Professional Documents
Culture Documents
PART 4-2
REARAXLES 4-11
Two t)'pes of axles are covered in gral with the axle housing. The re- ential carrier is bolted to the axle
this group. The integral carrier type movable carrier type axle is used in housing and can be removed from
axle is used only in Mustang and Mustang and Falcon 8-cylinder mod- th,e housing for service. A limited-
Falcon 6-cylinder models. In this type els, and all Comet and Fairlane slip differential is available as op-
axle, the differential carrier is inte- models. In this type axle, the differ- tional equipment in either type axle.
D DIAGNOSIS AN D TESTING
ognized since it produces a cycling
DIAGNOSIS GUIDE noise is in no way a sign of trouble
Certain rear axle and drive line in the axle. pitch and will be very pronounced in
trouble symptoms are also common . ~ere noise is present in an ob- the ~peed range at which it occurs,
to the engine,transmission,tires, and ]ectIonableform, loud and/or at all usually under drive, float, cruise or
other parts of the car. For this rea- speeds,the first efforts should be coast conditions. Gear noise tends to
son, be sure that the cause of the made to isolate the noise. Rear axle peak in a narrow speed range or
trouble is in the rear axle before ad- noiseis quite often confusedwith oth- ranges, while bearing noise will tend
justing,repairing,or replacingany of er. n.oisess';1chas. tire noise~tra.ns- to remain constant in pitch.
the axle parts. mISSIonnoIse, dnveshaft vIbration
Bearing Noise
and universaljoint noise.Isolation of
REAR AXLE NOISE DIAGNOSIS the noise in anyone unit requires Defective bearings will produce a
Noise characteristics in a rear skill and experience.An attempt to whine that is constant in pitch and
axle are more difficult to diagnose eliminate a slight noise may baffle varies with vehicle speed. This fact
and repair than mechanicalfailures. eventhe bestdiagnosticexperts.Axle will help distinguish between bearing
Slight axle noiseheard only at a cer- noisesfall into two basic categories: and/ or gear noise.
tain speedor under remoteconditions gear noise and/or bearing noise. 1. Pinion bearing noise can be
must be considered normal. Axle identified as a constant grinding
noise tendsto peak or be more pro- Gear Noise noise. Pinion bearings are rotating at
nounced at varying speedsand the Abnormal gear noise can be rec- a higher speed than differential side
4-2 GROUP 4 - REARAXLE
bearings or axle shaft bearings. The checked for proper operation with- shaft. Be sure that the transmission
noise is most noticeable at a slight out removing the carrier from the is in neutral gear, one rear wheel is
pull between 18 to 25 miles per hour. axle housing. on the floor, and the other rear
2. Wheel bearing noise may be Jack up one rear wheel and re- wheel is raised off the floor. The
confused with rear axle noise. To move the wheel cover. On a car with torque required to continuously ro-
differentiate between wheel bearings a removable carrier type axle, install tate the shaft should be a specified
and rear axle, drive the car on a tool T59L-4204-A on the axle shaft in Part 4-3. The initial breakaway
smooth road at medium low speed. flange studs as shown in Fig. 1. On torque may be higher than the con-
With traffic permitting, turn the car a car with an integral carrier type tinuous turning torque, but this is
sharply right and left. If noise is axle, use tool T65K-4204-A. normal. The axle shaft should turn
caused by wheel bearings, the noise Using a torque wrench of at least with even pressure throughout the
will increase on the defective bear- 200 ft-ibs capacity, rotate the axle check without slipping or binding.
ing because of side loading.
3. Side bearings will produce a
constant grinding noise of a slower
nature than pinion bearing, (side
bearing noise cannot be determined
by the wheel bearing test), but will
be in the same frequency as axle
shaft bearings.
Also, certain trouble symptoms are
common to both the conventional
and locking differential axles, while
still other symptoms are found only
in the locking differential.
To determine whether the car is
equipped with a conventional or a
locking differential, check the car
warranty plate and the axle ratio tag.
Refer to CAR IDENTIFICATION
at the front of this manual.
LIMITED-SLIP DIFFERENTIAL
The limited-slip differential can be FIG. 1-Checking Limited-Slip Differential
Since gears are in mesh, some rear Noise caused by a worn or dam-
axle noise is normal. However, exces- aged wheel bearing is often loudest
sive noise often indicates the begin- when the car is coasting at low
ning of other troubles in the axle. speeds,and it usually stops when the
A road test can help determine brakes are gently applied. To find the
whether the noise is being caused by noisy bearing, jack up each wheel and
trouble in the rear axle or in other check each bearing for roughness
parts of the car. Before road-testing while the wheel is rotating, provided
the car, make sure that the tire pres- that the car is equipped with a con-
sures and the rear axle lubricant ventional differential.
level are normal. Then drive the car If all possible external sources of
far enough to warm the axle lubri- noise have been checked and elimi-
cant to its normal operating tem- nated, and the noise still exists, road-
EXCESSIVE REAR AXLE perature. test the rear axle under all four driv-
NOIS£ (ALL REAR AXLES) With the car stopped and the trans- ing conditions-drive, cruise, float,
mission in neutral, run the engine at and coast. Any noise produced by the
various speeds.If the noise still exists sidegears and pinions in the differen-
during this test, it probably comes tial case will be most pronounced on
from the engine or the exhaust sys- turns. A continuous whine under a
tem. light load between 20 and 35 miles
To determine if the noise is being per hour indicates rough or brinnelled
caused by the rear axle or the tires,
pinion bearings. If the tone of drive,
drive the car over several different
coast and float noise differs with
types of road surfaces. Smooth as-
phalt or black-top roads minimize speed and if the noise is very rough
tire noises. Tire noises may be elimi- and irregular; worn, rough or loose
nated by cross-switching the tires. differential or pinion shaft bearings
Snow tires often cause noises not are indicated. Remove, disassemble,
heard with conventional tires. and inspect the axle.
PART 4-1 - GENERAL
AXLESERVICE 4-3
Excessive backlash in the axle tween the drive pinion and ring gear,
EXCESSIVE REAR AXLE driving parts may be causedby worn excessive backlash in the differential
BACKLASH (ALL REAR axle shaft splines, loose axle shaft gears, or bearings which are worn or
AXLES) flange nuts, loose V-joint flange out of adjustment.
mountings, excessivebacklash be-
Use the procedure given under the specified minimum, the differen-
ONE WHEEL SPINS limited-slip differential for checking tial is not functioning properly. To
EXCESSIVELY (LIMITED-SLIP the locking differentialwhile the unit repair the unit, remove it from the
DIFFERENTIAL ONLY) is in the car. If the torque required axle housing.
to rotate one rear wheel is lessthan
Drive the car in a fairly tight cir- standfor at leasttwo minutes.If the
cle, making five circlesclockwiseand samplenow has a blue tint, the lu-
five counterclockwise.This will per- bricant is approvedFord lubricant. If
mit the lubricant to work in between it has a yellow tint, it is not the cor-
the clutch plates. If the noise does rect lubricant. Drain and refill the
AXLE HAS A not disappearduring this driving test, axle with the approvedlubricant. It
HIGH-PITCHED, CHATTERING it is probablethat the axle doesnot is not necessaryto flush the axle
NOISE ON TURNS have the approvedFord lubricant.
(LIMITED-SLIP DIFFERENTIAL housing.
The lubricant may be checkedby After reffiling the axle drive the
ONLY) draining two tablespoonfulsfrom the car in fairly tight circles clockwise
axle and mixing it with an equal and counterclockwise. The chattering
amount of white alcohol, such as noiseshoulddisappearas soonas the
rubbing alcohol. Mix the lubricant new lubricant works in betweenthe
and alcohol thoroughly and let it clutch plates.
If the torque reading is less than THE mEAL TOOl1l PATTERN types of gear sets as well as differ-
the specified minimum, check the dif- Figs. 2 and 3 show the ideal tooth encesbetweenindividual gear setsof
ferential for improper assembly. pattern. This pattern is not a rigid the sametype will result in patterns
A car equipped with a limited-slip standard but merely a general role. that are acceptableyet different from
differential will always have both In general, desirable tooth pat- those shown in Fig. 3.
wheels driving. If, while the car is terns should have the following char-
being serviced, only one wheel is acteristics: HUNTING GEAR SET
raised off the floor and the rear axle (a) The drive pattern should be In a hunting-type gear set, anyone
is driven by the engine, the wheel on fairly well centered on the tooth. pinion gear tooth comes into contact
the floor will drive the car off the (b) The coast pattern should be with all drive gear teeth. In this type,
stand or jack. centered on the tooth but may be several revolutions of the ring gear
slightly toward the toe. are required to make all possible gear
GEAR TOOTH CONTACT (c) Some clearance between the combinations.
PATTERN CHECK pattern and the top of the tooth is
desirable. Acceptable Pa"ern
Paint the gear teeth and roll a pat- (d) There should be no hard lines
tern as describedin Section3. After where the pressure is high. The drive pattern shown in Fig.
diagnosingthe tooth pattern as ex- The individual gear set need not 4 was rolled on a hunting-type gear
plained here, make the appropriate conform exactly to the ideal pattern set. Since each pinion tooth came into
adjustmentsas outlined in Section2. in order to be acceptable. Character- contact with each ring gear tooth,
m making a final gear tooth con- istic differences between the three the pattern is a result of the com-
tact pattern check, it is necessaryto
recognizethe fact that there are three DRIVE SIDE COAST SIDE
different types of gear set, hunting, EL -- --- HEEL
non-huntingand partial non-hunting. HEEL SHIM CORRECT
BACKLASH CORRECT
Each type is determinedby the ratio
and the numberof teeth in the gears.
The non-hunting and partial non- TOE
hunting typescan be identifiedby the
paint timing markson the pinion and
ring gear teeth (Part 4-2, Fig. 30). E1468.A
SeePart 4-3 for completeidentifica-
tion specifications. FIG. 2-ldeal ToothPattern-IntegralCarrierTypeAxle
4-4
HEEL
DESIRABLE PATTERN
CORRECT
SHIM
CORRECTBACKLASH
E1336-A
FIG. 6-Unacceptable
Non-HuntingPattern-
FIG. 5-Unacceptable
Center-Heel-Center
bined tooth contacts. Therefore, the Non-Hunting Pattern-
pattern is uniform from tooth to Center-roe-Center
tooth.
to center. The pattern in Fig. 6 runs
from the tooth center toward the heel
Unacceptable Pattern
and then back to center. These
An erratic tooth pattern on a hunt- patterns are not unusual for non-
ing gear set indicates gear runout hunting gear sets ana are acceptable.
and possible need for gear replace- The pattern on anyone ring gear
ment. tooth was formed by only one pin-
A pattern that is uniform, but off ion tooth coming into contact with
center indicates a change in shim or it. Because of this limited tooth
backlash (Figs. 9 or 10). contact, the non-hunting pattern can
be more erratic than the hunting
NON.HUNTING GEAR SET pattern and still be acceptable. Like-
In a non-hunting type gear set, any wise, the coast pattern on a non-
one pinion gear tooth comes into con- hunting gear set is usually less uni-
tact with only a few ring gear teeth. form tooth to tooth than it would
In this type, only one revolution of be on a hunting gear set (Fig. 7).
the ring gear is required to make all Fig. 8 shows a pattern rolled on
possible tooth contact combinations. another gear set. In this case,the pat-
tern is fairly uniform from tooth to
Acceptable Patterns tooth.
The drive patterns shown in Figs. Unacceptable Patterns
5 and 6 were rolled on two different A non-hunting gear set should be
non-hunting type gear sets. The pat- checked for runout and possible re-
tern in Fig. 5 runs from the tooth placement if the pattern runs from
center toward the toe and then back the tooth center toward the toe and
PART 4-1 - GENERAL
AXLESERVICE 4-5
set, anyone pinion tooth comesinto the tooth, and the coast pattern is
contact with only part of the ring rolled on the concaveside.
gear teeth, but more than one revo- The movement of tooth contact
lution of the ring gear is required to patterns with changes in backlash
make all possiblegear tooth combi- and shimmingcan be summarizedas
nations. follows:
Tooth to tooth pattern uniformity
will usually be in betweenthe hunt- Integral Carrier Type Axle
ing and the non-hunting patterns.
Partial non-huntinggear set patterns 1. Thinner shim with the backlash
will usually be less uniform than constant moves the pinion farther
hunting gear set patterns, but more from the ring gear.
uniform than non-hunting gear set 8. Drive pattern moves toward
patterns. the top of the tooth (face contact)
SHIM AND BACKLASH and toward the heel.
CHANGES b. Coast pattern moves toward
The patternsshownin Figs. 9 and the top of the tooth and slightly to-
E1341-A ward the toe.
10 are typical of gear setsthat have
FIG. 8-Acceptable Non-Hunting 2. Thicker shim with the backlash
either an incorrect backlashor an in- constantmovesthe pinion closer to
Pattern-Uniform correct shim adjustment.Since each
change in shimming or backlash the ring gear.
gear set rolls a characteristicpattern, 8. Drive pattern movesdeeperon
when its pattern tendsto concentrate the patternsin Figs. 9 and 10 should
toward the heel or toe, top or bot- the tooth (flank contact) and slight-
tom of most teeth (Figs. 9 and 10). be consideredas typical only and ly toward the toe.
PARTIAL NON.HUNTING should be used as a guide rather b. Coast pattern movesdeeperon
GEAR SET than a rigid standard.The drive pat- the tooth and toward the heel.
In a partial non-huntingtype gear tern is rolled on the convex side of 3. Decreasingbacklashmovesthe
drive gear closer to the pinion:
DRIVE SIDE COAST SlOE 8. Drive pattern (convex side of
gear) moves slightly lower and to-
ward the toe.
b. Coast pattern (concaveside of
gear) moves lower and toward the
toe.
4. Increasingbacklashmoves the
ring gear away from the pinion:
8. Drive pattern moves slightly
higher and toward the heel.
b. Coastpattern moveshigher and
toward the heel.
If the patterns are not correct,
make the changesas indicated. The
differentialcaseand drive pinion will
have to be removedfrom the carrier
castingto changea shim. When re-
installing the pinion and ring gearof
SHIM CORRECT
DECREASE BACKLASH a non-huntingor partial non-hunting
.004 gear set, be sure that the marked
tooth on the pinion indexesbetween
the marked teeth on the ring gear
(Fig. 30, Part 4-2). Refer to Pin-
ion and Ring Gear Tooth Contact
Adjustment,Section2.
SHIM CORRECT Removable Carrier Type Axle
INCREASE BACKLASH
.004
1. Thicker shim with the backlash
constant moves the pinion farther
from the ring gear:
a. Drive pattern moves toward the
top of the tooth (face contact) and
E1469.A toward the heel.
b. Coast pattern moves toward the
FIG. 9-Typical GearTooth ContactPatternsIndicating Shimor top of the tooth and slightly toward
BacklashChange-IntegralCarrierType the toe.
4-6 GROUP 4 - REARAXLE
HEEL
TOE
1. BACKLASHCORRECT
0.004 THICKER
SHIM REQUIRED
2. BACKLASHCORRECT
0.004 THINNER
SHIM REQUIRED
3. SHIM CORRECT
DECREASE
BACKLASH
0.004
4. SHIM CORRECT
INCREASE
BACKLASH
0.004
E1342-A
ent shim. When reinstalling the pin- set, be sure that the marked tooth 30, Part 4-2). Refer to Pinion and
ion and retainer assembly of a non- on the pinion indexes between the Ring Gear Tooth Contact Adjust-
hunting or partial non-hunting gear marked teeth on the ring gear (Fig. ment, Section2.
i
I;.;.;;,...
the ring gear. On the integral carrier J.~ right nut is on the pinion side. Loos-
type axle, the pinion locating shim
en the right nut until it is away from
pack is installed between the pinion
~ the cup. Tighten the left nut until the
rear bearing cone and the pinion ~"-:'-"'~
"'"
rt shims to move the pinion away from
the ring .sear (Fig. 11). When adjust-
ing the removable carrier type axle,
remove shims to move the pinion to-
in their cups to be sure no bind is
evident. This step is important.
4. Install a dial indicator as
",SPACER
shown in Fig. 13.
PINla-I ward the ring gear; add shims to
S. Again loosen the right nut to
BACKLASH
"'" \ OCATING
SHIM move the pinion away from the ring
release the pre-load. If there is any
ADJUSTMENt gear (Fig. 12). backlash between the gears as shown
PACK
The tooth pattern check also indi-
by the dial indicator, tighten the left
cates whether the ring gear should
I
I be adjusted away from or toward the
nut just enough to remove this back-
I lash. At this time, make sure that one
pinion to increase or decrease back-
of the slots in the left nut is so lo-
lash between the gears.
cated that the lock can be installed
If the tooth pattern check indicates
without turning the nut. Carefully
a change in backlash only, follow the
tighten the right nut until it just con-
procedure under Backlash and Bear-
tacts the cup. On integral carrier type
ing Preload Adjustments. If the tooth
axles, set a preload of 0.008 inch
pattern indicates a change in shim
case spread for new bearings and
thickness, follow the procedure under
0.003 to 0.005 for the original bear-
Pinion Location.
ings. On removable carrier type
BACKLASH AND DIFFEREN- axles, the preload is 0.012 inch case
oJ,
,..J ~~
If~ DIFFERENTIAL BEARING
ADJUSTING
NUTS TIAL BEARING PREWAD spread for new bearings and 0.005
E1476-A ADJUSTMENTS to 0.008 for the original bearings. As
To secure a u :')re uniform control preload is applied from the right side,
FIG. 11-Pinion and Ring Gear of differential si' ,e bearing preload in the ring gear is forced away from
Tooth Contact Adjustment- service repairs, a dial indicator set- the pinion and usually results in the
Integral Carrier Type Axles up such as shown in Fig. 13 is used. correct backlash.
4-8 GROUP 4 REAR AXLE
INSPECTION BEFORE
DISASSEMBLY OF CARRIER
The differential case assembly and
the drive pinion should be inspected
before they are removed from the
housing. These inspections can help
to find the cause of the trouble and
to determine the correction needed.
On removable carrier type axles,
mount the carrier in the holding fix-
ture shown in Fig. 14.
condition. Gear scoring is the result (removable carrier type). The faces threads are not damaged.
of excessiveshock loading or the use of the nuts that contact the bearing Remove any nicks or burrs from
of an incorrect lubricant. Scored cups must be smooth and square. Pol- the mounting surfaces of the carrier
gears cannot be re-used. ish these with a fine abrasive on a housing.
Examine the teeth and thrust sur- flat surface. Replace the nuts or ex-
faces of the differential gears. Wear amine the threads in the carrier, if DIFFERENTIAL CASE
on the hub of the differential side their fit is not proper. Be sure that Make sure that the hubs where the
gear can cause a chucking noise the bearing caps and adjusting nuts bearings mount are smooth. Care-
known as chuckle when the car is are on the side which they were ma- fully examine the differential case
driven at low speeds.Wear on splines, chined to fit by observing the punch bearing shoulders, which may have
thrust surfaces, or thrust washers can marks and scribe marks made dur- been damaged when the beatings
contribute to excessive drive line ing disassembly operations. were removed. The bearing assem-
backlash. blies will fail if they do not seat firm-
DRIVE PINION FLANGE ly against the shoulders. Check the
BEARING CUPS Be sure that the ears of the flange fit (free rotation) of the differential
Check bearing cups for rings, have not been damaged in removing side gears in their counterbores. Be
scores, galling, or erratic wear pat- the drive shaft or in removing the sure that the mating surfaces of the
terns. Pinion bearing cups must be flangt: from the pinion. The end of two parts of the case are smooth and
solidly seated. Check by attempting the flange that contacts the bearing free from nicks or burrs.
to insert a O.OOI5-inchfeeler between cone (integral carrier type) or the oil
these cups and the bottoms of their slinger (removable carrier type) as LIMITEO-SLIP DIFFERENTIAL
bores. well as the flat surface of the pinion PARTS
nut counterbore must be smooth. Inspect the clutch plates for un-
CONE AND ROLLER Polish these surfaces if necessary. even or extreme wear. The dog-eared
ASSEMBLIES Roughness aggravates backlash clutch plates must be free from burrs,
When operated in the cups, bear- noises, and causeswear of the flange nicks, or scratches which could cause
ing rollers must turn without rough- with a resultant loss in pinion bear- excessiveor erratic wear to the bond-
ness. Examine the roller ends for ing preload. ing material of the internally splined
wear. Step-wear on the roller ends in- clutch plates. The internally splined
dicates that the bearings were not PINION RETAINER- clutch plates should be inspected for
preloaded properly or that the rollers REMOVABLE CARRIER condition of the bond, bonding ma-
were slightly misaligned. TYPE AXLE ONLY terial, and wear. Replace the bonded
If inspection reveals either a de- Be sure that the pinion bearing plates if their thickness is less than
fective cup or a defective cone and cups are seated. Remove any chips 0.085 inch or if the bonded material
roller assembly, both parts should be or burrs from the mounting flange. is scored or badly worn. Inspect the
replaced to avoid early failure. Clean the groove for the O-ring seal bonded plate internal teeth for wear.
and all lubricant passages.If the cups Replace them, if excessive wear is
DIFFERENTIAL BEARING were removed, examine the bores evident. Bonded plates should be re-
ADJUSTING NUTS carefully. Any nicks or burrs in these placed as a set only.
Temporarily install the bearing bores must be removed to permit Examine all thrust surfaces and
caps and test the fit of the adjusting proper seating of the cups. hubs for wear. Abnormal wear on
nuts in their threads. these surfaces can contribute to a
The nuts should turn easily when CARRIER HOUSING noisy axle.
the caps are tightened to 15 ft-lbs Make sure that the differential Inspect the Belleville spring for
(integral carrier type) or 20 ft-lbs beariniZ bores are smooth and the nroner free hei2ht of 1/4 inch.
4-11
REAR AXLES
PINIONGEAR
4215
LEFT-HAND
AXLE SHAFT
DIFFERENTIAL
CASE / (" ::
4735
I
X j
"",
f ~
/ ;" "
~
RIGHT
~'!i&i'!i&
AXLE SHAFT ~
.
4234
~ PINION
4209 SEAL
4859
FLANGE
4851
DRIVE PINION
,
BEARINGS
4630.
SEAL
4621.
'177
BEARING
1225
E1212.D
ing axle shafts at the outer ends. The side gear to allow differential action ferential action to take place. Under
inner ends of the shafts spline to the between the two axle shafts. adverse weather conditions, where
differential side gears. Bearing re- LIMITED-SLIP DIFFERENTIAL one or both wheelsmay be on a low-
tainer plates hold the shafts in the AXLE traction surfacesuch as snow,ice or
housing. The left and right axle shafts The locking differential is provided mud, the friction betweenthe clutch
are not interchangeable, because the as optional equipment in both the in- plates will transfer a portion of the
left axle shaft is shorter than the tegral and the removable carrier type
axle. usabletorque to the wheel with the
right. most traction. Thus, the wheel that
DESCRIPTION is on ice or snow will not spin, but
OPERATION The axle assembly, except for the will have a tendencyto operatewith
differential case and its internal com-
The rear axle drive pinion receives the opposite wheel in a combined
ponents, is identical to the conven-
its power from the engine through tional axle. driving effort.
the transmission and drive shaft. The A constant-friction locking differ- When performing the following
pinion gear rotates the differential ential, which employs automatic procedures,refer to Part 4-1, Section
case through engagement with the transmission-type clutch plates to 3 for cleaningand inspectionproce-
ring gear, which is bolted to the case control differential action, is avail- dures.
able as optional equipment (Fig. 3).
outer flange. Inside the case, there CARE OF AXLE
Four steel clutch plates are locked
are two differential pinion gears The lubricant level should be
into the differential cover. Three
mounted on the differential pinion checkedevery 6000 miles, with ve-
bronze, bonded clutch plates are
shaft which is pinned to the case. splined to the left-hand axle shaft. A hicle in normal curb attitude.The lu-
These pinion gears are engaged with Belleville spring washer maintains a bricant level should be at the lower
the side gears, to which the axle constant pressure between the steel edgeof the filler plug hole. It is un-
shafts are splined. Therefore, as the and bonded clutch plates so that the necessaryto periodically drain the
differential case turns, it rotates the clutch is always engaged. axle lubricant. The factory fill should
axle shafts and rear wheels. When it
OPERATION remain in the housingfor the life of
is necessary for one wheel and axle
The pressure between clutch plates the vehicle, exceptwhen repairs are
shaft to rotate faster than the other,
opposes differential action at all made.The specifiedlubricant should
the faster turning side gear causesthe times. When the car turns a corner be installed when the axle is over-
pinions to roll on the slower turning the clutch slips allowin2 normal dif- h""lplj
~
PART 4-2 - REARAXLES 4-13
LEFT-HANDAXLESHAFT
"
.),
,:
,,1
RING GEAR
DRIVEPINION
RIGHT-HANDAXLESHAFT
I[J
TAPEREDROLLER
11
BEARINGS
.:
PINION PILOTBEARING
PINION BEARINGRETAINER
E1304-B
REAR AXLE SHAFT, WHEEL semblyfrom the axle housing. the drum from the flange.
BEARING AND OIL SEAL 1. Remove the wneeI and tire 3. Working through the hole pro-
REPLACEMENT from the brake drum. vided in each axle shaft flange, re-
The rear axle shafts, wheel bear- 2. Remove the Tinnerman nuts move the nuts that securethe wheel
ings, and oil seal can be replaced that secure the brake drum to the bearingretainer plate. Then pull the
without removing the differential as- axle housingflange,and then remove axle shaft assemblyout of the axle
~
4-14 GROUP 4 REAR AXLE
Tnn/_A?~,,_r /~
-'---"" E1O32-D removed, the oil seal must be re- side of the brake carrier plate, and
FIG. 5-Removing Axle Shaft placed. Remove the seal with the then carefully slide the axle shaft in-
tools shown in Fig. 9. Soak new oil to the housing so that the rough
-Removable Carrier seals in SAE 10 oil for 1/2 hour be- forging of the shaft will not damage
Type Axle fore installing. the oil seal. Start the axle splines into
housiQg (Fig. 4 or 5). The brake car- 7. Inspect the machined surface of the side gear, and push the shaft in
rier plate must not be dislodged. In- the axle shaft and the axle housing until the bearing bottoms in the hous-
stall one nut to hold the plate in place for rough spots or other irregularities ing.
after the axle shaft is removed. which would affect the sealing action 15. Install the bearing retainer
4. If the rear wheel bearing is to of the oil seal. Check the axle shaft plate on the mounting bolts at the
be replaced, loosen the inner retainer splines for burrs, wear or damage. axle housing, and install the attach-
nick by nicking it deeply with a cold Carefully remove any burrs or rough ing nuts. Torque the nuts to specifi-
chisel in several places (Fig. 6). It spots. Replace worn or damaged cations.
will then slide off easily. parts. 16. Install the brake drum and the
8. Lightly coat wheel bearing drum attaching nuts.
bores with ball joint grease (C3VY- 17. Install the wheel and tire on
19586-B). ~hedrum.
9. Place the retainer plate on the
REMOVAL AND REPLACEMENT
axle shaft, and press the new wheel
OF DRIVE PINION OIL SEAL
bearing on the. shaft with the tool
shown in Fig. 7 or 8. The bearing Replacement of the pinion oil seal
should seat firmly against the shaft on either type axle involves removal
shoulder. Do not attempt to press on and installation of only the pinion
.)Qi' 1 both the bearing and the inner re-
tainer ring at the same time.
shaft nut and the universal joint
flange. However, this operation dis-
~!, 10. Using the bearing installation turbs the pinion bearing preload, and
tool, press the bearing inner retain- this preload must be carefuUy reset
er ring on the shaft until the retainer when assembling.
seats firmly against the bearing. 1. Raise the car and install safety
-_c -
':.: E1420-A
11. Wipe all lubricant from the in-
stands. Remove the rear wheels and
brake drums.
FIG. 6-Removing Rear Wheel side of the axle housing in the area
2. Make scribe marks on the drive
of the oil seal before installing the
Bearing Retainer Ring new seal.
shaft end yoke and the axle V-joint
flange to insure proper position of the
5. Remove the bearing from the 12. Wipe a small amount of oil drive shaft at assembly (Fig. 14).
axle shaft with the tool shown in Fig. resistant sealer on the outer edge of Disconnect the drive shaft from the
7 or 8. If the push-puller operation the seal before it is installed. Do not axle V-joint flange. Be careful to
shown in Fig. 8 is used, be sure that put sealer on the sealing lip. avoid dropping the loose universal
the puller arms contact the flat sur- 13. Install the new oil seal with joint bearing cups. Hold the cups on
fate of the axle shaft flange rather the tools shown in Fig. 9. Installation the spider with tape. Mark the cups
than the bolt heads. Also with this without use of the proper tool will so that they will be in their original
method, be careful not to damage or distort the seal and cause leakage. position in relation to the flange when
burr the oil seal journal as the bear- Be sure the new seal has been soaked they are assembled.Remove the drive
ing breaks loose. in SAE 10 oil for 1/1;hour. shaft from the transmission exten-
6. Whenever a rear axle shaft is 14. Place a new gasket on each sion housing. Install an oil seal re-
~
4-16 GROUP4 REAR AXLE
universal joint bearing cups. Hold 7. Check splines on the pinion is reached. (The preload should not
the cups on the spider with tape. shaft to be sure they are free of burrs. exceed 8 to 14 in-lb over the original
Mark the cups so that they will be If burrs are evident, remove them by reading, or bearing failure may re-
in their original position in relation using a fine crocus cloth, working sult.)
to the flange when they are assem- in rotational motion, then wipe clean. Under no circumstances should the
bled. Remove the drive shaft from Apply a small amount of lubricant pinion nut be backed off to lessen
the transmission extension housing. to V-joint splines. preload. If this is done, a new pinion
Install an oil seal replacer tool in the 8. Install the V-joint flange using bearing spacer must be installed. (In
transmission extension housing to the tool shown in Fig. 50. addition, the V-joint flange must nev-
prevent transmission fluid leakage. 9. Install a new integral nut and er be hammered on, or pneumatic
Refer to the transmission group for washer on the pinion shaft. (Apply a tools used.)
the appropriate tool. small amount of lubricant on the 13. Remove the oil seal replacer
3. Install an ip-lb torque wrench washer side of the nut.) tool from the transmission extension
on the pinion nut. Record the torque 10. Hold the flange with the tool housing. Install the front end of the
required to maintain rotation of the shown in Fig. 35 while the nut is be- drive shaft on the transmission out-
pinion shaft through several revolu- ing tightened. put shaft.
tions. 11. Tighten the pinion shaft nut, 14. Connect the rear end of the
4. While holding the flange with rotating the pinion occasionally to in- drive shaft to the axle V-joint flange,
the tool shown in Fig. 36, remove sure proper bearing seating, and aligning the scribe marks made on
the integral pinion nut and washer. take frequent preload readings until the drive shaft end yoke and the axle
S. Clean the pinion bearing retain- the preload is at the original recorded V-joint flange (Fig. 14).
er around the oil seal. Place a drain reading established in step 3. 14. Check the lubricant level.
pan under the seal, or raise the front 12. After original preload has Make sure the axle is in running posi-
of the car higher than the rear. been reached, tighten the pinion nut tion. Add whatever amount of spec-
6. Using the tool shown in Fig. slowly, until an additional preload of ified lubricant is required to reach
36, remove the V-joint flange. 8 to 14 in-ib over the original reading the lower edge of the filler plug hole.
of the proper tool will distort the axle. Remove the carrier assembly 7. Install the bearing retainers on
sealand causeleakage.Coat the out- from the axle housing. the attaching bolts on the axle hous-
side edgesof the new oil sealwith a ing flanges. Install the nuts on the
hardeningtype of sealersuch as Per- INSTALLATION bolts and torque to specifications.
matex No.2 or its equivalent. 1. Clean the axle housing and 8. Install the two rear brake
4. Install the axle shafts, brake shaftsusing keroseneand swabs.To drums and the drum retaining (Tin-
drums and wheelsas outlined in the avoid contaminationof the greasein nerman) nuts.
foregoingSection2. the sealedball bearings,do not allow 9. Install the rear wheel and tire
5. Attach the hydraulic brake line any quantity of solvent directly on assemblies.
T fitting to the axle housing,and se- the wheelbearings.Cleanthe mating 10. If the rear brake shoes were
cure the hydraulic brake line in its surfaces of the axle housing and backed off, adjust the brakes as out-
retainer on the axle housing. carrier. lined in Part 2-1.
6. Install vent tube to brake tube 2. Position the differential carrier 11. Fill the rear axle with speci-
junction and install vent hoseto vent on the studsin the axle housingusing fied lubricant.
tube. a new gasket between carrier and
7. Raisethe axle housingand con- housing. Install the copper washers AXLE HOUSING-REMOVABLE
nect the shock absorbers. and the carrier-to-housingretaining CARRIER TYPE AXLE
8. Connect the drive shaft at the nuts, and torque to specifications.
drive pinion shaft. 3. Remove the oil seal replacer REMOVAL
9. Fill the axle with the proper tool from the transmissionextension 1. Remove the carrier assembly
gradeand amountof lubricant. housing. Position the drive shaft so from the axle housingas outlined in
10. Road test the car. that the front U-joint slip yoke splines the foregoing procedure.
to the transmissionoutput shaft. 2. Positionsafetystandsunder the
4. Connect the drive shaft to the rear frame members.
axle U-joint flange, aligning the 3. Disengagethe brake line from
DIFFERENTIAL CARRIER- scribemarksmadeon the drive shaft
REMOV ABLE (:ARRIER TYPE the clips that retain the line to the
end yoke and the axle U-joint flange axle housing.
AXLE
during the removal procedure (Fig. 4. Disconnectthe vent tube from
14). Install the U-bolts and nuts and the rear axle housing.
REMOVAL torque to specifications. 5. Removethe brake carrier plate
1. Raise the car on a hoist and assembliesfrom the axle housing,
remove the two rear wheel and tire ,
DRIVE SHAFT END YOKE
and support them with wire. Do not
assemblies. AXLE FLANGE disconnectthe brake line.
2. Remove the two brake drums 6. Disconnecteachrear shockab-
(3 Tinnerman nuts at each drum) sorberfrom the spring clip plate and
from the axle shaft flange studs. If position out of the way.
difficulty is experiencedin removing
the drums, back off the brake shoes .
U-BOLT
7. Lower the rear axle slightly to
reducesomeof the springtension.At
each rear spring, remove the spring
as explainedIn Part 2-2. ..
SCRIBE MARKS E 13 51 -A
3. Working through the hole pro- clip (V-bolt) nuts, spring clips, and
vided in each axle shaft flange, re- spring clip plate. Removethe spring
FIG. 14-Drive Shaft-to-Axle lower insulator and retainer. See
move the nuts that securethe rear
wheel bearing retainer plate~ Pull U-Joint Connection Part 3-2.
each axle shaft assemblyout of the 8. Removethe rear axle housing
5. Soak two new rear wheel bear-
axle housing(Fig. 5). Install a nut on ing oil seals in SAE 10 oil for Ih from under the car.
one of the brake carrier plate retain- hour before installation. Wipe a
ing bolts to hold the plate to the axle small amountof an oil resistantseal- INSTALLATION
housingafter the shaft has been re- er on the outer edgeof eachsealbe- 1. Position the rear axle housing
moved. Whenevera rear axle shaft fore it is installed.Do not put any of on the rear springs.On a Comet or
is removed, the wheel bearing oil the sealeron the sealinglip. Install Fairlane, position the spring upper
seal must be replaced.Removeboth the oil sealsin the ends of the rear insulatorsand retainersbetweenthe
sealswith the tools shown in Fig. 9. axle housingwith the tool shown in axle housingand springs,and install
4. Make scribemarkson the drive Fig. 9. the lower insulators.
shaft end yoke and the axle V-joint 6. Install the two axle shaft assem- 2. Install the spring clips (U-
flangeto insureproper position at as- blies in the axle housing.The shorter bolts), spring clip plate, and nuts.
sembly.Disconnectthe drive shaft at shaft goes into the left side of the Torque the spring clip nuts evenlyto
the rear axle V-joint, remove the housing. specifications.
drive shaft from the transmissionex- When installing an axle shaft, 3. If a new axle housingis being
tensionhousing.Install an oil sealre- place a new gasketon each side of installed,removethe bolts that retain
placer tool in the housingto prevent the brake carrier plate and carefully the carrier plate and bearingretainer
transmissionleakage. Refer to the slidethe axle shaft into the housingso from the old housing flanges.Posi-
transmission group for the appro- that the rough forging of the shaft tion the bolts in the new housing
priate tool. will not damagethe oil seal. Start flanges to hold the brake carrier
5. Place a drain pan under the the axle splinesinto the differential plates in position. Install the carrier
carrier and housing,removethe car- side gear,and push the shaft in until plates with new gasketsto the axle
rier retaininv; nuts. and drain the the bearin2 bottoms in the housin2. housinl! flanl!es.
PART 4-2 - REARAXLES 4-19
4. Connect the vent tube to the the rear shock absorbers to the spring 7. Install the carrier assembly and
axlehousing. clip plates. Connect the lower stud of the two axle shaft assemblies in the
5. Position the brake line to the each shock absorber to its spring axle housing as outlined in the In-
axle housing, and secure with the clip plate, and install the bushing,
washer, and nut on the stud. Be sure stallation procedure under Differen-
retaining ciips.
6. Raise the rear axle housing and the spring clip plate is free of burrs. tial Carrier-Removable Carrier
springs enough to allow connecting Tighten the nut to specified torque. Type Axle.
;
AND THRUSTWASHER~V
~-- E1216-E
FIG. 1 5-DisassembledRear Axle
MATCHED GEAR-SET
IDENTifiCATION
MARKING FOR
SHIM SELECTION
E 1226-8
FIG. 28-Differential
Torque Check
,
_c ~",. ...~""..,~ ., ~.~- . ~,. IN WHICH GEARS WERE LAPPED E1335-A
FIG. 30-Typical Gear Set Timing Marks
DIFFERENTIAL
CASE
PINIONSHAFT --
FIG. 34-Assembly of DifferentialCase
DIFFERENTIAL
E1174-A
FIG. 32-Removing bearings from the differential as out- REMOVAL AND DISASSEMBLY
lined in steps 1 through 4 in the OF DRIVE PINION AND
Differential Pinion Shaft
foregoing procedure. BEARING RETAINER
Lock Pin 2. Place the differential case in a 1. Turn the carrier case upright,
hydraulic press, and apply about one and remove the pinion shaft nut
7. Drive out the pinion shaft with ton pressure across the case bearing
a brassdrift (Fig. 33). (Fig. 35). Then remove the V-joint
hubs while removing the ring gear flange (Fig. 36).
attaching bolts. This procedure will
contain the spring pressure between
the differential case and cover until
after the bolts are moved, and there-
by prevent stripping of the threads.
Loosen alternate bolts an equal
amount so that the spring pressure
will release evenly.
3. Release the hydraulic press
ram, and remove the differential
case cover.
4. Remove the Belleville spring
(Fig. 21).
5. Remove the steel and the
bonded clutch plates.
FIG. 33-Driving Out
6. Remove the differential clutch
Differential Pinion Shaft hub, outer side gear, and thrust
washer.
8. Remove the gears and thrust
7. Remove the ring gear from the
washers.(Fig. 34). differential case. Tool- T57l.4851.Aor 4851.K -.
8. Drive out the differential pin-
REMOVAL AND DISASSEMBLY ion shaft lock pin. FIG. 35-Removing Pinion
OFLIMITED-8LIP 9. With a brass drift, drive out Shaft Nut
DIFFERENTIAL CASE the differential pinion shaft. Then
1. Remove the differential case remove the pinion gears, inner side 2. Removethe seal (Fig. 37) and
from the carrier and remove the gear, and thrust washers. the slin2er.
4-26 GROUP 4 - REAR AXLE
E1307-B
FIG. 36-Removing
U-Joint Flange
Too/-T62F-4625-A
or 4625-AC- J and 2
FIG. 37-Removing
Pinion Seal
3. Remove the pinion, bearing,
and retainer assemblyfrom the car-
rier housing (Fig. 48). Measurethe
shim thickness with a micrometer.
Record this original shim thickness.
If a new gear set is installed during FIG. 39-Removing Pinion
assembly,a new shim will have to be
installed.The original shim thickness Rear Bearing (one -R
in Fig. 42. On cars equipped with the correct shim thickness for the by a warped gear, a defectivecase,
high performance engines, use the new gear set to be installed,follow or excessivelyworn differential bear-
following tools: T57L-46l4-A with thesesteps: ings.
T57L-46l6-A for front cup removal 1. Measure the thickness of the To determinethe causeof exces-
except Comet; tool 46l5-D for original shim with a micrometer. sive runout proceed as follows:
Comet front cup removal; T57L- 2. Note the shim adjustmentnum- 1. Assemblethe two halvesof the
46l4-A with T57L-46l6-A2 for front ber on both the old pinion and the differential casetogetherwithout the
cup installation and T57L-46l4-A new pinion. Each pinion gear is ring gear, and pressthe two differ-
with T55P-46l6-A2 for rear cup in- marked with an adjustmentnumber ential side bearingson the casehubs.
stallation. such as the + 1 marking in Fig. 44. 2. Place the cups on the bearings
and set the differential case in the
carrier.
3. Install the bearingcapsand ad-
justing nuts as outlined in step 11
thru 14 under Assembly and In-
stallation of Conventional Differen-
tial Casein this section.
4. Tighten the right nut fwo
notches beyond the position where
it first contacts the bearing cup.
Rotate the differential case several
~
- "-
A new ring gear and pinion with the new bearings.If the runout
should always be installed in an axle is now within limits, the old bear-
as a matched set (never separately). ings were excessivelyworn. Use the
Be sure that the same matching num- new bearings for assembly.If the
-,~.~vu-~ ber appears on both the drive pin- runout is still excessive,the caseis
ion and the ring gear. Note the num- defectiveand shouldbe replaced.
FIG. 43-lnstalling Pinion ber 170 in Fig. 44.
Bearing Cup 4. After determining the correct ASSEMBLY
shim thickness as explained in the Refer to Part 4-1 for Cleaning
DRIVE PINION AND foregoing steps, install the new pin- and InslJection before starting as-
GEAR SET ion and ring gear as outlined under semblyoperations.Fig. 45 showsthe
When replacing a ring gear and Assembly. disassembledparts.
pinion, note that the original fac-
tory installed shim is of the correct DIFFERENTIAL CASE, ASSEMBLYAND
thickness to adjust for individual BEARINGS AND RING GEAR INSTALLATION OF DRIVE
variations in both the carrier hous- If the ring gear runout check (be- PINION AND BEARING
ing dimensionand in the original gear fore disassembly) exceeded specifi- RETAINER
set dimension. Therefore. to select cations, the condition may be caused 1. Install the drive pinion rear
4-28 GROUP 4 - REAR AXLE
pound torque wrench is not available line up the pinion shaft lock pin
tool 4209-C may be used in combi- holes.
nation with tool 4209-CI2. Correct 4. Place the second side gear and
preload will be obtained when the thrust washer in position (Fig. 34),
torque required to rotate the pinion and install the cover on the differ-
in the retainer is as specified in Part ential case. Install the pinion shaft
4-3. If the torque required to rotate lock pin. A pinion or axle shaft
the pinion is less then specified, spline can be inserted in the side
tighten the pinion shaft nut a little gear spline to check for free rotation
at a time until the proper preload is of the differential gears.
established. Do not overtighten the 5. Insert two 7/16(N. F.) bolts two
nut. If excessive preload is obtained inches long through the differential
as a result of overtightening, replace case flange, and thread them three
the collapsible bearing spacer. or four turns into the ring gear as a
Do not back off the pinion shaft guide in aligning the ring gear bolt
nut to establish pinion bearing pre- holes. Press or tap the ring gear into
load. If the torque on the pinion
shaft nut is less than 175 ft-lbs. after position.
bearing preload is established, a new 6. Install and tighten the ring gear
collapsible spacer must be used. bolts and washers evenly, and torque
them alternately across the gear to
ASSEMBLY AND
INSTALLATION OF specification.
CONVENTIONAL 7. If the differential bearings have
FIG. 46-lnstalling Pinion DIFFERENTIAL CASE been removed, press them on as
Rear Bearing (one 1. Place a side gear and thrust shown in Fig. 52.
LOCK NUT
'1'
I~', "c
i
, ,j
SEAL
I n
FIG. 50-Installing
U-Joint Flange
E1474-A
8. Wipe a thin coating of lubri-
FIG. 49-lnstalling Oil Seal cant on the bearingboresso that the
washer in the differential case bore differential bearing cups will move
FIG. 48-lnstalling Fig. 34). Lubricate all differential easily.
Pinion and Retainer parts liberally with axle lubricant 9. Place the cups on the bearings.
tighten the pinion shaft nut to 175 during assembly. If the gear set is of the non-hunting
ft-lbs. Do not exceed 175 ft-lbs at 2. With a soft-faced hammer, or partial non-huntingtype, assemble
this time. As the pinion shaft nut is drive the pinion shaft into the case the differential case and ring gear
tightened, rotate the pinion shaft only far enough to retain a pinion assemblyin the carrier so that the
frequently to allow the bearing to thrust washer and pinion gear. marked tooth on the pinion indexes
seat. 3. Place the second pinion and between the marked teeth on the
11. Check the pinion bearing pre- thrust washer in position, and drive ring gear as shownin Fig. 30.
In:lrl :I~ ~hnwn in Fill. 51. If an inch- the pinion shaft into place. Carefully In almost every caseof improper
4-30 GROUP 4 REAR AXLE
SPECIFICATIONS
~
, WCY.R
WCY-AA
WCY-E N
71/4
71/4
Conventional
Limited-Slip
Conventional
2.88:1
CDlnch-pounds
ADJUSTMENTS(Continued)
ADJUSTMENTS
-
Inch