GENERAL AXLE SERVICE - Octopup.orgoctopup.org/img/car/lincoln/info/1964-Lincoln--Maintenance-Manual--04--Rear-Axle.pdfA GENERAL AXLE SERVICE LI-I Section Page Section Page 1 Diagnosis

PARTA GENERAL AXLE SERVICELI-I

Section Page Section Page1 Diagnosis and Testing 4-1 3 Cleaning and Inspection 4-42 Common Adjustments and Repairs 4-2

U DIAGNOSIS AND TESTINGCertainrearaxle trouble symptoms parts of the car. For this reason, repairing, or replacing any of the

arealso commonto the engine, drive be surethat the causeof the trouble axle parts.line, transmission,tires, and other is in the rear axle before adjusting,

REAR AXLE TROUBLE DIAGNOSIS GUIDE

Since gears are in mesh, some when the car is coasting at lowrear axle noise is normal. However, speeds, and it usually stops whenexcessive noise often indicates the the brakes are gently applied. Tobeginning of other troubles in the find the noisy bearing, jack up eachaxle. wheel and check each bearing for

A road test can help determine roughnesswhile the wheel is rotatwhetherthe noise is beingcausedby ing, provided thatthe caris equippedtrouble in the rear axle or in other with a conventionaldifferential.parts of the car. Before road-test- If all possible external sourcesing the car, make sure that the tire of noise have been checked andpressuresand the rear axle lubri- eliminated, and the noise still exists,cant level are normal. Then drive road-testthe rear axle under all fourthe car far enough to warm the driving conditions:axle lubricant to its normal oper- 1. Drive: Higher than normal

EXCESSIVE REAR AXLE ating temperature. road-load power, where the speedNOISE With the car stopped and the gradually increases on level road

ALL REAR AXLES’ transmissionin neutral, run the en-/ gine at various speeds.If the noise

acceleration.2. Cruise: Constantspeed opera

still exists during this test, it prob- tion at normal road speeds.ably comes from the engineor the 3. Float: Using only enoughexhaust system. throttle to keepthe car from driving

To determineif the noiseis being the engine.Car will slow down verycausedby the rear axle or the tires, little load on rear axle gears.drive the car over several different 4. Coast: Throttle closed- enginetypes of road surfaces. Smooth as- is braking the car. Load is on thephalt or black-toproadsminimize tire coast side of the gearset.noises.Tire noisesmay be eliminated Any noise producedby the sideby cross-switching the tires. Snow gearsand pinions in the differentialtires often cause noises not heard case will be most pronouncedon

I with conventionaltires. turns. A continuouswhine under aNoise causedby a worn or dam-

j aged wheel bearing is often loudestlight load between20 and 35 milesper hour indicates rough or brin

GENERAL AXLE SERVICE 4-1

REAR AXLE 4-6

PART 4-1 PAGE PART 4-3 ‘PAGESPECIFICATIONS 4-19

PART 4-2

U

CONTINUED ON NEXT PAGE

4-2 GROUP 4-REAR AXLE

0 COMMON ADJUSTMENTS AND REPAIRS

058

PINION AND RING GEARTOOTH CONTACT ADJUSTMENT

Two separate adjustments affectpinion and ring gear tooth contact.They are pinion location and backlash Fig. 1. Painting the ring gearteeth with marking compound androlling a pattern, as describedunder"Inspection Before DisassemblyofCarrier" in Section 3, will indicatewhat adjustments should be madeon a particulargear set.

PINION LOCATION

Individual differences in machining the carrier housingand the gearset require a shim pack betweenthe pinion rear bearing cup and

the carrier housing to locate thepinion for correct contact with thering gear. The original factory installed shim pack is of the correctthicknessfor a given original carrierand gear set assembly. In service,shims should be added or removedfrom the original pack only as indicated by the tooth pattern checkFig. 2. Adding shims moves thepinion toward the ring gear;removing shims moves the pinion awayfrom the gear Fig. I.

BACKLASH BETWEEN RINGGEAR AND PINION

The tooth pattern check also indicateswhetherthe ring gear should

be adjusted awayfrom or towardthepinion to increaseor decreasebacklash betweenthe gears. The shimsinstalled behind the differential sidebearings locate the differential caseand ring gear assembly in the carrier housing.To increasethe backlash betweenthe ring gearand pinion move ring gear away frompinion, removethe necessaryshimsfrom behindthe bearingon the ringgear side of the differential caseand install them behind the bearingon the pinion side of the case Fig.1. To decreasebacklashmoveringgear toward pinion, remove thenecessary shims from behind thebearing on the pinion side of the

REAR AXLE TROUBLE DIAGNOSIS GUIDE Continued

EXCESSIVE REAR AXLE nelled pinion bearings. If the tone rough andirregular; worn, roughorNOISE of drive, coast andfloat noisediffers loosedifferential or pinion shaftbear-ALL REAR AXLES with speedand if the noise is very ings are indicated.

EXCESSIVE REAR AXLEExcessive backlash in the axle

driving parts may be caused bytween the drive pinion and drivegear, excessive backlash in the dif

BACKLASH worn axle shaft splines, loose axle ferential gears, or bearings whichALL REAR AXLES shaftflange nuts, looseU-joint flange

mountings, excessive backlash be-are worn or out of adjustment.

Before removing the "DirectedPower" differential for overhaul,change the lubricant as describedin the following procedure and op-eratethe car for 200 miles.

1. Operatethe vehicle enough to

cant that did not drain. Flushingthe unit with solvents is not recommended due to the undesirableeffect the solvents may have onthe new lubricant.

6. Clean the gasket surfaces.In-

DIFFERENTIAL CHATTERSthoroughly warm the rear axle lu-bricant.

stall a new gasket, and install thecover and bolts.

DIRECTED POWER ONLY 2. Thoroughly clean the areaaroundthe rear axle housing cover.

3. Removethe housing coverboltsandcover. Drain the lubricant,

4. Rotate the wheels by hand toallow the lubricant in the unit todrain,

5. Syphon or wipe out all lubri-

7. Torque the cover bolts to spec-ifications.

8. Refill with the specified lubricant.

If the chatteris still evident after200 miles of operation, removeandoverhaul the "Directed Power" differential.

The pulling power of each rearwheel should be tested separately.Place one wheel on good tractionsuch as dry cement and the other

required to apply the clutch at thepoor traction wheel. Now, the carshould move. Turn the car aroundandtest the oppositewheel. If either

AXLE WILL NOT DRIVEWITH POOR TRACTION AT

wheel on ice, snow, mud, gravel, orgrease.Try to drive the car eitherforward or backward. To avoid

wheel continues to spin even withthe light brake application, removeand overhaul the differential.

ONE WHEEL "break-away" of the good traction Do not test the "Directed Power"DIRECTED POWER ONLY wheel, apply the throttle lightly. If

thecar doesnot move andthe poortraction wheel spins, the parkingbrake should be applied to causea

differential while one wheel is ona jack. The unit could cause thecarto jump off thejack. This couldalso occur during "on car" rear

slight drag. This light brake applica-tion should provide the resistance

wheel balancing. Wheels should,therefore,bebalancedoff the car.

PART 4-I-GENERAL AXLE SERVICE 4-3

case and install them behind thebearingon the ring gear side of thecase.

PINION BEARING PRELOAD

Any load applied to the pinionexerts a great amount of end thruston the pinion shaft. On pull enginedriving rearwheels,the pin ion tendsto "walk" away from the ring gear,and the rearbearingtakes the thrustFig. 1. On coast rear wheelsdriving engine, the pinion tends to"walk" toward the ring gear, andthefront bearing takes the thrust. Ifthis end-play or "walk" were allowed, pinion and ring gear toothcontact would change every timethe end thrust on the pinionchanged. The pinion, therefore,must he held firmly in one placezero end play to maintain correct tooth contact.

Any changein the pinion locatingshim pack requires a correspondingchangein the bearing preload shimpack Fig. 1. The bearingcups arefixed in the housing and the conesare fixed to the pinion shaft; therefore, if the rear bearingcup positionwere changedby addingor removingshims, not only would the pinionshaft move in or out, but the conesmoving with the shaft would moveinto or out of their cups to increaseor decrease tension. The preloadshim packmust be changedto compensatefor this change of bearingcone tension against the cups.

For example, if a 0.002 inch shim

a TOE CONTACTTO CORRECT-INCREASE BACKLASH,MOVE RING GEAR AWAY FROM PINION

Ic HEEL CONTACTTO CORRECT-DECREASE BACKLASH,MOVE RING GEAR TOWARD PINION

e CONTACT AT BASE OF TOOTHTO CORRECT-MOVE PINION AWAYFROM RING GEAR, THEN ESTABLISHCORRECT BACKLASH.

NCTE Contact patterns to, ct, d and e indicate Incorrect placement of shims and will result in noise and gear foilure.Pattern b shows Correct contact pattern. The above ring geor tooth contact patterns would be mode under Loadconditions only actual operation. Do ,,ot attempt to check a new installation for correct contact under No Load cond,tior,s. TOOTH CONTACT WILL BE CORRECT AS SHOWN AT B IF SHIMS HAVE BEEN PROPERLY INSTAUED.

059

FIG. i-Pinion and Ring Gear Tooth Contact Adjustments

B CORRECT CONTACT

d CONTACT AT EDGE OF TOOTHTO CORRECT-MOVE PINION INTOWARD RING GEAR, THEN ESTABLISHCORRECT BACKLASH.

FIG. 2-Tooth Contact Pattern Check E14 17-A

GROUP 4-REAR AXLE

were removed from the locatingshim packto move the pinion 0.002inch farther away from the ringgear, the rear bearing cup wouldmove closer to the front bearingcupby 0.002 inch. As the pinion shaftand rear bearing cone shifted withthe rearbearingcup, the front bearing conewould move0.002 inch outof its cup thus decreasingpreload.A 0.002-inch shim, therefore,mustbe removedfrom the preloadshimpack also so that the front bearingcone can movethe 0.002 inch backinto its cup to restore the originalpreload.

Similarly, if a 0.002-inch shimwere added to the locating shimpack to move the pinion 0.002 inchcloserto the ring gear, the rearbearing cup would move farther awayfrom the front bearingcup by 0.002inch. As the pinion shaft and rearbearing cone shifted rearward withthe rear bearingcup, the front bearing cone would move 0.002 inchfarther into its cup thus increasingtension. A 0.002-inch shim, therefore, must be added to the preloadshim packalsoso that the frontbearing cone will move the 0.002inch out of its cup to relieve the

tension and restoreoriginal preload.

DETERMINING THE SHIMPACKS

To makeany of the foregoingadjustments,the differential case,drivepinion, andpinion bearingswill haveto be removedfrom the housing asoutlined under "Disassembly" inPart 4-2. The correct thickness forthe four shim packs shown in Fig.1 can then be determinedby following the "Installation of Pinion, Bearings, and Differential Case" procedure outlined under "Assembly" inPart 4-2.

U CLEANINGAND INSPECTION

INSPECTION BEFOREDISASSEMBLY OF CARRIER

The differential carrier should beinspected before any parts are removed from it. The checks givenin the following procedurecan helpto find the causeof the trouble andto determinethe correctionsneeded.

1. Placethe housing assemblyin aholding fixture, tool 4005 as shownin Fig. 3.

2. Thoroughly clean the housingandcoverassembly,andthen removethe cover-to-housingbolts.

3. Using a suitable solvent, cleanthe lubricantfrom the internalworking parts and visually inspect theparts for wear or damage. Rotatethe gearsto seeif thereis any roughness which would indicate defectivebearingsor chippedgears.Checkthegear teeth for scoring or signs ofabnormalwear.

4. Set up a dial indicator Fig. 4,and check the backlashbetweenthedrive gearand pinion at four equallyspacedpoints aroundthe drive gear.

FIG. 3-Axle HousingAssenbIy in Holding Fixture

Backlashshould be within specifications.

5. If no obvious defect is noted,check the geartooth contact. Paintthe gear teeth with suitable gearmarking compound,such as a pastemade with dry red lead and oil. Amixture that is too wet will run andsmear. Too dry a mixture cannotbe pressed out from between theteeth. Wrap a cloth or rope aroundthe drive pinion flange to act as abrake. Rotate the ring gear backandforth use a box wrench on thering gear attachingbolts for a leveruntil a clear tooth contactpattern isobtained.

Certaintypesof gear toothcontactpatternson the drive gear indicateincorrect adjustment.Noise causedby incorrect adjustment can oftenbecorrectedby readjustingthe gearsas outlined in Section 2. Typicalpatterns and the necessarycorrections are shown in Fig. 2.

6. Gear tooth runout can sometimes be detectedby an erratic pattern on the teeth. However, a dialindicator should be used to measurethe runout of the back face of the

ring gear,as shown in Fig. 5. Withthe indicator at zero setting, revolvethe ring gear one revolution andnote the total runout. If the totalindicator reading exceedsspecifications, it may indicate a loose ringgear or a sprung differential caseor housing. Disassemblethe carrierand replace necessaryparts a indicatedin Part 4-2, Section 4.

7. Check the clearance betweenthe side bearing caps and bearingcups. If the clearanceis 0.003 inchor more, it could indicate that thebearing is turning in the housing.Visually check to determine thatthe cap is properlyseatedagainstitsmating surface on the housing. Ifthe clearanceexists with the capproperly seatedand thebolts properly torqued, check the mating surfaces of the housing and caps fordamage.Replacethe housingand/orcaps as necessary.

INSPECTION AFTERDISASSEMBLY

Thoroughly clean all parts Fig.6 except wheel bearings in clean sol

4-4 060

Tool -4201-C

FIG. 5-Ring Gear Runout Check

FIG. 4-Backlash Check

4-5,PART 4-1--GENERAL AXLE SERVICE

vent, and dry them with compressedair. Inspect the parts for defects.Clean the inside of the carrier beforerebuilding it. When a scored gearset is replaced, the axle housingshould be washedthoroughly andsteamcleaned.This should he doneonly after the axle shafts, wheelhearings,andsealsare removedfromthe housing. Inspectindividual partsas outlined below.

GEARS*

Examinethe pinion and ring gearteeth for scoring or excessivewear.The patterntaken beforedisassemblyshould be helpful in judging if gearscan he re-used. Worn gearscannothe rebuilt to correct a noisy condition. Gear scoring is the result ofexcessive loading or the use of incorrect lubricant. Scored gears cannot he re-used.

Examinethe teeth and thrust surfaces of the differential gears. Wearof splines, thrust surfaces, or thrustwasherscan contribute to excessivedrive line backlash.

BEARING CUPS AND CONEAND ROLLER ASSEMBLIES

Check the hearing cups for rings,scores, galling, or excessively worn

wear patterns. Pinion cups must besolidly seated. Check by attemptingto insert a 0.0015-inch feeler between thesecups and the bottoms oftheir bores.

When operated in the cups, coneand rtller assembliesmust turn without roughness. Examine the rollerendsfor wear. Stepwearon the rollerends indicates the hearings were notpreloaded properly or the rctllerswere slightly misaligned.

If inspection reveals either a defective cup or a defective cone androlier assemblyboth parts should bereplaced to avoid early failure.

U-JOINT FLANGE

Re sure that the earsof the flangehave not been damagedin removingthe drive shaft or in removing theflange from the axle. The end of theflange that contactsthe oil slinger aswell as the flat surface of the pinionnut counterhore must he smooth.Polish these surfaces if necessary.Roughness aggravates backlashnoises, and causes wear of theslinger and pinion nut with a result-all loss in pinion hearing prcload.

CARRIER HOUSING

Make sure that the dillercrttial

hearing bores are smooth and thatthe threadedholes are not damaged.Remove any nicks or burrs from themating surfaces of the carrier housing.

DIFFERENTIAL CASE

Make sure that the hubs wherethe bearings mount are smooth.Carefully examine the differentialcase bearing shoulders,which mayhave been damagedwhen the bearings were removed. The bearing assemblies will fail if they do not seatfirmly against the shoulders.Checkthe fit free rotation of the differential side gears in their counter-bores.

DIRECTED POWERDIFFERENTIAL

Inspect all parts, particularly thespring plates and discs, the clutchplates and discs, the plate surfacesof the casehalves, and the side gearrings for excessivewear or scoringPart 4-2, Fig. 23. Replace anyparts that are worn or damaged.

If one or more of the plates ordiscs in a clutch pack on one ofthe sidesneedreplacing,theentirestack of plates and discs on thatside should be replaced.

061

TI-tRUST

FIG. 6-Rear Axle Disassembled

NUTE1390-A

4-6 062

PARTREAR AXLE

Section Page Section Page1 Description and Operation 4-6 3 Removal and Installation 4-102 In-Car Adjustment and Repair 4-8 4 Major Repair Operations 4-1 1

0 DESCRIPTION AND OPERATION

CONVENTIONAL AXLE

DESCRIPTION

The rear axle is of the integralcarrier-housing,hypoid gear type, inwhich the centerline of the drivepinion is mounted below the centerline of the ring gear Fig? 1.

The integral pinion gear and shaftis supportedby two opposedtaperedroller bearings which are assembled

in the forward side of the carrierhousing. Pinion locating shims, installed between the rear bearingcup and the cup seat, control thedrive pinion depth adjustment.Thepinion bearing preload is controlledby shims located between the pinion front bearing and the shoulderon the drive pinion shaft.

The differential case assembly issupported by two opposed taperedroller side bearings and cups,

which are retained in the housingby removablecaps. Shims, installedbetweeneach differential side bearing and the shoulder on the case,perform three functions: they takeup the differential case side clearance; they adjust the backlash between ring gear and pinion; andthey establish differential side bearing preload.

A cover on the rear of the carrierhousing provides accessfor inspec

RING GEAR

PINION

REAR WHEEl. BEARING

DRIVE

TPINION

TAPERED BEARINGSPINION

FIG. i-Rear Axle Assembly

£1410-A

063 PART 4-2-REAR AXLE 4-7

tion, removal and installation of thedifferential assemblyand drive pinion. A metal tag, stampedwith thegear ratio plus the number of teethon the ring gear and pinion, is secured to the housing by one of thecover bolts.

Cars equipped with "DirectedPower" differential assemblies willhave an additional metal tag identification attached to one of thecover bolts.

Ball bearing assemblies rearwheel bearings are pressed ontothe outer ends of the axle shaftsandset in theouterendsof the axle housing. Thesebearingssupport the semi-floating axle shaftsat the outer ends.The inner ends of the shafts splineto the differential side gears. Bearingretainer plates hold the shafts in thehousing. The axle shafts are equalin length and are, therefore, inter-changeable.

OPERATION

The rear axle drive pinion receivesits power from the engine throughthe transmission and drive shaft.The pinion gear rotates the differential case through engagementwiththe drive gear, which is bolted tothe case outer flange. Inside thecase, two different pinion gears aremounted on the differential pinionshaft which is pinned to the case.These pinion gears are engagedwiththe side gears, to which the axleshafts are splined. Therefore, as thedifferential caseturns, it rotates theaxle shafts and rear wheels. Whenit is necessary for one wheel andaxle shaft to rotate faster than theother, the faster turning side gearcauses the pinions to roll on theslower turning side gear to allowdifferential action between the twoaxle shafts.

‘DIRECTED POWER" AXLE

DESCRIPTION

The "Directed Power" axle is thesame as the conventional axle withrespectto the ring gear and pinionthe bearings, the housing, and theaxle shafts. The difference is in thedifferential assembly.

has an identical clutch assemblywhich connectsone of the axle shaftsdirectly to the case half as drivingconditions demand. Each clutchpack consistsof five steel plates setbetween the case and the side gearring. The two outer plates and thecenter plate are locked to the differential case half by external lugs.The remaining two plates discshave internal spline teeth which lockto the splined huh on the side gearring. The external lug plate and thespline discplate that are locatednextto the case half are spring plates,which are installed with the convexbowed side against the case. Theside gear ring is internally splinedto the axle shaft and acts as a pressure plate against the clutch pack.

Unlike the single pinion shaft ofthe conventional unit, the two pinion mate shafts are not rigidly attached to the differential case, norare they attachedto each other. Atboth ends of the mate shafts, thereare two flat surfacesso arrangedthatthey form a "V" which mates withcorresponding"V" shaped surfacesramps cut in the shaftopeningsofthe differential case.

OPERATION

The "Directed Power" axle has apower flow identical to the coniventional rear axle, plus a more directpowerflow which automaticallytakeseffect as driving conditions demand.This more direct power flow is fromthe differential case to each axleshaft through clutches.

The mate shafts are assembledinthe case with enough clearance sothat when the case tries to rotatethe mate shafts and the mate shaftsresist rotation, they will be forced tohear against one side of their "V"ramps. Since the two "V" rampsof one mate shaft point in a direction opposite to that of the two

rampsof the other mate shaft.the two shafts with their pinionswill be forced apart as they resistrotation. This mate shaft movementcompressesthe clutch pack throughthe pinion gearsand side gear rings.

When the differential caserotatesin the opposite direction, the mateshafts will be forced to bearagainst

the oppositeside of their "V" rampsand will again be forced apart toapplyagainsttheclutch packs.Therefore, sincethe rampsare "V" shaped,the clutches will apply during eitherforward or reverse operation. Likewise, the clutcheswill apply whetherthe power flow is from the differential caseto the axle shafts, or fromthe axle shaft to the differential case.

The amount of compression onthe clutch plates will be proportionate to the load applied to the differential case and the resistancetoturning offered by each mate shaft.For example, if the car is drivenstraight ahead and the traction orload on both wheels is equal, bothmateshaftswill give equal resistanceto the rotating differential case andwill thus bearagainsttheir respectiveramps with equal force. This equalmovement of the mate shafts willcause them to exert equal pressureagainst both right and left-handclutch packs. Both axle shafts will,therefore, be locked directly to thecase with equal force.

Clutch application prevents momentary spinning of one of thewheels when it leaves the road becauseof a bump, or encounterspoortraction becauseof a slippery road.Under these conditions, even thoughthe traction load is relieved on theone wheel, the acceleration load issimultaneously applied to the differential case as the engine triesto spin the wheel.

When the rear axle is in a turn,the appropriateclutch releasesautomatically to allow normal differential operation as required. In thestraight ahead position, the differential case is driving both wheelsand thus applies an equal loadagainst both mateshafts. Since bothmate shafts offer resistanceto thisload, both clutches are applied. Ona turn, however, the outside wheelturns faster than the inside wheel.The outside wheel, instead of beingdriven by the case, now tends todrive the case.With the power thusrelieved,the differential casereleasesits load against the outside wheelmate shaft which, in turn, releasesits pressure against the outsidewheel clutch pack. With the clutchreleased, normal differential actionwill take effect.

The differential is of a two-piececasedesign Fig. 23. Eachcasehalf

4-8 GROUP 4-REAR AXLE

fl IN-CAR ADJUSTMENT AND REPAIRREAR AXLE SHAFT, WHEELBEARING, AND OIL SEALREPLACEMENT

The rear axle shafts, wheel bearings and oil seals can be replacedwithout removing the axle assemblyfrom the car.

1. Removethewheel andtire fromthe brake drum.

2. Remove the Tinnerman nutsthat securethe brake drum to theaxle shaft flange, and then removethe drum from the flange.

3. Working through the hole provided in the axle shaft flange, remove the nuts that securethe wheelbearingretainer to the axle housingFig. 2.

4. Pull the axle shaft assemblyoutof the axle housing Fig. 3. Installone nut to hold the brake backingplate in place after the axle shaftis removed.

5. Check the bearing for smoothfree rotation. Check the axle shaftsplines for burrs, wear or damage.Replaceworn or damaged parts.

6. If the rear wheel bearing is tobe replaced,loosenthe inner retainerring by nicking it deeply with a coldchisel in several places Fig. 4. Itwill then slide off easily.

7. Pressthe bearing from the axleshaft with the tool shown in Fig. 5.

8. Inspect the machined surfaceof the axle shaft and the axle housing for rough spots or other irregularities which would affect the sealing action of the oil seal. Carefullyremove any burrs or rough spots.

9. Lightly coat the wheel bearingboreswith ball joint grease.

10. Place the retainer plate on theaxle shaft, and press the wheel bearing on the shaft with tool 4621-A asshownin Fig. 6.

FIG. 2-Wheel Bearing RetainerPlate Removal or Installation

Too!-.- 4235-C

Tool-TSOTIOOC

£1032-C

FIG. 3-Axle Shaft Removal

11. Presson a new wheel bearingretainer ring with tool 4621-A. Donot attempt to press on both thewheel bearing and retainer ringat the same time.

12. Whenever a rear axle shaftis removed, the oil seal must bereplaced. Remove the seal with thetool shown in Fig. 13.

13. Soak new seals in SAE 10 oilfor ½ hour before use. Install thenew sealwith tool 4245-B as shownin Fig. 14. Wipe a small amountofan oil resistantsealer on the outeredgeof the seal beforeit is installed.Do not put sealer on the sealinglip. Install the seal with its sealinglips towardthe axle housing.

14. Place a new gasket on eachside of the brake backing plate,andthen carefully slide the axle shaftinto the housing so that the roughforging of the shaft will not damagethe oil seal. Start the axle splinesinto the side gear, and push theshaft in until the bearingbottoms inthe housing.

El 357-A

064

Removal

15. Install the bearing retainerplate and the nuts that secure iLTorque the nuts to specificationFig. 2.

16. Install the brakedrum arid thedrum retaining nuts.

17. Install the wheel and tire onthe drum.

DRIVE PINION OIL SEALREPLACEMENT

The drive pinion oil seal can bereplaced without removing the rearaxle assemblyfrom the car. Soakthenew seal in SAE 10 oil for ½ hourbefore use.

1. Raisethe car on a hoist, or therear of the car on a suitable jack.

FIG. 6-Rear Wheel BearingInstallation

Tool -.1225-DA

412-A

FIG. 5-Rear Wheel Bearing

E141 1-A

FIG. 4-Wheel Bearing RetainerRing Removal

PART 4-2-REAR AXLE

11I

FIG. i-Pinion Shaft Nut Removalor Installation-Axle in Car

2. Remove the retaining bolts andwashers,and then removethebumper, bracket, and spacers from thehousing.

3. To maintain proper drive linebalance, the drive shaft should heinstalled in its original position. Toinsure proper installation at assembly, make scribe marks on the driveshaft rear end yoke and the axleU-joint flange Fig. 12. Also, makechalk markson the drive shaft frontslip yoke and the transmission extension housing.

4. Disconn..ectthe rear end of thedrive shaft by removing the U-jointbearing caps that hold the spider tothe axle U-joint flange. Be careful

FIG. 9-Pinion Shaft Oil SealRemoval

to avoid dropping the loose universal joint bearing cups. Slide thedrive shaft forward, and removeit from the transmission extensionhousing. install tool 7657-J in thetransmissionhousing to preventleakage.

5. While holding the flange withtool 4851-K, removethe pinion shaftnut Fig. 7.

6. Cleanthecarrier-housingaroundthe oil seal. Place a drain pan underthe seal, or raise the front of thecaf higher than the rear.

7.. The U-joint flange removingtool 4858-D must he modified to fitthe larger 1961-64 U-joint flange.This can be easily accomplishedbydrilling two additional 3/s-inch diameter holes through the flat plateportions of the tool to correspondtothe opposing diagonal holes in theflange. See Fig. 8 for drilling di-mensions.

8. Usereworkedtool 4858-Dto remove the U-joint flange from thedrive pinion, asshown in Fig. 8. Remove the dust deflector if damaged.

9. Remove the pinion shaft sealassembly using tool 1l75-AE, asshown in Fig. 9.

10. Inspectthe parts. Replaceanythat are worn or damaged.

11. Clean the pinion oil seal seat.Coat the outer edge of the new sealwith a small amount of oil resistantsealer. Do not put sealer on thesealing lip. Drive the seal into thehousing, using the tool shown inFig. 10.

12. Start a new dust deflectoroverthe U-joint flange and drive the deflector into position on the flangeas shown in Fig. 38.

13. Coat the inside of the U-jointflange with specified lubricant, andpress the flange into position withtool 4858-B as shown in Fig. 11.

14. Remove the flange installingtool, and install the pinion shaftwasher and nut. While holding theflange with the tool shown in Fig.7, torque the pinion shaft nut tospecifications.

15. Removetool 7657-I from thetransmission extension housing. Install the drive shaft to the transmis

END YOKE . . .- i-.. -

FLANGE -- /

DRIVE SHAFT

:-- -

..."i. r’- ‘ -. - SCRIBE MARKS

‘BEARING CAP E1418-A

FIG. l2-Drive Shaft-to-AxleU-Joint Flange Connection

065 4-9

TooI-4858- B

llFIG. il-U-Joint FlangeInstallation on Car

TooI.-4676

FIG. 8-U-joint Flange Removal-Axle in Car

FIG. lO-Pinion Shaft Oil SealInstallation

4-10 GROUP 4-REAR AXLE 066

sion, so that the chalk marks on flange during the removal procedure 17. Install the spacers, bumperthe slip yoke and the transmission Fig. 12. Connect the shaft to the bracket, and bumper on the housextension housing are aligned, flange by installing the U-joint bear- ing, and secure with the retaining

16. Position the drive shaft to the ing caps that hold the spider to the bolts and lockwashers.axle U-joint flange, aligning the flange. Install the bearing cap re- 18. Check the lubricant level, andscribemarksmadeon thedrive shaft taming bolts and torqueto specifica- add whatever amount of specifiedrear endyoke and the axle U-joint tions. lubricantis necessary.Lower the car.

U REMOVAL AND INSTALLATION

REAR AXLE HOUSINGASSEMBLY

REMOVAL

1. Raisethecar on a hoist or therear of the car on a suitable jack.Place a jack standunder each side,at the rear of the spring hangers.

2. Lower the car until the weightis supportedby the jack stands.

3. Drain the axle housing bylooseningthe rearcoverbolts.

4. Removethe retaining bolts andwashers, and remove the bumper,bracketand spacersfrom the housing.

5. To maintain proper drive linebalance, the drive shaft should beinstalled in its original position. Toinsure proper installation at assembly, make scribe marks on the driveshaft rear end yoke and the axleU-joint flange Fig. 12. Also, makechalk marks on the drive shaft frontslip yoke and the transmission extension housing.

6. Disconnect the rear end of thedrive shaft by removing the twoU-joint bearing caps that hold thespider to the axle U-joint flange. Becareful to avoid dropping the looseuniversal joint bearing cups. Slidethe drive shaft forward, and removeit from the transmission extensionhousing. Install tool 7657-J in thetransmissionhousing to prevent leakage.

7. Removethe two rearwheel andtire assemblies.

8. Remove the Tinnerman nutsthat secureeach brake drum to theaxle shaft flange, and then removethe drum from the flange.

9. Working through the hole provided in each axle shaft flange Fig.2, remove the nuts that securethewheel hearing retainer to the axlehousing. Pull each axle shaft andhearing assembly out of the axlehousing using the tool shown inFig. 3.

10. Removeboth wheel hearingoilseals Fig. 13.

11. Disconnectthe rear shock ah

14.platesbody.lines.

sorbersfrom the mounting studs onthe axle housing.

12. Removethe brake line-to-axlehousing retaining clips and the retaining bolt holding the junctionblock to the axle housing.

13. Remove the parking brakecable retainersfrom the U-bolts.

Remove the brake backingand wire them to the underDo not disconnectthe brake

15. Remove the axle U-bolt retaining nuts.

16. Removethe U-bolts, the springcenter mounting, insulator retainersand the insulators.

17. Remove the axle housing assembly.

INSTALLATION

1. Clean the axle housing andshafts using keroseneand swabs.Toavoid contamination of the greasein the sealedball bearings, do notallow any quantity of solvent directly on the wheel bearings.

If the axle housing is being replaced, disassemblethe drive pinionand differential case assemblyfromthe old housing and assemblethemin the replacement housing as desscribed in Part 2-2, Section 4. Remove the bolts that retain the brakebacking plate and wheel bearing retainer from the old housing flanges.

Positionthe bolts in the replacementhousing flanges.

2. Soak two new rear wheel bearing oil seals in SAE 10 oil for ½hour before installation. Wipe asmall amount of an oil resistantsealeron the outer edge of eachsealbeforeit is installed.Do not putsealer on the sealing lip. Installthe oil seals in the ends of the rearaxle housing with the sealing liptoward the housing Fig. 14.

3. Position the rear axle housingon the rear springs. Position thespring center mounting upper andlower insulators and retainers, theshim wedge,and the U-bolts.

4. Install the U-bolt retaining nutsand torque to specifications. Makesure that the spring lower insulatorcontacts the upper retainer.

5. Install the brake backing plateswith new gasketson the axle housing flanges.

6. Connect the parking brakecablesto the U-bolts with the hooktype retainers.

7. Install the junction block onthe axle housing and secure withthe retainingbolt. Positionthe brakeline to the axle housing, and securewith the retaining clips.

8. Raisethe rear axle housing andsprings enough to allow connectingthe rear shock absorbers to the

FIG. 14-Rear Wheel BearingOil Seal Installation

FIG. 13-Rear Wheel BearingOil Seal Removal

E14 14-A

PART 4-2-REAR AXLE

mounting studs on the axle housing.Install the washersand nuts on thestuds and torque to specifications.

9. Install the two axle shaft assemblies in the axle housing. Carefullyslide eachaxle shaft into the housingso that the rough forging of the shaftwill not damagethe oil seal. Startthe axle splines into the side gear,and push the shaft in until the bearing bottoms in the housing.

10. Install the hearing retainerplatesand the nuts that securethem.Torque the nuts to specificationsFig. 2.

ii. Install the brake drums andthe Tinnerman drum retainingnuts.

12. Install the wheel and tire assemblies on the drums.

13. Remove tool 7657-i from thetransmission extension housing. Install the drive shaft to the transrnission, so that the chalk marks onthe slip yoke and the transmissionextension housing are aligned.

14. Position the drive shaft on theaxle U-joint flange, aligning thescribe marks madeon the drive shaftrear end yoke and the axle U-joint

flange during the removal procedureFig. 12. Connectthe shaft to theflange by installing the U-joint bearing caps that hold the spider to theflange. Install the bearing cap retaining bolts, andtorqueto specifications.

15. Install the spacers, bumperbracket, andbumperon the housingand securewith the retaining boltsand lock washers.

16. Fill the rear axle with specifiedlubricant. Remove the jack standsand lower the car.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

Mount the axle housing in theholding fixture tool 4005 Fig. 3,Part4-1, and perform the "Inspection Before Disassemblyof Carrier"as explained in Part 4-1, Section 3.Then disassemblethe carrier as outlined in the following procedures.

REMOVAL OFDIFFERENTIAL CASE,PINION, AND BEARINGS

1. Removethe attachingbolts andthe differential side bearing capsFig. 15. Note the identificationmarksstampedon the bearingsandhousing for proper assembly.

2. Install the carrier spreader sothat the dowels on the tool enterthe openings in the housing Fig.16. Tighten the hold-down clampscrews.3. Release the wing nuts on the

holding fixture, and spread the carrier housing by rotating the turn-buckle on the spreadingtool. Spread

with its respective bearing forproper assembly.

4. Removethe spreadertool, andturn the housing in the holding fixture so that the drive pinion shaftis in a vertical position. Removethe nut from the pinion shaft asshown in Fig. 17.

5. Removethe U-joint flange fromthe pinion shaft using the modifiedtool shown in Fig. 8.

6. Turn the housing in the holding fixture so that the drive pinionis in a horizontal position, and thenremovethe pinion shaft oil seal withthe tool shown in Fig. 9. Lift outthe gasket and slinger.

7. Turn tool 4201 onto the pinionshaft threads and drive against thetool until the pinion shaft and rearbearing are loosenedfrom the housing Fig. 18. Removethe tool fromthe pinion shaft, withdraw the pinion and rear bearing assemblyfromthe rear of the housing, and removethe front bearing and preload shimsfrom the front of the housing. Tieall the shims together for assembly. Record the thickness of theshims in casethey should be lost.

067 4-11

CLAMP SCREW Carrier Spreader 4000-C- *DOWEL

FIG. l6-Spreading CarrierHousingthe housing until the differential assembly can be forced out with a prybar or long screwdriver. Do notspread the housing more than0.020 inch to remove the differential. Loosen the spreader turn-buckle immediately after liftingout the differential assembly toprevent springing the housing.

Placeeachdifferential bearingcupBEARING CAP LOCATING MARKS

BOTH LETtERS HORIZONTAL

E1352-A

FIG. 15-Differential BearingCap Locating Marks

1Tool- 4201

FIG. li-Pinion Shaft Nut FIG. l8-Pinion and BearingAssembly Removal

E1383-A

Removal

4-12

Cup Removal

8. Removethe pinion rear bearingcup asshownin Fig. 19. Removethepinion locating shims and tie themtogether. Record the thickness ofthe shims in casethey should belost.

9. With the forward end of thehousingup, removethe pinion frontbearing cup Fig. 20.

10. If necessary,the pinion rearbearingmay be pressedoff the drivepinion. Usetool 4621-BA.

If inspection before disassemblyshowedexcessivering gear runout,do not proceed to the disassemblyof the differential case at thispoint. First, determine which partsshould be replaceddifferential case,bearings,or ring gear as explainedunder"PartsRepairor Replacement"in this section.

GROUP 4-REAR AXLE

CONVENTIONALDIFFERENTIAL CASEDISASSEMBLY

1. Position the differential case inthe holding fixture, locatethe fingersof the puller tool in the cast recessesof the differential case, and pull oneof the differential side bearingsFig.21. Tie the shims together forassembly and label "ring gearside" or "pinion side." Record thethickness of the shims in casetheyshould be lost.

- 2. Reverse the differential case inthe holding fixture, and remove theseconcLside bearing and shim packas directed in step 1.

3. Remove the ring gear-to-differential case bolts, and remove thegear from the case.

4. With apunch,drive out thedifferential pinion shaft lock pin. Remove the differential pinion shaft,pinions, andthrust washers.Removethe side gears and thrust washers.Referto Fig. 6, Part 4-1.

"DIRECTED POWER"DIFFERENTIAL CASEDISASSEMBLY

1. Mark the differential casehalves for correct alignment at assembly. Seethe "Case Markings" inFig. 22.

2. Mark one end of each mateshaft exactlyas shownin Fig. 22 sothat the "V" shapedend of eachshaftwill matchthe same"V" rampin the case when the unit is assembled.

068

FIG. 22-Alignment Marks forProper Assembly

3. Place the assembly in holdingfixture 4205-B shown in Fig. 21. Ifthe side bearings and/or ring geardo not require replacement, skipsteps4 and/or 5 and proceed withstep 6.

4. Using the puller tool shown inFig. 21, removeoneof thedifferential side bearings. Tie the shimstogether for assembly, and label"Ring Gear Side" or "Pinion Side."Record the thickness of the shimsin case they should be lost. Reversethe differential case in the fixture, and repeat the procedure forthe oppositeside bearingand shims.

5. Remove the ring gear-to-differential case bolts and remove thegear from the case.

6. Loosen but do not remove theeight bolts that hold the differential case halves together. Removethe differential casefrom theholdingfixture andset the caseon the benchwith the ring gear half of the casedown as in Fig. 22.

7. Removethe caseattaching.’boltsand the coverhalf of the case. Remove the upper clutch plates anddiscs, side gear ring, side gear, andupper mate shaft and pinions Fig.23. Keepthesepartswith thecoverhalf of the case so that they willbe installed in their original positions during assembly.

8. Removethe corresponding partsfrom the ring gear half of the caseFig. 23, and keep the parts withthe ring gearhalf for proper assem

PARTS REPAIR ORREPLACEMENT

Cleanand inspect all the parts asoutlined in Part 4-1, Section 3. Before assemblingthe rear axle, repairor replace all parts as indicatedbythe inspection.

bly.

FIG. l9-Pinion Rear Bearing

"‘TooI-4ó28-B

E1385-A

FIG. 20-Pinion Front BearingCup Removal

FIG. 2l-Differential BearingRemoval

PLATE

SIDL GEARRIN2,

CLU H DISC

PART 4-2-REAR AXLE 4-13

DIFFERENTIALSIDE GEARS

FIG. 23- "Directed Power" Differential- Disassembled

SIDE GEARRING

FRICTION CLUTCH

The principal replacementoperations are covered in the followingprocedures. All other repair or replacementoperations are performedduring "Cleaning and lnspectionPart 4-1, Section 3, or during the"Assembly" procedures in this sec-lion.

DRIVE PINION AND RINGGEAR SET

When replacing a ring gear andpinion, note that the original factoryinstalled pinion locating shim is olthe correct thickness to adjust forindividual variations in both the carrier housing dimension and in theoriginal gear set dimension. Therefore, to select the correct shim thickness for the new gear set to he installed, follow these steps:

1. Measure the thickness of theoriginal pinion locating shim witha micrometer.

2. Note the shim adjustment number on both the old pinion and thenew pinion. Each pinion uear ismarked with an adjustiiien I n unibersuch as the --- I markinu in Hg. 24.

3. Refer to the table in Part 4-3

shown under the new pinion shimadjustmentnumber and in line withthe old pinion number is the amountof change that should be made tothe original shim thickness.

II the old pinion is marked ±4,for example, and the new pinion ismarked -2, the table indicates that

0.006 inch of shim stock should beadded to the original shim pack.

If the original shim pack was lostor if a new axle housing is being installed, substitute a nominal 0.030inch shim for the original, and repeat the foregoing steps for a trialbuild-up. If any further shim changeis necessary, it will be indicated inthe tooth pattern check.

A new ring gear and pinionshould always be installed in an

MATCHED SET IDENTIFICATIONMANUFACTURING -

SYMBOL

44AATHIS FIGURE TO BE USED W1TH CALIBRATIONCHART FOR PINION DEPTH SETTING

F 1387-A

FIG. 24-po and Ring Gear

axle as a matched set never separately. Be sure that the samematching number appears on boththe drive pinion and the ring gear.Note the number "666F" in Fig. 24.

4. Start the rear bearing on thedrive pinion with its taperedend up,then press the bearing on the pinion

069

FRICTION CI

CASERING GEAR FLANGE HALF COVER HALF

E1391-A

. PRESS RAM

WOOD ORFIBER BLOCK

/

_-4621-A

FIG. 25-Pinion Rear BearingInstallation

for the correct amount of shim thickness change. The amount that is Markings

GROUP 4-REAR AXLE

shaft as shown in Fig. 25. Usea 0.0015-inch feeler gauge betweenthe bearing and the pinion gear tobe sure that the bearing is fullyseated.

5. After determining the correctshim thickness and installing therearbearingasexplainedin the foregoing steps, install the new pinionandring gearas outlined under "Assembly."

DIFFERENTIAL CASE,BEARINGS, AND RING GEAR

If the ring gear runout checkbefore disassembly exceeded specifications,the condition may be causedby a warped ring gear, a defectivecase,or by excessivelyworn differential side bearings.

To determinethe causeof excessive runout proceed as follows:

1. Removethe ring gear from thecase,andinstall the casebackin thehousing with side bearings and cupsstill installed.

2. Check the runout of the caseflange with a dial indicator. If therunout does not now exceedspecifications, install a new ring gear tothe caseduring assembly.If the run-out still exceedsspecifications, thering gear is true and the trouble isdue to either a defective case orworn bearings.Continue with steps3 through 5.

3. Remove the differential casefrom the carrier housing and remove the side bearings from thecase,using the tool shownin Fig. 21.

4. Pressnew bearingson the casehubs with tool 4222-H, and againinstall the differential case assemblyin the housingwithout the ring gear.

5. Check the case runout againwith the new bearings.If the runoutis now within specifications,the oldbearingswere excessivelyworn. Usenew bearings for assembly. If therunout is still excessive,the case isdefectiveand should be replaced.

SPRING PLATE ASSEMBLED WITH SIDECONVEX SIDE TOWARD CASE GEAR RING

CLUTCH

SPRING DISC ASSEMBLED WITHCONVEX SIDE TOWARD CASE E1393-A

FIG. 26-Positioning of Parts for

ASSEMBLY

CONVENTIONALDIFFERENTIAL CASEASSEMBLY

1. Place a thrust washer overeach pinion and side gear. Assemblethe pinion and side gears in thedifferential case and secure themwith the pinion shaft Fig. 6, Part4-1. Lubricate all differentialparts liberally with axle lubricantduring assembly.

2. Slide the side gears and thrustwashers tightly against the piniongear. Then, using a feeler ribbon,checkthe clearancebetweenthecaseand the thrust washers.If the clearance exceeds0.015 inch, new thrustwashersmust be installed.

3. Align the lock pin hole in thepin ion shaft with the bole in the caseand install the lock pin. Peen thecasemetal over the lock pin.

4. Place the differential case assembly in a holding fixture, tool4205-B. Install the ring gear andsecureit with bolts. Torquethe boltsto specifications.

"DIRECTED POWER"DIFFERENTIALCASE ASSEMBLY

1. Select the side gear ring andthe clutch pack that pertains to thering gear half of the differentialcaseFig. 26. Assembleto the sidegear ring in order: a flat clutchplate with external lugs, a clutchdisc with internal splines, a clutchplate, the spring disc with convexside toward the case, and thespring plate with convex side toward the case.

2. Assemble the remainingclutch

FIG. 2l-Installation of Side GearRing, Discs, and Plates in Case

FIG. 28-Assembly of DifferentialCase Halves

platesanddiscs to the side gearthatpertains to the coverhalf of the case.Follow the same order of assemblyas in the foregoing step.

3. Hold each differential case halfon its side and install the pertinentside gear ring with plates and discsassembled. Make sure that theclutch plate lugs are aligned andthat they enter the slots in the caseFig. 27. The side gear ring willrotate with a slight drag whenproperly seatedin the case.

4. With the ring gearhalf of thecase in an upright position, as inFig. 28, place the proper sidegear on the sidegear ring. Placethelower ring gear half mate shaftand pinions on the side gear ringso that the locating marks on the

FIG. 29-Spline Alignment of SideGear and Side Gear Ring

4-14 070

AXLE SHAFTS MUSTBE INSERTED ALL

THE WAY TOALIGN BOTH

El 396.A

Assembly

PART 4-2-REAR AXLE

mate shaft are aligned with the correspondingmarks on the case. Position the upper cover half mateshaft and pinionswith marksaligned,and set the cover half side gear ontop of the four pinions Fig. 28.

5. While holding the side gear andclutch pack in the cover half of thecase, install the cover half on thering gear half so that the locatingmarks on each differential casehalfare in alignment Fig. 28.

6. Install the differential caseboltsand turn them in a few threads.

7. Align the splines of the sidegears and side gear rings by inserting the axle shaft on each side ofthe case.Be sure the shaft goes allthe way in to engageboth side gearand side gear ring splines Fig.29.

8. With the axle shafts in position, torque the differential casebolts evenly and alternately to specifications.

9. Remove the axle shafts andcheck for proper assembly. If thedifferential has been properly assembled, each mate shaft shouldbe tight in its ramp; or, if there isclearance between the shaft andthe ramp, the clearance should beequal at all four mate shaft ends.

INSTALLATION OF PINION,BEARINGS, ANDDIFFERENTIAL CASE

1. Before installing the pinion andhearings, measure the differentialeasesideclearanceas outlined in thefollowing steps.

a Turn the axle housing assembly in the fixture so that the

down. Place dummy4205-C on the difhubs, and install the

casein the housing.b Install the bearing caps in

their correct position as indicatedby the identification marks, and install the cap retaining bolts fingertight.

c Set up a dial indicator withits contact point against the backface of the ring gear as shown inFig. 30. Grasp both sides of thering gear firmly as shown, andwith a steady pressuremove the entire differential assembly in one direction to the limit of its travel.Adjust the indicator to zero.

d in the same manner, movethe differential assemblyas far as itwill go in the opposite direction.Note the reading on the dial indicator. This reading indicates theamount of shims neededbehind thedifferential side bearings to take upihe total clearance between thehearing caps and the case. Recordthis reading for use later in theassembly procedure.

e Remove the differential casefrom the housing, and remove thedial indicator and dummy bearings.

2. Install the pinion locating shimpack, and then install the rear bearing cup Fig. 3 I . If the originalring gear and pinion is being installed, use the original shim pack.If a new gear set is being installed,use a corrected shim pack as explained under "Parts Replacementand Repair" in this section.

FIG. 32-Pinion Front BearingCup Installation

3. Turn the front end of the axlehousing up, and install the frontbearing cup Fig. 32.

4. The rear face of the piniongear either new or old should belightly stoned to remove any irregularities or burrs before attempting a pinion gear depthreading.

Turn the housing to a horizontal

E1398-A

071 4-15

FIG. 3l-Pinion Rear BearingCup Installation

front end isbearings toolferential case

-TooI- 4616

E 1419-A

‘TooI-4858-B

FIG. 3O-Measuring DifferentialCase Side Clearance

FIG. 33-Drive Pinion and BearingAssembly Installation

4-16

TooI-.-4858-B

FIG. 34-Measuring PinionBearing Preload

GROUP 4-REAR AXLE

position, andinstall the drive pinionand rear bearing assembly by inserting it from the rear side of thehousing. Install the front bearingwithout preload shims and tool4858-B on the pinion shaft, thenturn the housing to an upright position. Draw these parts together inthe housing by turning the nut onthe tool Fig. 33.

5. Tighten the nut on tool 4858-Buntil the torque required to rotatethe drive pinion in the housing is15 in-lbs as shown on the torqueindicator Fig. 34.

6. To verify the selection of thepinion locating shim, measurethepinion depth as outlined in the following steps:

a Check the micrometer accuracy of the pinion depth gaugetool4020-B. The zero setting on the

barrel should coincide with the 1-inch mark on the thimble Fig. 35.If the micrometeradjustmentis out0.003 inch or more,loosen the Allenscrewand turn the barrel until thezero mark reachesthe 1-inch markon the thimble.When the adjustmentis set, tighten the Allen screw. Forerrors smaller than 0.003 inch turnthe barrel with the spannerwrenchuntil the error is corrected.

b Remove the outer lock ringsfrom the gauge shaft Fig. 35.

Position the aligning bushings asE1400-A shown in the insert in Fig. 36.

c Install the gauge shaft andmicrometerassemblyin the housingas shownin Fig. 36. Install the bear-

ing capsand bolts. Torquethe boltsto specifications. Attach the anvilclamp assembly to the differentialhousing.The anvil clampshouldbepositioned, as shown, with the embossed letters facing downward.Place the anvil block on the pinion,as shown. Tighten the clampingscrew against the anvil block.

d Refer to the calibration chartin Table 1 to determinethe correctshim thickness for the pinion thatis installed. Check the pinion marking Fig. 24. The micrometerreading shown in the calibrationchart under the pinion marking ofthe pinion being used indicatesthecorrect shim thickness.

072

j

Torque Indicator-4209

FIG. 36-Measuring Pinion Depth

MICROMETER ASSEMBLY

FIG. 35-Pinion Depth GaugeAdjustment

073

TABLE 1-Calibration Chart Gauge 4020-B

Marking

Pinion*Micrometer

Reading

+10

.865

+9

.866

+8

.867

+7

.868

+6

.869

+5

.870

+4

.871

+3

.872

-F2

.873

+1

.874

0

.875

-1

.876

-2

.877

-3

.878

4 1

.879

*Allowable Tolerance: 0.001 inch.

*TooI4859

DUST DEFLECTOR

COMPANION FLANGE

E1404-A

flange Fig. 38. Start the companion flange over the drive pinionand pressthe flange into position asshown in Fig. 39.

14. Install the washer and locknut on the pinion shaft.While holding the flange with the tool shownin Fig. 17, torque the nut to specifications.

15. Refer back to the readingrecordedin step 1. This readingtakenbeforethe pinion wasinstalled representsthe total clearancebetweenthe differential side bearingcups andthe case.Performthe following stepsfor determiningthe numberof shimsrequired at eachbearing to take up

Tool- 4858-B

I IFIG. 39-U-Joint FlangeInstallation-On Bench

PART 4-2-REAR AXLE 4-17

e Turn the micrometerthimbleuntil the spindle just contacts theanvil of the gauge tool, and takethe micrometer readings. Figs. 35arid 36. If the micrometer readingvaries more than 0.001 inch fromthe specifications in the calibrationchart, the pinion shim pack will require an adjustment.If themicrometer readingobtainedis greaterthanthat specified in the chart, it will benecessaryto remove 0.001 inch inshim stock for each 0.001 inch difference between the micrometerreading and that specified in thechart.

Conversely, if the micrometerreadingis less than that specified inthe chart, it will requirethe installation of 0.001 inch in shim stock foreach 0.001 inch difference betweenthe micrometer reading and thatspecified in the chart.

7. Remove the gaugetool. If themicrometerreadingwas within specifications, proceed with step 9. ifshim adjustment is required, removethe pinion and rear hearing assembly Fig. 18. Then remove thepinion rear bearing cup. Fig. 19.When adding or removing shims,measure each shim separately.Check the bearing bore for burrsor upset metal. If any is present,it must be removed. Make surethat the bearing cup and shimpack are fully seated in the bore.

Install the pinion rear hearing

FIG. 38-U-Joint FlangeDeflector Installation

cupFig. 31, then install the pinionand bearing assemblyin the housingFig. 33.

8. If shims were installed or removed, recheck the pinion depthas outlined in step 6.

9. Establish the pinion bearingpreloadas outlined in the followingsteps.

a With the drive pinion set atits correctdepth, removethe pinionand the pinion front bearing Fig.18.

b Install the drive pinion again,andplacethe bearingpreloadshimsover the forward end of the pinionshaft. If the pinion location shimpack behind the rear bearing Cup

wasnot changed,install theoriginalpreload shim pack. if the pinionlocation shim pack was changed,add or subtract the same numberof shims from the preloadpack aswas added or subtractedfrom thepinion location pack.

c Start the front bearing overthe shaft with its taperedend down.Pressthe bearing on the shaft withthe tool shown in Fig. 33. Usingtool 4858-G, torque the nut on thetool to 200-220ft-lbs Fig. 37.

d With the pinion shaft in avertical position, and using tool4209 as shown in Fig. 34 checkthe torque required to rotate thedrive pinion. Correct preload willbe obtained when the torque required to rotate the pinion is asspecified in Part 4-3.

e If the torque is less than theminimum specified,removethe frontpinion bearing and remove, shims.If the torque exceedsthe maximumspecified, install shims. Install thefront bearingagain, andrecheckthepreload.

10. Place the oil slinger over thedrive pinion and againstthe bearingwith its concaveside up Part 4-1,Fig. 6.

11. Install the oil slinger gasket.12. Start the new seal over the

drive pinion with the sealing edgepointing down; then, using the toolshown in Fig. 10, drive the sealinto position.

13. Start a new seal deflectoroverthe companion flange and drivethe deflector into position on the

FIG. 31-Establishing PinionBearing Preload

GROUP 4-REAR AXLE

the clearanceand establish preloadand backlash:

a Place the dummy bearingstool 4205-C on the differentialhubs, and again install the differential assemblyin the housing thistime with the pinion installed. Install the bearingcapsin their properpositions. Install and tighten the retaining bolts finger tight. Install thedial indicator with the contactpointagainst the back face of the ringgear as shown in Fig. 30. Movethe differential and ring gear assembly tight against the piniongear, andthen set the dial indicatorto zero. Move the differential andring gear assembly away from thepinion as far as possible, and notethe reading.

b This reading indicates theamount of shims necessaryto takeup the clearancebetweenthe bearing cup and the case at the ringgear side of the differential assembly. Subtract this reading from

the previously recorded total reading to obtain the amount of shimsnecessaryto take up the clearancebetween the bearing cup and thecase at the pinion side of the differential. Increase this pinion sideshim pack by an additional 0.015inch in orderto providecorrectbearing preload and backlash.EXAMPLE Fig. 40:Total Clearance

previouslyrecorded . . .0.070 inchLess readingin foregoing

step aAmount of shimsnecessaryto takeup clearanceat ringgear side 0.038inch

Shims necessaryto takeup clearanceatpinion side 0.032 inch

Plus 0.015 inch shims forpreload and backlash..0.015inch

Total amount ofshims atpinion side 0.047inch

16. Remove the dial indicator,bearing caps and differential casefrom the housing. Remove thedummy bearings from the differential case.

17. Install the required numberof shims on the bearingcase.Usingtool 4222-H, pressthe side bearingson the case.

18. Attach the spreadertool tothe housing, as shown in Fig.16, making certain the dowelson the tool enter the openingsin the housing. Spreadthe housingenoughto permit installation of thedifferential case and bearing assembly.Do not spreadthehousingmore than 0.020 inch.

19. Install the bearing,caps intheir respective positions as indicated by the markings on the capsand housing Fig. 15. Removethespreader.Place some sealing compound on the bearing cap bolts.Install and torque the bolts tospecifications.

20. With the dial indicator attachedto the housing, as shown inFig. 4, Part 4-1, check the backlashbetweenthe ring gear andpinion atfour equally spacedpoints aroundthe ring gear.

The backlash should not be lessthan 0.003 inch or exceed 0.008inch, and must not vary more than0.002 inch between the positionschecked.

21. Attach a dial indicator to thedifferential housing as shown inFig. 5, Part 4-1. With the indicatorset at "zero", revolve the ring gearat least one revolution and checkthe total ring gearrunout. The totalindicator reading, or runout, shouldnot exceed0.006 inch.

22. Make a final tooth contactpattern check.

23. Install the gasketand differential cover with the gear identification taB beneathoneof the coverbolts. Torque the bolts to specifications.

24. Refill the axle with specifiedlubricant.

4-18 074

FIG. 40-Differential Bearing Preload and Ring Gear Backlash Adjustment

0Th

P1TSPECIFICATIONS

REAR AXLE

ADJUSTMENTSDescription Inches

Backlash Between Ring Gear and Pinion

Maximum Backlash Variation Between Teeth

0.003-0.008

0.002

0.006

0,030

Maximum Runout of Backface ofRing Gear as Assembled

Nominal Pinion Locating Shim

Available Pinion Locating Shims Inches 0.0025, 0.0035,0.0045, 0.0055, 0.009,

0.011, 0.027, and 0.033

0.003, 0.005,0.010 and 0.030

0.020

Available Pinion BearingPreload Shims

Maximum Carrier Housing Spread -

PINION AND DRIVE GEAR IDENTIFICATION

[ Capacity 4.8 Pints

TORQUE LIMITS Ft-Ibs

Differential Bearing Cap Retaining Bolts 70-90

Ring Gear to Differential Case 50-60

"Directed Power" Differential Case Half Retaining Bolts 35-45

Carrier Rear Cover Retaining Bolts 15-25

Bumper Bracket to Carrier Housing Retaining Bolts 20-30

U-Joint Flange to Drive Pinion Shaft Nut 200-220

Drive Shaft to Axle U-Joint Flange Bearing Cap Bolts 15-20

Minimum Pinion Nut TorqueRequired to Obtain Correct Pinion Bearing Preload 200-220

Rear Spring U-Bolt Nuts 50-60

Rear Wheel Bearing Retainer Plate to Axle Housing 50-65

Rear Shock Absorber to Axle Mounting Stud Nuts 30-40

PINION BEARING PRELOAD ADJUSTMENT

.lescription InchPounds

With Seal New Bearings 22-24

With Seal Old Bearings 12-16

Without Seal New Bearings 18-20

Without Seal Old Bearings 8-12

DRIVE PINION ADJUSTING SHIM THICKNESS CHANGES Inches

New Pinion MarkingPinion .___________ -___________

3 -2 -1 +1 +2 +3 +4

+0.008 +0.007 +0.006 +0.005 +0.004

-

+0.003 +0.002 +0.001 0

+0.007 +0.006 +0.005 +0.004 +0.003 +0,002 +0.001 0 -0.001

+0.006 +0.005 +0.004 - +0.003 +0.002 +0.001 0 -0.001 -0.002

+0.005 +0.004 +0.003 - +0.002 - +0.001 0 -0.001 -0.002 -0.003

0 +0.004 +0,003 +0.002

+0.001 -

+0.001

0

0

-0.001

-0.001 -0.002 -0.003 -0.004

+0,003 +0.002 -0.002 -0.003 -0.004 -0.005

+0.002

+0.001

+0.001-,.---,4

0

0 -0.001 -1.002

-0.003

-0.003 -0.004 -0.005 -0.006

-0.001 -0.002---,-

-0.004 -0.005 -0.006--

-0.007

0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

4-19

LUBRICANT

cc=

0"4