Online Guide and Manuals

Differential has hypoid ring and drive pinion gear set and may have a clutch pack type limited slip unit. Differential housing has removable rear cover. Differential carrier is retained in the sides of the housing by retaining plates, and is supported by roller bearings. Drive pinion gear is supported by roller bearings, and in addition, a long neck housing has a ball bearing supporting the drive pinion at the companion flange. Drive pinion preload is maintained by a collapsible spacer in the short neck housing, and by a spacer and shims in the long neck housing.

The ring and pinion gear set with Klingelnberg tooth design, can be identified by the letter "K" stamped on the head of the drive pinion gear; Gleason teeth are noted by an "H" or "F" stampling. To determine axle ratio, divide number of ring gear teeth by number of drive pinion gear teeth. The number of teeth on ring and drive pinion gears is stamped on forward left side of differential housing.

Remove drive shaft after removing retaining bolts from axle and half shaft flanges. For universal joint or dust boot replacement, use the appropriate procedure below.

Constant Velocity Joint - Remove cover from joint housing, then remove snap ring from end of drive shaft. Remove clamps from boot then press drive shaft from joint. Remove dust boat. To install, reverse removal procedure using sealer on boat-to-joint surfaces and install seal cover after packing joint with suitable grease.

Sliding U-Joint - Drain oil from joint, note position of hose clamps, then remove clamps. Pull off housing and roller caps and coat needle bearings with grease. Remove dust boot from spacer ring and then remove boat and ring. To install, reverse removal procedure, locating hose clamps in original position.

Cross and Roller U-Joint - NOTE - If yoke is bent or twisted, complete drive shaft must be replaced. Remove bearing cup snap rings, then press out bearing cups using suitable arbor press or vise and supporting tools. Remove cross assembly from yoke. To install, hold cross between ears of drive shaft and partially install two bearing cups. Align cross with cups, then using arbor press or vise, press cups into yoke until snap rings can be inserted.

Raise and support vehicle. Remove wheel, loosen castellated nut securing flange to axle shaft, then using a suitable puller, remove flange. Remove drive shaft, then using a soft headed mallet, drive axle shaft inward and out of housing. Drive out bearings and seals, then remove spacer sleeve and shim. To install, reverse removal procedure noting the following: Install inner bearing, then determine distance between outer race of inner and outer gearing. Measure spacer and shim, then install spacer and suitable shim that will obtain a wheel bearing play of .002-.004" (.05-.10 mm). Pack bearings and hub with suitable grease, then using new seals, complete installation procedure.

NOTE - On short neck differential housing, complete disassembly of differential is required for seal replacement. Refer to Drive Pinion Gear Removal and Installation procedures for seal replacement.

Long Neck Differential Housing - Remove propeller shaft, nut retaining companion flange on drive pinion gear, companion flange, and seal. To install, reverse removal procedure insuring seal installed depth is .24" (6 mm) from front of seal to front edge of housing.

Removal - Remove drive shaft. Hold axle flange using suitable tools (604 wrench; 6040 Spacer) then remove flange retaining bolt. Using a suitable puller (20/10) and support bracket (7011-1) remove axle flange. Remove oil seal.

Installation - Fill between sealing lips of seal with grease, then install seal in retaining plate to a depth of .16" (4 mm). Thoroughly clean flange and carrier splines an if any backlash between splines exists, apply small amount of locking compound to flange splines. Install flange and retaining bolt.

Remove propeller shaft and drive shafts, tie drive shaft up out of way. Support differential and remove four frame-to-housing attaching bolts, two differential cover-to-bracket nuts, and two bracket-to-fram bolts. Remove differential assembly. To install, reverse removal procedure, insuring rear bracket is stress free when installed.

Differential Housing - Remove differential assembly as previously outlined, and mount assembly in suitable holding fixture. Drain oil and mark drive pinion shaft and companion flange fro reassembly reference. Remove rear cover plate. Remove both axle flanges, as previously described, keeping right and left side ports separated. Mount a dial indicator to housing and check ring gear runout for reference at time of reassembly. Make a gear tooth patter check. NOTE - Refer to Rear Axle Gear Tooth Patterns in this section. Mark and remove carrier bearing retainer plates and shims. Turn housing rear opening upward, move carrier to right side, tilt and remove carrier from housing. Proceed as follows for standard or limited slip differential carrier disassembly.

Standard Differential Carrier - Remove carrier bearings using suitable puller (Rollex LM503349). Remove both securing ring gear to carrier, then remove ring gear. Drive out pinion shaft lock pin, remove pinion gears shaft and pinion gears. Remove side gears with shims and thrust washers.

Drive Pinion Gear - 1) Remove differential carrier as previously outlined, then using an inch pound torque wrench, check preload on drive pinion gear. Hold companion flange and remove retaining nut. Press drive pinion from flange and housing, then remove bearings. NOTE - On long neck housing, first remove flange nut, flange, cover and shim. Using a suitable tool (6046) remove drive pinion lock nut, then press gear out.

2) Remove drive pinion shaft oil seal then using suitable tools (5109 and 5120) press drive pinion outer bearing cones from housing. NOTE - On short neck housing, remove rear bearing cone first. On long neck housing, remove forward bearing cone first.

Differential Assembly - Reverse disassembly procedure noting the following checks and adjustments.

Drive Pinion Bearing Preload - 1) If original ring and pinion gear set is being installed, install drive pinion gear using original shim and new collapsible spacer. If a new gear using original shim and new collapsible spacer. If a new gear set is being installed determine correct size of shim to use in the following manner. Drive pinion gears may be stamped either "+1,2,3, etc", or "-1,2,3, etc". compare marks on tapered ends of old and new gears. Subtract the two numbers. In relation to original shim, a plus remainder means a thinner shim is required; a minus remainder means a thicker shim is required.

2) Remove then reinstall drive pinion, bearings and cones, as required, so new shim(s), collapsible spacer, and seal can be installed. NOTE - On long neck housing, preload must be established with pinion lock nut before installing front housing cover.

3) Install companion flange and nut (short neck housing), or pinion lock nut (long neck housing) and tighten nut to obtain specified preload. NOTE - If preload is exceeded, new collapsable spacer must be installed, and procedure repeated.

Side-to-Pinion Gear Backlash (Standard Differential) - With pinion gears and one side gear installed, mount dial indicator to carrier. Force side gear against case, zero indicator then force side gear against pinion gears. With proper shim and thrust washer, backlash should be as specified and preload of all three gears should not exceed 14 ft. lbs. (1.9 mkg). Repeat procedure on opposite side gear, then retain both side gears pressed outward against carrier, so axle drive flange retaining bolts can later be installed.

Clutch Assembly Endplay (Limited Slip Differential) - Assemble differential clutch and gear assembly, without ring gear or case. Apply 220 psi (15.5 kg/sq. cm) to one end of assembly. Measure from inner surface of flange to top surface of spacer ring. Measure depth of case. If clutch assembly-to-housing end play is not to specifications, adjust by using thicker or thinner inner clutch discs.

Checking Pinion Gear Torque (Limited Slip Differential) - With differential carrier assembled, install axle flanges in carrier. Clamp one flange in vice and using an inch pound torque wrench, turn other flange. If rotating torque of side and pinion gears is not to specification, install thicker or thinner case cover-to-clutch assembly thrust washer.

Differential Bearing Preload - With differential carrier installed in housing without ring gear, and with carrier bearing retainer plates installed without shims, thread a bolt against differential pinion gear shaft. Equally tighten retainer plate bolts until specified bearing preload is obtained. Using feeler gauge, check clearance between retainer plate and housing to determine required shim thickness. Take required shims and install them equally under both retainer plates.

Ring-to-Drive Pinion Gear Backlash - After establishing differential bearing preload, check ring-to-pinion gear tooth contact pattern. While maintaining established shim thickness, move shims from one retainer plate to the other, as necessary, to obtain proper contact pattern. After setting backlash, complete differential reassembly procedure.

Axle assembly is a semi-floating type with integral carrier. Drive pinion is carried on two taper roller bearings adjusted to a preload condition by use of collapsible spacer. A one piece differential case with a hypoid gear assembly is carried in axle housing on adjustable taper roller bearings, secured by caps and bolts. Ring gear-to-pinion mesh is controlled by screw adjusters which are locked in position with lock plates. Steel thrust washers are used between differential gears and case. Axles are carried by sealed ball bearing which are retained by pressed-on collars. No drain plug is provided, if necessary, oil is drained by removing rear cover

Both manual and automatic transmission models have an axle ratio of 3.889-1. There are 35 teeth on the ring gear and nine teeth on the pinion gear.

CRICKET REAR AXLE ASSEMBLY

CHECKING BEARING PRELOAD

Removal - 1) Jack up rear of vehicle and place floor stands under axles. Clean all dirt from around brake support plate and axle flange. Remove setscrew and pull of brake drum.

2) Remove four self-locking nuts attaching axle shaft retaining plate. Using suitable slide hammer (S-93 & C-637), remove axle shaft and bearing form axle housing. NOTE - Do not pry axle shaft out against brake support plate or plate may be distorted.

3) Using a suitable arbor press and tool (C-3926), press bearing and retaining collar from axle.

Installation - 1) With axle retainer plate positioned on axle with swaged center towards axle flange, press collar and bearing onto axle until extended boss of bearing is fully seated against axle face. NOTE - A minimum ram load of 3000 lbs. (1361 kgs.) is required for a correct fit. Otherwise it will be necessary to install a replacement axle.

2) Slide axle shaft into housing and align splines with those in differential side gear. Push shaft in and enter bearing into recess in axle housing.

3) Position retaining plate over four studs and tighten self-locking nuts. NOTE - Do not use retaining plate to draw bearing and axle shaft into position or excessive axle shaft end play will result.

CRICKET DIFFERENTIAL ASSEMBLY

Removal - 1) Jack up rear of vehicle and support on floor stands. Scribe mark propeller shaft and pinion flanges for correct reassembly. Remove attaching bolts and tie propeller shaft aside. Wrap a card around flange and attach a spring scale to determine amount of preload poundage required to rotate flange. Note poundage for reassembly.

2) Scribe mark flange and pinion shaft for reaasembly. Using a suitable tool (C-3281) to hold flange, remove flange nut and flange. Drive one side of seal inward as far as it will go. Grasp other side of seal and pull from housing.

Installation - 1) Coat internal flange with grease and place seal lip facing housing. Using suitable tool (C-3837), drive oil seal into housing until tool contacts housing.

2) Install flange to previous marks. Install a new pinion nut (being careful not to overtighten) and tighten until pinion end play just disappears. Rotate pinion to seat bearings.

3) Progressively tighten nut a very small amount at a time, rotate pinion and measure preload. Continue this procedure until previously noted preload is restored. CAUTION - Recorded preload must not be exceeded. If preload is exceeded, remove differential assembly and install a new collapsible spacer.

Removal - 1) Raise rear of vehicle and place floor stands under rear body jacking points. Using care not to damage housing cover, jack up rear axle enough to remove rear wheels. Block brake pedal in the up position with a wooden block.

2) Disconnect shock absorbers at lower mounts. On station wagons, disconnect Panhard rod at axle. Scribe mark axle flange and propeller shaft for correct reassembly. Disconnect propeller shaft and tie aside.

CHECKING DIFFERENTIAL GEAR CLEARANCE

3) Disconnect hydraulic lines at flexible hose and seal off both ends to prevent contamination. Release parking brake, disconnect parking brake cable at rear and slid outer cable forward until it can be lifted out of its bracket. Lower axle assembly approximately one inch (25 mm). Place stands under rear stands under rear ends of lower links. Remove pivot bolts from upper and lower links at axle ends and remove axle from vehicle.

Installation - To install, reverse removal procedure. Final tightening of suspension components is done with vehicle setting on its wheels. Bleed hydraulic brake system and fill rear axle to proper level with suitable lubricant.

1) Remove rear cover and drain oil. Remove rear axles and bearings. See Axle Shafts and Bearings. Disconnect parking brake rod and hydraulic lines to remove brake support plates.

2) Mark differential bearing caps for reassembly to original locations. Remove locking plates, bolts and bearing caps. Remove two adjuster nuts at same time lifting out ring gear assembly and outer  bearing cones.

3) Scribe mark pinion shaft and flange for reassembly. Using suitable tool (C-3281) to hold flange, remove self-locking nut and flange. With a soft mallet, gently tap pinion shaft out rear of axle housing. Using suitable tools (C-293-P and RGM-4221A-34), remove inner bearing from pinion, retaining shims for reassembly. Remove outer bearing from housing and drive bearing and seal from housing using a brass drift.

NOTE - If bearing and comes are to be reused they should be marked so that they will remain mated and return to their original positions.

4) Using suitable tools (C-293-10 and SP3183), remove bearings from differential case if necessary. Mark ring gear and differential case for reassembly. Remove eight bolts and ring gear. NOTE - Ring gear bolts are discarded and new bolts used for reassembly. Bolts are of special design and require no locking devices.

5) Drive out locking pin retaining the cross pin. Push out crosspin and rotate pinion gear 90 degrees to case openings. Lift out pinion gears and thrust washers. Side gears and washers can now be removed.

NOTE - If gear replacement is necessary, a complete set of matched gears including cross pin and locking pin will be required.

Case Assembly - 1) Install thrust washers on differential side gears and position gears in differential case. Place thrust washers on pinion gears and position gears in case in such a manner that they are 180 degrees apart when they are in mesh with side gears.

2) Rotate side gears until holes in pinion gears are in alignment with cross pin holes in case. Install cross pin and locking pin. Then push side ear on cage side (opposite ring gear) against pinions until all gear end play is removed. Measure clearance between thrust washers and side gear clearance should not exceed .010" (.25 mm).

3) Peen over locking pin hole to retain pin. Inspect ring gear and case for burrs. Install ring gear on case with marks aligned. Install a new set of bolts and tighten evenly.

Drive Pinion Depth - 1) Using suitable differential assembly jig (RG.545), pinion depth is determined with a dummy pinion shaft and mandrel. Shims to space pinion depth in differential case are available in .003" (.08 mm), .005" (.13 mm), .10" (.25 mm) and .020" (50 mm) sizes.

2) Lightly oil inner pinion bearing and place it on pinion shaft. Slide pinion shaft into housing and install outer bearing spacer and nut (do not install oil seal at this time). Tighten nut by hand until end play is removed. Rotate pinion shaft to seat bearings and continue to tighten until nut cannot be tightened further by hand. A slight drag should be felt.

3) Place mandrel in differential case and install bearings caps, torquing bolts to 15 ft. lbs. (2.1 mkg). Measure clearance between dummy pinion and mandrel with a feeler gauge. Measurement will be the actual thickness of shims required between real pinion shaft and bearing. Remove dummy pinion and mandrel. Place shims on pinion shaft and press on inner bearing until they are fully seated.

Pinion Bearing Preload - 1) Place collapsible spacer on pinion shaft and install in differential housing. Install outer bearing and oil seal. Install pinion flange and a new self-locking nut making sure marks are aligned.

2) Using suitable tool (C-3281) to hold flange, tighten nut until end play just disappears. Rotate pinion shaft to seat bearings. Wrap a cord around flange and attach a spring scale. Note reading while maintaining a steady pull. Progressively tighten nut a small amount at a time and measure preload until desired poundage is achieved. Preload for original bearings is 6-11 lbs. (2.7-5 kg) or new bearings is 8-15 lbs. (3.5-6.8 kg). Make a note of figure obtained for late calculation.

CAUTION - Do not back off nut to lessen preload. If desired preload is exceeded, a new collapsible spacer MUST be installed and nut retightened until proper preload is obtained

This axle assembly incorporates a removable carrier differential, having a hypoid type ring and pinion gear set, with the pinion being retained in the carrier by a companion flange and nut. Semi-floating axles are secured in the housing by the shaft bearing retainers.

Only one type of axle assembly is used. Axle ratio (4.11-1, 4.37-1 or 4.62-1) can be determined by dividing the number of teeth on ring gear by the  number of teeth on pinion gear.

Removal - After removing complete brake assembly, including nuts securing backing plate and bearing housing-to-axle housing, slide axle shaft out of housing. Remove inner oil seal from axle shaft, spread locking tabs on lock washer, then using a suitable spanner (T72J-4252) remove lock nut and washer. Using a suitable puller (T72J-1225), remove bearing with housing from shaft. Remove bearing cap and outer seal from bearing housing.

Installation - Using suitable tool (T72J-1177), install new outer seal in bearing housing. Press or drive new bearing cup into retainer using suitable tool (T72J-4252-B). Install brake backing plate and bearing housing on axle shaft, then position bearing  on axle shaft. NOTE - Insure bearing taper points in the right direction. Slide a suitable tool (T72J-4252-A) over shaft, place axle shaft on end in press, and press bearing into place. Install axle shaft and loosely assemble two bolts through bearing housing and axle housing. flange. Mount a dial indicator to backing plate so axle end play can be measured.

NOTE - If both axles have been removed, check end play of each shaft as it is installed. If end play is not to specification, adjustment is made by using appropriate shims between axle housing flange and bearing housing. After correct end play is obtained, install and tighten as necessary, all remaining components.

Removal - Raise and support vehicle. Drain lubricant from differential, replace drain plug, then remove remove axle shafts as previously outlined. Mark drive shaft and companion flange at differential for reference at time reassembly, then remove drive shaft. Remove carrier-to-housing retaining nuts, then remove carrier from housing.

Installation - Reverse removal procedure using a suitable sealer between the carrier and axle housing, and insure the drive shaft-to-companion flange reference marks are aligned.

1) Remove differential carrier as previously outlined, then mount carrier assembly in a suitable holding fixture with ring gear facing upward. Mount a dial indicator to carrier housing and check ring gear runout for reference at time of reassembly. Also make a gear tooth contact pattern check. Refer to Rear Axle Gear Tooth Patters in this section.

2) Punch mark differential bearing caps and adjusters for reference at time reassembly. Remove adjuster lock plates. Loosen bearing cap nuts and back off adjusters using a suitable spanner (T72J-4067). NOTE - Adjuster on left has left hand thread. Remove nuts, bearing caps, and adjuster, keeping each bearing cap with its own adjuster.

3) Lift out differential assembly keeping each bearing outer race with its own bearing. To remove differential bearings, use a suitable puller (T70P-4221). Remove bolts and locks retaining ring gear to case, then remove ring gear. Drive out differential pinion shaft lock pin and remove pinion shaft and thrust black. Rotate pinion gears 90 degrees and remove them with their thrust washers. Lift out the differential side gears along with their thrust washers.

4) Hold pinion gear companion flange and remove nut then the flange. Remove drive pinion and rear bearing. NOTE - If required, use soft headed mallet to top pinion gear from case, and guide pinion out to avoid damage to gear teeth. Remove oil seal and front bearing. Remove pinion bearing races from carrier using a drift in the slots provided. Remove and save the shims under the outer race, and remove bearing from pinion using a suitable tool (T72J-4630).

Case Assembly 1) If original ring and pinion gear set is being install, use original shim pack found under the pinion bearing outer race. If a new gear set is being used, determine the correct number of shims to use in the following manner: Drive pinion gears may be stamped either "+1,2,3" or "-1,2,3", or they may be unmarked. Compare marks on tapered ends of old and new gears. Subtract the two numbers. A plus remainder means to remove that number of shims from the original shim pack. A minus remainder means to add that number of shims to the original shim pack. If the number is the same on both gears, or if both gear are unmarked, use the original shim pack. Each shim is .0004" (.01 mm) thick, and no more than four shims should be used.

2) Install the correct shim pack and then using a suitable tool  (T72J-4616), install pinion gear bearing cases. Install bearing on pinion gear using a suitable tool (T70P-4625) and a press. Install pinion gear and bearing in carrier followed by the spacer, shims, front bearing and companion flange, without the oil seal. Tighten companion flange nut to 145-250 ft. lbs. (20.0-34.5 mkg).

3) Using an inch point torque wrench, check the rotating torque of pinion gear. If torque is not 15-30 INCH lbs. (17.3-34.6 ckg) through one complete revolution, refer to the shim thickness and spacer size tables and install appropriate shims and spacer which will obtain that specified preload. After setting preload, install the oil seal and reinstall the companion flange and nut.

                   Pinion Gear Shim Thickness

4......................................................   .013" (.33 mm)

6......................................................   .014" (35 mm)

8......................................................   .016" (.38 mm)

                   Pinion Gear Spacer Size

20.....................................................  2.291" (58.19 mm)

28.....................................................  2.294" (58.27 mm)

36.....................................................  2.297" (58.37 mm)

44.....................................................  2.300" (58.42 mm)

Differential Assembly - Reverse disassembly procedure noting the following checks and adjustments.

Side-to-Pinion Gear Backlash - After installing side and pinion gears, insert pinion shaft, without thrust block, into its proper position. Check side-to-pinion gear backlash. If backlash exceeds .008" (.20 mm), refer to table and install appropriate side gear thrust washers to obtain the correct backlash. Remove pinion shaft, then reinstall it with the thrust block

                  Side Gear Thrust Washers

6................................................   .063" (1.6 mm)

7................................................   .067" (1.7 mm)

8................................................   .071" (1.8 mm)

Ring-to-Drive Pinion Gear Backlash - After differential is completely assembled and installed in carrier, snug bearing cap nuts. Turn adjusters, using spanner, until bearings are  properly seated and end play is eliminated with a slight amount of ring-to-drive pinion gear backlash. Slightly tighten one bearing cap nut on each side. Mount dial indicator to carrier flange with indicator plunger set at right angle to ring gear teeth. Check ring-to-drive pinion gear backlash at four or five points around ring gear. Turn both adjusters equally to obtain specified backlash. Proceed by setting differential bearing preload.

Differential Bearing Preload - Taking car not to disturb ring-to-drive pinion gear backlash, set preload using a dial indicator as shown in illustration. After setting preload, tighten bearing cap nuts and complete assembly procedure.

Rear axle is of the banjo type, utilizing the removable carrier style differential. Light weight construction joins split tublar housing for each side with center covers welded to alxe housing. Final drive is of the hypoid style. Axle shafts are semi-floating type supported with bearings at their respective ends in axle housing. Bearings are fitted to axles with pressure type bearing retainers. Pinion bearing preload, side bearing preload, and pinion depth adjustments are made with shims while differential side gears are adjusted with spacers.

Colt does not attach any tag or other easily identified item to the rear axle housing. Colt vehilce do however, utilize only one kind of rear axle assembly: Removable carrier. NOTE - In 1974 there were two different types of differential cases, side gears, and pinion gear.s When replacing these components, ensure proper parts are selected.

Differential Gear Radio

1971-73...........................................................   3.889-1

1974

     97.5" Engine.............................................   3.869-1

     121.7" Engine...........................................   3.545-1

Removal - 1) Raise and suitably support rear axle housing so rear wheels clear ground. Remove rear wheel and brake back plate nuts, then disconnect wheel cylinder brake line. Fix suitable puller set (CT-1003 & C-637) to lug studs and work slide hammer until axle shaft is free to be withdrawn. Set brake back plate with parking brake attached out-of-way. Using suitable tool (C-637 with hook) remove axle shaft oil seal.

2) To remove axle bearing proceed as follows. Grind down bearing retainer at one point until retainer thickness is .04-.06" (1.0-1.5 mm), then chisel ground portion and remove retainer. Using suitable bearing puller or press (CT-1120) remove bearing from axle.

3) Using a dial indicator, inspect axle shaft deflection in three spots (see illustration). Replace axle shaft if specifications are exceeded

Axle Shaft Deflection Table

Point "A"....................  0-.004"............................  .004"

                                    (0.-.10mm)                         (.10 mm)

Point "B"..................... 0-.002".............................  .002"

                                    (0-.05 mm)                         (.05 mm)

Point "C"..................... 0-.08"................................   .08"

                                    (0-2.0mm)                          (2.0 mm)

MEASURING AXLE SHAFT DEFLECTION

4) Rear axle bearing should be replaced when bearing noise is detected, when bearing axial free play exceeds .014-.016" (.36-.41mm) or if bearing radial free play exceeds .001-.002" (.03-.04 mm) at approximately 11 lbs. (5.0 kg) measuring force.

5) Inspect wheel hub bolts for tightness and bearing outer retainer for deformation, replace defective parts as necessary.

Installation - 1) Fit outer bearing retainer flat side against shaft splined end, then install bearing and inner bearing retainer. Seat bearing retainer with smaller chamfered side directed to the bearing NOTE - Ensure bearing is completely seated.

2) Lightly coat lips of oil seal and using suitable oil seal installer (DT-1007B and CT-1008) fit axle shaft oil seal in rear axle housing.

3) Using packings and shims in proper sequence, set clearance between bearing and outer bearing retainer to .00-.01" (.0-.25 mm).

REAR AXLE SHAFT COMPONENTS

4) Carefully insert axle shaft assembly into axle housing using care not to damage seal. Slightly turn axle shaft until splines line up with differential side gears. Align packing oil holes with outer bearing retainer and tighten bearing retainer to axle housing flange. Connect brake line to wheel cylinder and bleed air from system.

Removal - Drain oil from rear axle differential housing, then disconnect propeller shaft. Pull out both rear axle shafts approximately 2 1/2". Remove differential gear housing mounting nuts and withdraw the differential gear carrier. It may be necessary to top outside of housing to break gear carrier loose.

REMOVING DIFFERENTIAL GEAR HOUSING

Installation - Lightly coat each bearing and gear with oil. Apply sealing compound on packing and axle housing seat, then assemble gear carrier to axle housing with nuts and tighten. Fill differential gear housing with .96 quart of suitable multi-purpose gear oil (API GL-5)

Differential Gear Assembly - 1) Remove bearing carrier cap and lever gear case assembly from housing. Using suitable bearing puller tool (C-293-P and C-293-39) pull differential side bearing. Keep right and left bearings and shims in sequence for reassembly.

REMOVING DRIVE PINION BEARING

2) Remove ring gear lock plate tabs and loosen bolts in diagonal sequence, then remove ring gear. Drive out pinion shaft lock pin from ring gear back side using a punch; pull out pinion shaft and pinion. Pinion side gears and spacers are now accessible. Note placement of pinion side gear and spacers and ensure they are reassembled in some position.

Drive Pinion Disassembly - 1) Hold end yoke with suitable tool (C-3281) and remove lock nut, then remove end yoke. Using a wheel puller, force out drive pinion with adjusting shim, rear inner bearing race, spacer and preload adjusting shim.

REMOVING DIFFERENTIAL PINION SIDE BEARINGS

2) With suitable bearing puller (C-293-P & C-293-39) remove rear bearing inner race and at same time, pull of drive pinion adjusting shim. Using suitable drift, remove front drive pinion bearing outer race and oil seal. Repeat some procedure to remove bearing outer race.

Check differential gears for correct tooth contact and replace gears of wear is excessive. Inspect bearing faces for roughness or score marks and replace, if necessary, bearing assembly. Ensure splines of side gears and rear axle shafts fit correctly. Check clearance between pinion gears and pinion shaft, if wear is excessive, replace components.

REMOVING FRONT DRIVE PINION OUTER RACE

NOTE - To check gear tooth contact using point impression method, refer to beginning of this section.

COLT SEPARATE HOUSING REAR AXLE ASSEMBLY

CHECKING PINION & SIDE GEAR BACKLASH

Case Assembly - 1) Install thrust washers (spacers) behind side gears in their original position and assemble pinion and side gears in differential. Insert both pinion gears, with pinion washers attached, so they mesh with side gears. It may be necessary to slightly rotate pinion to achieve desired meshing. Insert drive pinion shaft.
2) Check pinion and side gear backlash as shown in illustration. If backlash is beyond 0-.003" (0-.08 mm) adjust by selecting a side gear thrust washer (spacer) of correct size. If backlash is to be adjusted, ensure right and left sides are equally shimmed.
3) Thoroughly clean all dirt from ring gear mounting surface of differential case. Install bolts and lock washers. Tighten bolts alternately in a diagonal sequence and bend over lock tabs. Ensure lock washers are in contact with case rib after final torque has been performed.

Drive Pinion - Using a suitable drift and hammer or a press, seat front and rear bearing outer races into gear carrier ensuring that outer races do not cock. Ensure bearing races are completely seated before proceeding. Install shim between drive pinion and rear bearing. Using suitable bearing installer (CT-1075) press bearing onto drive pinion shaft. If drive pinion and bearing are scheduled to be reused, shims should be replaced with new ones of some thickness. In instances where the gear set is to be replaced, install new shims that are the same thickness as the used shims on drive pinion. NOTE - When determining the desired thickness of shim pack, amount of compression (sinkage) of shim pack and wear of the bearing (where old bearing is reused) must be taken into consideration.

Drive Pinion Depth - Install drive pinion spacer, front bearing, washer, end yoke and waher in order of removal. Fit pinion shaft retaining nut and slowly tighten nut, continuously checking, until pinion bearing preload is 6-9 INCH lbs. (7-10 cmkg) with oil seal not installed. Place suitable cylinder gauge on inside bearing pedestals of gear carrier housing. Place a black gauge on top end of drive pinion and slip a feeler gauge between the two gauges to obtain the correct clearance. The clearance between gauges should be .0118" (.300 mm). This is the standard height and any deviation from this height will be marked on the head of the pinion shaft and side of ring gear. To calculate the correct pinion height, add or subtract the variation value from the standard height. NOTE - Stamped values are in hudredth millimeters. Add or subtract the correct amount of shims as necessary.

Pinion Bearing Preload - This adjustment must be performed after the setting of the drive pinion depth. Remove end yoke and insert the bearing preload adjusting shim between pinion spacer and bearing, then tighten end yoke to 9-11 INCH lbs. (10-13 cmkg). In addition to the preload adjusting shims there are spacers available to provide proper adjustment. After finishing adjustment of drive pinion bearing preload remove the end yoke and apply a thin coat of grease to outer surface of oil seal, then drive seal into position in gear carrier. After greasing oil seal lip, insert end yoke and tighten nut.

Side Bearing Preload - Fit each side bearing into differential case leaving shims out; use suitable tool (CT-1102) for this procedure. Ensure side bearing are completely seated before proceeding. Install differential case assembly on gear carrier, then calculate the clearance between side bearing outer race and gear carrier as shown in illustration. After obtaining clearance add .002" (.05 mm) preload figure to each side, Insert shims equally on both sides. Align gear carrier and bearing cap index marks, then tighten cap retaining bolts.

MEASURING CLEARANCE BETWEEN SIDE BEARING AND GEAR CARRIER

Ring Gear Deflection - Attach a dial indicator to back side of ring gear and measure deflection. If ring gear has excessive deflection, correct position of the assembly in relation to differential case and again perform measurement. Replace ring gear or differential case as necessary.

Drive Pinion Backlash - Measure backlash of drive pinion in at least for different spots on ring gear with drive pinion securely fixed in final position. Set up a dial indicator on ring ring gear teeth edges. If measured backlash is greater than .005" to .007" (.13-.18 mm), shift shims from ring gear side to back of the ring gear to obtain proper backlash. If the measure value is less than standard value, reverse the moving of shims as stated above. Side bearing shims are available in various thicknesses.
NOTE - Check gear tooth contact using point impression method described to beginning of this section.

Final Inspection and Assembly - Ligthtly coat each gear and bearing before and during reassembly  with gear oil. After installing each component, ensure oil rotating parts are free to move smoothly. Install differential gear assembly to axle housing after applying sealing agent and tighten gear carrier mounting nuts in diagonal sequence.

An integral type housing, hypoid design, with centerline of pinion set below centerline of ring gear. Semi-floating axle shafts are retained in housing by ball bearings and a bearing retainer at axle housing outer ends. All-adjustments are pre-formed using selective fit shims and gaskets.

1) Remove brake drum retainers and remove brake drum. Remove bolts securing bearing retainer plate to axle housing. These bolts are accessible through holes in axle shaft flange. Pull axle shaft and bearing assembly out of axle housing.

2) Loosen inner retainer ring by nicking it deeply with a cold chisel in several places. It will then slide off easily. press bearing and seal assembly from axle shaft using arbor press and suitable tool to hold and support bearing.

3) To install, inspect housing and axle shaft and lightly coat wheel bearing bore with axle lubricant. Place bearing retainer plate on axle shaft, and press new wheel bearing on shaft using suitable tool. NOTE - Do not attempt to press on both bearing and inner retainer at the same time.

4) Using suitable bearing installation tool, press bearing inner retainer ring on shaft until retainer seats firmly against bearing. Insert axle shaft in housing and engage splines. Top shaft into position. Install bolts securing bearing retainer plate and install brake and drum retainers.

1) Raise vehicle and remove wheels. Mark propeller shaft for proper alignment and disconnect from drive pinion flange. Release parking brake; then rmeove locknut and adjusting nut from handbrake cable and disconnect cable from relay lever. Disconnect brake line from brake hose.

2) Raise and support center of rear axle and disconnect shock absorbers from axle. Remove rear axle support. Remove two stabilizer bar retaining clamps from rear axle housing. Remove rear spring "U" bolt nuts and detach bolts and plates. Lift axle assembly and remove from vehicle.

3) To install, lift rear axle assembly into position on spring, being sure that it is correctly located over spring pilot bolts. Align and loosely fit propeller shaft to drive pinion flange. Fit "U" bolts over axle, slide on lower plates, install new locknuts and tighten.
4) Using a suitable tool, hold rear stabilizer bar onto mounting pads on axle housing and install retaining clamps. Insert retaining clamp bolts, check for binding, and tighten. Raise center of rear axle and install shock absorbers. Remove axle support.

5) Reconnect brake line to brake hose and handbrake cable to relay lever on rear axle housing. Adjust nut until relay lever is just clear of stop, tighten locknut. Tighten driveshaft to pinion flange bolts and bleed rear brake system. Fill rear axle housing with lubricant, mount rear wheels and lower vehicle.

Disassembly - 1) Raise vehicle and remove wheels and axle shaft assemblies. Mark propeller shaft for correct realignment and disconnect from pinion flange. Remove ten cover attaching bolts, cover and gasket and drain rear axle oil. Discard gasket and thoroughly clean cover.

2) Remove differential bearing caps and mark caps for correct repositioning. Lift differential out of axle housing using two pry bars. Remove tapered roller bearing from each side of differential assembly using a suitable puller. Remove adjusting shims from differential housing. Remove ring gear attaching bolts and ring gear from differential assembly.

3) Using a suitable drift, remove locking pin securing differential pinion shaft in differential case and remove differential pinions, side gears and adjusting shims. Hold drive pinion flange and remove pinion nut, retain nut for use during assembly operations. Remove pinion flange using a suitable puller, then remove pinion from axle housing. Remove bearing spacer from pinion. Remove large  roller bearing from pinion shaft using press and suitable fixtures. Remove small tapered shaft using press and suitable fixtures. Remove small tapered roller bearing and seal from axle housing using a suitable drive. Drive bearing races out from axle housing with a drift.

CHECKING PINION DEPTH

Reassembly - 1) Install pinion bearing races into axle housing. Set pinion depth as follows. Position cross bar of pinion depth gauge tool (T70P-4133) and side bearings in rear axle housing. Instal bearing caps (number to number) and tighten attaching bolts. Loosen bolts and retighten finger-tight. Preload side bearing by expanding depth gauge cross bar by holding bar and rotating nut. Seat side bearings and check that side bearings are still preloaded. Do not over expand cross bar. Tighten bearing attaching bolts.

2) Install dummy pinion (part of special tool) into axle housing with pinion bearing but no shims. Lightly lubricate bearings and tighten tool until correct pinion bearing pre-load is obtained. Rotate dummy pinion several times to unsure seating of bearings. It is essential that the torque reading be recorded and followed for further adjustment of drive pinion. This torque must also be check after installation of drive pinion with selected spacer.

3) Mount dial indicator on mounting bracket and set to zero on dummy pinion. Slowly rotate dial indicator over cross bar of tool and read total deflection of pointer. This reading gives the exact thickness of the shims to be used. When pinion is marked "-1" or "-2" this amount must be added to indicator reading. When gear is marked "+1" or "+2" this amount must be subtracted from reading to obtain correct shim thickness. Using a micrometer, select a shim of the determined thickness.

MEASURING SIDE GEAR CLEARANCE

4) Position shim(s) on pinion and press on large tapered roller bearing using a press and suitable fixture. Position differential side gears, with one shim each, in differential case. The grooved side of shim must be towards  side gear. Position differential pinions and thrust washers between differential side gears. Push the differential pinion shaft into position in case, taking care to align locking pin holes. Measure play of each side gear using a feeler gauge. If side gear play is not to specifications, install new shims. Secure differential pinion shaft with a locking pin.

5) Position ring gear on differential case and locate with bolts. Pull ring gear evenly into position with bolts. Remove old bolts and install new bolts and tighten. To determine total play of differential case in axle housing: Press tapered roller bearing onto differential case without shims after first inspecting bearings for damage. Install pressure blocks (part of tool 170P-4136) into axle housing on each side of differential case and install bearing caps (number to number) and tighten attaching bolts. Now, loosen and tighten finger tight.

6) Tighten pressure spindle (tool T70P-4136) to a torque of 43 INCH lbs. Rotate differential several times and recheck torque. Mount dial indicator on rear axle housing so that feeler attach inner side of ring gear flange and zero indicator. Place pressure spindle into other side of housing and tighten to 43 INCH lbs. Read and note amount of indicator delfection and record as total play of differential case is rear axle housing. Loosen pressure spindle, tilt dial indicator to side and remove differential, pressure spindle and pressure blocks.

7) To determine thickness of pinion bearing spacer: Slide master spacer (tool T70P-4137) onto pinion. Using soft wire solder of about .08" (2 mm) diameter, form a ring which matches drive pinion shaft diameter and place it onto gauge ring. Position pinion into rear axle housing and slid on small taper roller bearing and pinion flange. Install old self-locking nut, hold drive pinion flange and slowly tighten nut to its specifications using care not to exceed torque value or procedure must be respected with new solder wire. Carefully remove compressed solder wire and measure thickness at two opposite points. If thickness varies, average the two values.

DIFFERENTIAL SETUP & BLOCKS INSTALLATION

8) Add this value to the gauge ring thickness to give spacer thickness required. Install the pinion with selected thicness spacer, small tapered roller bearing drive pinion flange and old self-blocking nut. Tighten nut to 72-87 ft. lbs. and rotate drive pinion several times and the check preload torque. This should be to specifications. If torque is exceeded, a thicker spacer should be installed. If torque is less, a thinner spacer is required. Check that new radial oil seal has grease between the sealing lips and coat it with sealing compound on the other side. Install new oil seal and new self-locking nut and tighten.

9) To determine differntial case bearing shim thickness. Place pressure blocks back into axle housing and place differential case with bearing races into axle housing. Install bearing caps, tighten screw, then loosen  and tighten finger  tight. Using pressure spindle, press differential housing with a torque of 43 INCH lbs. away from drive pinion. Rotate pinion several times. Position feeler of dial indicator gauge at right angle to one tooth of ring gear. Measure tooth flank backlash at 4 points, each time turning gear two bolt heads further. Deviations of tooth flank backlash must not exceed .002" (.05 mm). Insert pressure spindle into other side of axle housing and screw in slowly until there is the specified value of tooth flank backlahs.

10) Position dial indicator so that feeler contact ring gear flange and zero indicator. Insert spindle into the other side of axle housing and torque to 43 INCH lbs. Read and record indicated deflection on indicator as ring gear back side shim thickness. Remove pressure spindle, differential case and pressure blocks from axle housing.

MEASURING RING GEAR BACKLASH

11) To calculate shim thickness, first take the value of differential case total play obtained in step 6) and add to this value a value for ring and pinion backlash which will give an even number. For example, if total play is .0529" (1.344 mm), add for preload the value of .0021" (.056 mm) (preload value selected from specified range) to obtain .055" (1.40 mm). Next, take the value for ring gear back side shim thickness is .025"  (.64 mm), subtract .005" (.13 mm) to obtain .020" (.51 mm). Now subtract value just obtained (.020" or .51 mm) from total play value obtained above (.055" or 1.40 mm) to obtain ring gear face side shim pack, in this example .035" (.89 mm).

12) Remove differentail case bearings and position required shims on differential case. Using suitable tools, press tapered roller bearing onto differential case after checking bearing for damage. Insert differential case in axle housing and position bearing caps as previously marked. Coat bolt threads with sealing compound and insert bolts.

13) Position dial indicator feeler in a vertical position on one ring gear tooth and check that pinion to ring gear backlash is to specifications. If not, differential must be removed and shims adjusted. If backlash is too greast, remove shims from ring gear face side and transfer to ring gear back side and vise versa. Do NOT increase or decrease number of shims, but only interchange between one side and the other.

14) Finally check gear contact pattern and adjust as necessary to obtain correct patter. Position housing cover and gasket on axle housing and install and tighten bolts. Attach parking brake operating lever to rear axle housing and connect return spring to bracket on housing. Install rear brake assemblies on axle housing and connect parking brake cable to brake assemblies.