;tl Iwa·lenued pullel "lid suilable th.uS I polll drllw (1)0) jllI"')I) dllve lIiuIue from Ihe en d 01 the pInion shMI 14 11", pmlon shalt m"y now be Icmoved from the I,nill (h ,ve housrng. C,'lI"lully "'SIICCI lire la'ge w per loller beirring behInd Ihe pUlIon gear .111(1 " ,I :.hows s'Ul1s o f weill or 1);lIing an tho roliers Of cilge the lm:ulIl\1 must Il() renewed. 1 5 U~&#34;ll1 " lllllversaltwo·leVged pulle. ""d soitable th.uS I pad. dr~w till! !>,)<III"\) 110m Iho 1)1Il10n shah 1 G Tllu slI1;;1l1e. taper rolle. heolllnu and oil seil l may next be ,emoved IlUm till! 1111011 (IIIVO housing. pillion dlivo flanVe end. 1.0 do Ihis uso a solt l\lr:wl drift wllh a I<lpered end 01 $ui l<lble d'ilmetCI lube <Ind. wo,kl"!) OIlsI(le Ihe housing. lilP Ihe bC,l'"IU circumfe,ence OulwardS so rel e;;lsII' U fllst the 0,1 se al and then Iho OOallnu . 17 AU,,"1 u srn g thO solt metal drrft and wo.kmU ,n Slde Ihe housing. d,,1t olllll1e I>carrn!) CUllS. These mUSI nOl be used wllh new beallngs. 18Th" Ilnal UIIV(! assembly rs now drSl1lilllllod and should ho washed ,,,,,I d,u,d wrth <I cleJn tinl· I,ee rag leildy for inspoctlon Check all be;;l,rrilis lor silIns at WColl or piwrrg "nd II ovidenl a new ~I&#39;I 01 h Catings ~h{)uld he ohlmned 19 Ex;r"",,e the lCelh 01 the crownwheel and prn,on or J/'Ulllg. score marks. ch ll >PinU and uene'ill weal. If a c.ownwheel ami pinIon is .equllt.-d. a mated c.ownwheel and p inion muSI be II1I..,d and undor no
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4 5 6
2 3
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1 3 @~~-@
9 10
Fig . 8.1 0 ElIl>loded view o f the reM C1Kle {Sec 8)
I Axle housing 2 Diffcrcnlilll case (lJper lolle/ belJriJlg 3 DiffcIClltiDl r;ase Sillill 4 Crowflwhccl 5 GoskCI 6 COVCI 1 Drive (Jillion flange
8 Od seal 9 Drive pinion Ii/per follt·, bemiflg 10 Drive 11111;0'1 SIJaCCf _fixcd Icoglll 01 CQfl.1psllJlc II VI.IIIl Vilfve 12 O,ive {limon
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13 PmiOIl yea! 5".111 14 DlflClenliM C(lSf! 15 Sil/C yellr 16 O,flCfCIJ/ii!l pillion 17 Rctllininy filly 18 Axfcsh,1!1
137
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r'9' 8.11 Differential ClOsing and bCiHillU C<lP identificatio n '''nrks (Sec 8)
Fig. 8 .1 3 Removing tholockinu pin IrOtlllh c pinion goar shaft (Sec 8)
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~i9. 8.1 5 Checking tho d iff erential sid e gear ontilioal (Sec 8)
Fig. 8.12 RClll ovin!J the differential assemhlv (Sec 8)
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fig . 8 .1 4 Oiffercntiill cOIllI)oncnlS (Sec 8)
Fig. 8.1 6 Chocking the crownwheel and pinion backlash (Sec 8)
1
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Chapter 8 Rear axle 139
ci,cumS«"Ulces mny only one pmt of the two be renewed. fnspect the dllfe,enti,ll pinions nnd side gems for signs of pitting. score mMks. Chipping nnd general wem. Obtain new gears as necessa,y . Inspect the th,ust washers lor signs of weM or deep sco,ing. Obwin new thrust wnshe,s as necessary. Once the pinion o il senl has been disturbed it must be discMded and a new one obtained. 20 When new pnrts have been obwined ns required. reassembly cnn begin. First lit the thrust washers to the side gems and place them in position in the differential housing. The ground side of the thrust washers IllUSt lace the side gC.Jrs. 21 Place tile thrust wilshers behind the dillelentini pinion genrs i1nd mesh these twO Oems with the Side gears through the tWI) ilpertores in the lilllerentlill housing. Milke sure they ilre diametlicilily opposite 10 each other. RO«l!e the clillerent'i11 pinion gears through 90' so brinUlI1\j them into line with the pinion genr shnlt bore 111 the housinlt 22 Insert the pinion genr shnft with the lock In!) p'n hole III line with the pill hole. 23 Usinu leeler 1),IU!Jcs. measure the en{lll(",t 01 ench s,de Be,,,. II the speclficd h\Jure IS excecrt"d. IU!W tl&#34;u~t washlllS mu"t he olJt,uned
-omnlllie the a~~el)lhly ,lg,llll ,trld ht new thll,st wa:,lu'<IS . Lock the P""O" near shalt U~I&#34;\I the pill whn:h should hc wpped hilly h01)1I, UStrlO n SlIlIah l" d,a",,:ter parallel pill pUIH.:h. Peen ()V,,' thc ()I the p", hole to stop the pill WOlklll!J liS wily out t." The tlowllwhcui m;,y next I,,, Idllted F,,~t heat 11 101 nppro~I&#39; ","lllly 10 nHIHltc~ III 1I0111IIIJ W,lter Wipe the ,,,nl"IIJ l aces 01 the c,ownwhuui ,Ind dllferuntlal houslI'U ;,nd. II OliOlnal p,lItS ,lie l,utnU used. plate the Clownwlll!cl tnto p(l~ltton With the prev,oll~ly m,llie marks nhOllud Relit the elO1ot IHlllS th;11 sucule the ,;r()wllwlwel ,trld tighten Ihese III a I"og'esslve and dla\lunill rlt"nner to the spe.:,fled torquc. 26 PI<lce the Shlill packs b<ltk III thell Oll!)lnal foiled pOSition on the differential housing be<lrlllU IOC<lllon USllllJ .1 p,cce of sUlla!Jle diameter tube ve,y c,1refully ftt tim d ifferential housln!J bearlllgs with the smaller dlnmeter 01 the taper outw,Hds The hearing t,lge must nut in nny wny be dilrllnged. 27 PI,1ce the shims hehllld the hcnd of the pinion geM nn[1. using ,I
suilahle dinmetci tul!c . cmclully lit the larg"r ti!per rollI)' benllll\) onto Ihe pillion shafl. The lar\ler dlilllleter 01 the be,lllllU !\lust be nex110 the pInion head
28 Using soitable diameter tubes. fit the two Wper roller bearing cones into the finnl dlive housing. making sure that they ale litted the correct way round. 29 Slide the shim and spncer onlO the pinion shalt and insert inlo t he final drive housing. 30 Relit the second and smaller diameter wper loller bea,ino onto the end of the pinion shaft lind 101i0w Ihis Wilh a new oil seal. Sefore Ihe senl is nctually fitted. apply some grense to the inner Ince between the two lips of the seal. 31 Apply n little jOinting compoond to the outer Ince of the seD I. 32 Using n tuhulilr dllft 01 suitable dinmeter, carefully drive the oil seal into the fillal (hive housinlJ. Make quite sore thnt it is lilted squarely and flush with the housinU. 33 Refn the drive pinion IInnge nnd hold securely in n bench vice. It II fixed lenIJth spncCl is Itlted. fit ilnd tighten the pinion nut 10 the spec ,lied lorque. If a collapsihle spnce r is f,tte d. follow the prOCedlHe
g iven in Section 7 paragraph 14. setting the pinion turning to'que to hetween 25 nnd 2.7 Nnt (1.810 2 0 Ihf It) which includes 0.2 to 0.<1 Nm (0.15 10 0.30 Ibl It) lor the ndriitional friction of the new oil senl II new hea,inns h~ve heen filted. logether With n li~e(l len(Jth SP,lCer. check thm the tOrlllllg torque is bel ween the limits just stmed. If not. a longer or shorter spilcer must he I,tted until the setting IS correct 34 Fit the healing cones to the cf,fierenllal houslIlg heallll(Js and carefully ease the housing Into posilion in the finill drive housmg 35 Relit the be,IIII'!J CilpS in thell originnl pOSitions. Srnc,ll n httle JOlntmg compound on the threilcfs 01 each cnp secuIII'O bolt nnd fit 11110 position. When ,111 low halts have bcen rein ted tiUhten these up in a (h"IJonal and progresSive milnne, to the speCi fied torque. 36 I I pOSSIble. 1Il00nt n dlnl in(licntor onu(Je so thnt the probe IS resting on one of the teeth of the crownwheel and determine the backlash hetween the clownwheel and pillion. The bileklash may be vMicd by elecreasll'\) the thickness of the shims bellind one beilling nnd incrensing the thickness of shirns behind the othcr. thus moving the crownwheel ;nlO or out ofmcsh as requi,ed. The tOt.llthlckness 01 the shims must not be chnn\)ed. 37 The hesl check the do·it·yourself owner cnn make to aSCerta", the correct meshinu of the crownwheel ilnd pinion is to smear ,I htt le engineer's blue onto the crownwheel and pinion iJnd then lot"te the pinion. The con1<lct lIlil,k should nppenr rl\fht ill the Iluddle oJ th..,
COlleCI 100110 CO"t.1ct
_
t Heavy conWCl 0" huel. at 100lh !,leu Move p'",on lowa,ds crownwhcd u:.!:.crt:1 3nd c,ownwhuel towards p,n,on
.~\;!~&#34; •. ,;.';,;,"",.,=,"--
l ' Fig. 8.17 CrownwheeJ and pinion setting chart (Sec 8)
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