tire type FORD CAPRI 1974 Workshop Manual
Page 137 of 205
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~':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"II·I()c~"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' 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'!] ~"I)P(Ht ,.ecllllI'(J l,olt5, ~I""'!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\",: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"~H'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\(Ih l{) (i"unete. parallel pIn pmch. lap 0\11 Ihe pin Ihal Iud , ... Ilu, rI,'lcrelll,;,1 Illnial1 gea. Shilll 10 the dlftmrmll.11 housrnlJ.
NOLI! : 1 hu h"le 11110 willch thc peu Irts IS shghlly "'I>c.ed. lind the I>pl''''.'I'! "",1 may he IrIJhLly peelH)d over ;'Iml should he r.:!e;rned with a ·.u,I.II,I" ,".11111;1". ,tr,ll 11 th'''!1 a ... "It IIlI;t.11 dllfl. "'i> out Ihe drllelenli"l p"uon Ue", slr"h. 1.011 .Iw.ly tlr" d,lh;u!Oltl;r1 pinian ue,us. sido {leMS "lid IhruSI was hers; IA"'!l':,"" 10 ell::ure Ih"t the th,usl washe.s ",e lell wllh Ihe ir relative
liP,"" 12 1'",1"~"If)f .. ,1 Il1te.s (It Ihe <le<lle'5 usc a 51)OClal 1001 la r hlJldln(lthe pillion ,llIvl: lI;rllue StilIIOllil'Y wlulsl Ihe nul OIl Ihe cenl.e 01 rhe n"nge IS \l1I ... ".;w"d SI nce II IS ve,y \Oght ,I Wlllle(IUOfe sOllie lor ce 10 ullda il. ll,,! .IV\l,.IHe oWlle, w,1I not n O''''iJlIv hilV C the use 01 Ihls ~p(.'C,.111001 so.,,~ .1" "11,,,11;lllve method. clamp the pnllon lIanU e in;r vic e "lid then unoi"lir" "ul Any (1'''''"\le cJused 10 I he edge of Ihe flail!] " hy the vice ~llIluld I,e calelully I lled smOOlh This nut must 1101 he u s1!1I .1\).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~"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'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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Page 179 of 205
17 8 Chapter 11 B odywork and fitting
If the owner is renewing ~ complete component himself. he will be left with the problem of IlIldmg a sUI1<Jble p;linl for finishing which is compJliblc with the type of pl,lSt;C used. Alone lIme the use of il uniVCfsat pil int was not possIbl e QWII10 [0 the complex '<loge of plastics encountered in body componelll applicillions. Standa,d paints. generally spc1Jking. will 1101 hond 10 pl<Js!ic Of rubber satis factorily. However. IllS now possible to Obtain a plastic body parts finishing kit whIch consists 01 a prc ·primer treatment. il prime, ilnd coloured top COD!. Full II1S1rUC1,ons alc nO"ll"liy supplied with a kit. but bnsicaliy the method of use is to f"st apply the pre -primer 10 the component concerned [lnd nllow It to dry 10' up 10 30 minules. Then Ihe prime, is ~pplred ~Ild left 10 dry for all'.Hrl iH1 hal" uelo,e finnlly npplying Ihe special colowed top coal The result rs a co"eclly coloured campanellI whera the paUlI wrll fle x wrth the plaslic a. r ubUer. a property Ih';l standard parnl docs not normally possess .
6
Major u o d y damage - repair
Where serious danHlge has or.cur",d or la,ue aW<lS rllJed reneW;ll due 10 neglect. rl means cerlirrnly th.n r.o'''plC:tely new ~cr.trons or parlels wrll need welding Ul <lnti th,S rs hest tdt 10 profcs~ronals. 11 the d<llll<lge is due 10 imp<lCI rl wdl ,llso he necesS<l'y !O conlplctely ched the <llignmenl of the hodyshell ~Ifl,ct"re Due 10 the prrnciple of ~nlslruclion Ihe st.englh <lnr! ~h.;p(! of Ihe whole can fJC "ifeclCd by dnma(le 10 01 p<lrl In such rnstance~ Ih" s".vrc(!s of <l Ford o1W"H with speci<llrst check'n(J JilJS ilre essc:nllal If a Ir;u11O rS Ic:fl mrSirlr!lned it 'so li.st 01 illi. d,lnUerolis as tlw velur.le Will nOI h.lrnlln l>roperly and. secondly. nneven slresses w,1I be Impos".r nil tli,! S1o:"rmu. (!n\l'n(~ nnrt
Ir<lrlsmission. Cillrsing nbuon",,1 W"i" or r.ompl"l" l;rrl"", lyre w,~ar mily illso he excessive.
7 Door r<lttles -trllcing and reClificatior
The most common C<llrSe of door rallle~ rs ir nHs'rhuned. loose or worn striker pl:ue. Other c(luses Ill<ly be
(,1)
Loose door or window winde, ",,,,dft,!; (Ii) Loose 0' lIIiS.lliUned d(Jo, lock c(lillj/olJC!lJl~ (c) Loose or worn relllOle con/iol ""."/."";",i$III
2 It IS quite possrule 10' r,rllies 10 he the ",suit of" [O,,,lrrllirl,Orl 01 111<.1 atrove laullS. so a c;,r(:/ul <.1xanrrrr;riron should he rn",h, 10 ilCIl'UllU1e III<, exact CillrSf:! 3 If <l 's Imrnd Ilec",;~.rry to ,rdl',:;t lit(' sl"\..'" pl"I" (phOIO). t:1osr: til" door 10 the llr~t 01 Ill<: Iwo locking P()~lt'ons. Vrsu;rlly check the <l;laliVe ntlrlude of the strrker Olrts,de ed\Je to Ih,) lod suppo,t pl"le edUe. The
cd\Jes A and B (FIIJ . 11 1) should I", p,Hirl l,,) ,md "an he d1ecked by slrrnm\J a torch tlrrou\jh Ihe dOllr \Jap lrom "iJovo 'Irld Irelow the strrker • Cheek the <l1110Unl I,y wh'cll the door Slarrds p'oud 01 the adlaCerll ,,~nel. AdJustlhe strrke' pl;rte as IWCE;s~,lry to olJt<lrll a d"l1en~rOr1 01 6 0 111m (024 rn) .
..
)
7 .3 Door striker plate
f ,i
j
I
j
I
\:
it
1
(.'----+"<, --'-1 ------<0
00>-----1\.. -~--.
F i!J.1l.1 A lignin!J the s triker 10 lock support plnte (Sec 7)
Edyes A and lJ shoold be 1'.1(.lllel
A
'0- - -- . ,
,'---I.::i.I I ,
--/
F ig 11.2 Lock claw·to·striker cleiHance (Sec 7)
A -70,11111 (028111)
5 Wrlh t he lock in the open positron. check the lock cl<Jw strrke< cleoll""ca (drmensron A in Frg 11.2). This should ha 7 0 mm (0 28 in) and can Ire checked uy plilCIt1(1 <l sm<J1I hall of pinstrcrne. or simllJr
milterral on Ihe siroker POSI ,lnd cheding Its hergllt n!tar gently closll1g the doo •. The striker plale call be reposnroned verlrC<llly to Obtilrll thiS
d lmensron. bw t~ke Colle 10 not to dislurb any prevrous milral se1\lI1gs 01 Ihe pl,lte.
8 Bumper s -removal nnd refitlin g
FrOIll bumpN 1 D,sconnect the u<.rttery earth lend. Also where necessary dis connect the IIldrC<Jtor wrrrng. 2 Remove the r<Jdrator grdle (Section 9).
3 Renlove the fOI" bumper rewining screws (pholo) nnd hit away the bumper. On Imer models drser1!lage the bumper corner sectiOns f,om the body side clips as the I)umper IS wnhdrJwn. <1 Refrl1ing r$ the reverse 01 the removal p.ocedure. but do nOI fully truhlCn Ihe uolts unlrl tire bumper is correclly aliUned .
Rear bUll/pel 5 Open the lJ.tgate. Ihen rernOve the mal ilnd the sub·floor. G Remove the Jack ilnd washer water reservOIr (where applrcable) . 7 Remove the two nuts. Sp",l(J wilsher and 11m wilshers. <Jt each end and lilt away the bumper (photo).
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