Online Guide and Manuals

Axle housing is banjo type with removable differential carrier and semi-floating axle shafts. Ring and pinion gears are hypoid type in which centerline of pinion is set below centerline of ring gear. Differential case is one piece, two pinion design. The axle shafts are retained in housing by cone type roller bearing retainers at axle housing outer ends.

All LUV models are equipped with one type of rear axle assembly. Any differences in Removal and Installation or Overhaul procedures will be noted where they occur. To determine axle ratio, divide number of ring gear teeth by number of pinion teeth

Removal - Raise vehicle and remove wheel and tire assembly. Remove brake drum, brake shoes and disconnect parking brake inner cable. Disconnect brake line from wheel cylinder and cover end to prevent loss of fluid and entry of dirt. From inboard side of brake backing plate, remove four nuts from the bearing holder through bolts. Pull axle shaft from housing.

Bearing Replacement - 1) Flatten locking tab of lock washer, then mount axel shaft in a vise, clamping vise jaws around lock nut. Using suitabl tool (J-24246) positioned on lub bolts, turn axle shaft loose from lock nut. Mount axle assembly in a press and remove lock nut, lock washer, bearing and holder, and brake backing plate. Remove oil seal from outboard side of bearing holder, then drive off bearing outer race with a drift.

2) To reassemble, install bearing outer race and grease seal into bearing holder using suitable drivers. Apply wheel bearing grease to bearing holder, rear axle tube, and bearing inner race. Insert the four through bolts into backing plate, making sure oil seal side of bearing holder is against backing plate. Place backing plate assembly over axle shaft, position bearing over axle shaft and press into bearing holder. Install new lock washer with dished side away from bearing, and thread lock nut onto shaft. Place lock nut between vise jaws, and using tool used during disassembly, tighten lock nut securely. Bend over portion of lock washer opposite locating tab to prevent lock nut from turning.

Installation - 1) If both axle shafts were removed ,isert a .079 (2 mm) shim between bearing holder and axle tube flange of first axle shaft to be installed. Insert shaft into axle tube and install and tighten bearing holder-to-flange bolts. For the second axle shaft (or if only on shaft was removed), insert shaft without shims into axle tube until it comes in contact with thrust block in differential. Measure clearance between bearing holder and axle tube flange (see illustration).

2) Proper size shim for this location may be determined by adding .004" (.1 mm) to measurement just obtained. Select a shim or combination of shims, withdraw axle shaft, and install shims between bearing holder and flange face. Reinstall axle shaft and tighte four though bolts. Connect brake line to wheel cylinder, then install brake shoed, parking brake cable, and brake drum. Install wheel and tire assembly, adjust broken and bleed system.

Removal and Installation - Raise rear of vehicle, remove wheels and brake drums, and disconnect brake lines at rear wheel cylinders. Disconnect parking brace cable brackets at rear spring locations, remove four through bolts from each end flange, and partially with draw axle shafts from axle tubes. Disconnect propeller shaft from pinion flange and place out of way. Remove nuts attaching carrier to axl housing and remove carrier assembly To install, reverse removal procedure, making sure to refill axle with lubricant.

1) Mark side bearing caps for reassembly reference, remove nuts and bearing caps, then remove differential case assembly. NOTE - Keep right and left side bearing races with respective bearings. Remove differential side bearings from case using a suitable puller and adapter (J-22888 and J-81072). Record thickness of each side bearing and each shim pack, then place with appropriate bearing race.

2) Remove ring gear bolts and separate ring gear from case. Drive out pinion shaft lock pin using a long drift. NOTE - It may be necessary to remove caulking in lock pin using a 5mm drill. Remove pinion shaft using a drift, then withdraw thrust block, pinion gears, side gears, and thrust washers.

3) Remove pinion nut and pinion flange. Drive the pinion gear from carrier using a soft hammer or drift. Withdraw front pinion bearing and oil seal. Using a drift, remove pinion bearing races from carrier. Mount pinion gear in a press and remove rear pinion bearing and depth shim from pinion gear.

Drive Pinion Depth - 1) Install front and rear pinion bearing races into carrier bores, lubricate pinion bearings, and position in respective races. Install a suitable gauging plate (J-23597-7) and preload stud and pilot (J-23597-9) through pinion bearings and tighten nut snugly. Rotate bearings to insure proper seating, then tighten lock nut until 20 in. lbs. (25 cmkg) of torque are required to rotate new bearings, or 8-10 In. Lbs. (9.2-11.5 cmkg) are required to rotate used bearings.

2) Place mounting discs (J-23597-8) onto arbot tool (J-23597-1) and place assembly in position in side bearing bores. Install bearing caps. Mount dial indicator on arbor post, preload dial 1/2 revolution, then tighten indicator in this position. Position indicator plunder on gauge plate, slowly swing across until highest reading of gauge plate. Swing plunger off gauge plate and note indicator reading. Reading is the correct thickness of rear pinion bearing depth shim for a nominal to .101". An indicator reading of .000" or .001" requires shims of .100" and .101" respectively.

3) Examine head of drive pinion; pinion depth code is stamped by chemical ink and is the lower of three numbers. A "+" (plus) number indicates need for greater mounting distance (decrease shim thickness), while a "-" (minus) number indicates need for smaller mounting distance (increased shim thickness). See following chart to determine proper shim variation to compensate for plus or minus markings. NOTE - If no pinion depth code is present, pinion is "nominal" and no correction to dial indicator reading is required.

+10............................................ Subtract .005" (.13 mm)

+8.............................................. Subtract .004" (.10 mm)

+6.............................................. Subtract .003" (.08 mm)

+4.............................................. Subtract .002" (.03 mm)

+2.............................................. Subtract .001" (.03 mm)

0................................................ No Correction Required

-2............................................... Add .001" (.03 mm)

-4............................................... Add .002" (.05 mm)

-6............................................... Add .003" (.08 mm)

-8............................................... Add .004" (.10 mm)

-10............................................. Add .005" (.13 mm)

4) Place selected shim on drive pinion and press rear bearing on pinion. NOTE - Do not press on roller cage; press only on bearing inner race. Remove gauging tools from carrier.

Pinion Bearing Preload (W/ Solid Bearing Spacer) -  1) Place drive pinion and bearing spacer into carrier, then position original pinion shim and front pinion bearing over pinion gear. Install pinion flange and nut, tightening nut snugly. NOTE - Do not install oil seal at this time. Rotate bearing to insure proper seating, then tighten pinion nut to 190 ft lbs. (26.3 mkg). Wind a small amount of string (approximately 4-6 windings) around pinion flange. Using a pull scale, note pull scale reading required to rotate flange.

2) Reading should be approximately 13-17 lbs. (5.9 - 7.7 kg) for new bearings, or 8-10 lbs (3.6-4.5 kg) for reused bearings. If necessary to adjust preload, remove nut and pinion flange and remove or install shims behind front bearing. Shim are available in thicknesses of .003" (.08 mm), .005" (.13 mm), and .010" (.25 mm). NOTE -To increase preload, decrease shim thickness; to decrease preload, increase shim thickness. When correct preload is obtained, remove pinion nut and flange, install oil seal, then reinstall flange using a new pinion nut.

Pinion Bearing Preload (W/Collapsible Bearing Spacer) - 1) Place drive pinion and collapsible spacer into carrier, then install front pinion bearing and oil seal. Mount pinion flange on drive pinion, apply lubricant to pinion threads, install pinion nut and tighten to 85 ft. lbs. (11.3 mkg). Rotate pinion to insure bearings are seated, then wind a small amount of string (approximately 4-6 windings) around pinion flange. Using a pull scale, note reading required to rotate flange.

2) Continue tightening nut in small increments until pull required to rotate flange in 17 lbs. (7.7 kg) for new bearings or 7-9 lbs (3.2-4.1 kg) for reused bearings. CAUTION - Preload builds quickly. Nut should be tightened only in small increments and pull scale used after each small amount of tightening. If preload is exceeded, a new collapsible bearing spacer must be intalled.

Case Assembly - Install side gears and thrust washers in case. Position thrust washers 180 degrees apart, then roll gears into position making sure they are in alignment to allow installation of pinion shaft. Place thrust block between pinion gears and drive pinion shaft into position, making sure roll pin hole aligns with hole in case. Measure backlash between side gears and pinion gears; if greater than .003" (.08 mm), install selective thrust washers to bring backlash within specifications. Washers are available in thicknesses of .037" (.94 mm), .041" (1.04 mm), and .045" (1.14 mm). NOTE - Increasing washer thickness decreases backlash; decreasing washer thickness increases backlash. Install lock pin into pinion shaft and caulk end to prevent loosening. Install ring gear into position on case, apply Lactite to bolt threads, and install and tighten ring gear to case bolts in a diagonal sequence.

Backlash & Side Bearing Preload - 1) If original side bearings, differential case, ring and pinion, and differential case, ring and pinion, and differential carrier are being reused, the original shims may be reinstalled in their respective positions. If only new side bearings are being installed, measure new bearings with a micrometer and compare thickness with original bearings. If new bearing is thicker, SUBTRACT difference from shim pack. If new bearing is thinner, ADD difference to shim pack.

2) If new bearings and/or differential case, ring and pinion, or differential carrier are being installed, new shims must be selected as follows: Install side bearings onto differential case, but do not install shims at this time. Mount case into carrier bores. Move ring gear tightly against carrier on ring gear side (away from pinion), and hold in this position. Using a feeler gauge, measure clearance between bearing and differential carrier on side opposite ring gear. Record clearance.

3) A predetermined dimension (.018" on 1972 models, .002" on 1973 and later model(s) is needed to establish proper preload. Therefore, ADD this dimension to clearance obtained in this step 2) for proper preload. This will give necessary combined total thickness of both shim packs. Divide the total dimension into two packs equals the difference between original shim packs.

4) Remove case from carrier, remove side bearings and install shim packs, then reinstall bearings. Install differential case into carrier, tapping carefully into place. Install side bearing caps in original positions, install and tighten attaching bolts. Measure run-out of ring gear (see illustration). If run-out exceeds .002" (.05 mm), correct by cleaning or replacement of parts.

5) Mount a dial indicator against ring gear teeth and measure backlash in three locations. Backlash should be .005-.007 (.13-.18 mm): if not, shims behind side bearings must be adjusted. NOTE - To maintain preload when backlash is adjusted, the total thickness of both shim packs must not be altered. Therefore, if it is necessary to increase one shim pack, the opposite shim pack must be decreased by the same amount. To increase backlash, right side bearing shim must be increased, and left side decreased. To decrease backlash, rigth side shim must be decreased, and left side increased. NOTE - Backlash changes approximately .002" (.05 mm) for each .003 (.08 mm) shim change. After adjustment, make gear tooth pattern check to insure correct assembly.

Rear axles are hypoid design with center line of pinion set below centerline of ring gear, Jaguar uses, as standard equipment on XKE models and optional equipment on XJ models, a traction lock or "Powr-Lok" differential which utilizes, clutch discs and plates. All differential adjustments are performed  using shims. As independent rear suspension is utilized on all models, stub axles are used for drive output. These stub axles require a shim adjustment also. A collapsible spacer is used on drive pinion shaft.

AXLE RATIO AND IDENTIFICATION

Jaguar uses only one basic rear axle design, however, unit may or may not be fitted with a traction lock device. Also several different axle ratios are used. To determine axle ratio divide number of ring gear teeth by number of pinion gear teeth. Whether or not axle is fitted with traction lock should be determine by owner inquiry or not.

NOTE - This procedure is provide since may operation on the final drive require removal of rear suspension assembly before starting work or final drive.

1) Raise and support vehicle. Place stands forward of radius arms on body with wood blocks between body and stands. Remove wheels. Remove mufflers from tail pipes. Remove safety wire and bolts securing safety strap to body. Remove radius arm securing bolt, safety strap and radius arm from body mounting post. Disconnect and plug brake lines of body.

2) Remove clevis pin securing hand brake cable to actuating levers on crossmember. Loosen lock nut and remove outer hand brake cable screw from adjuster block. Detach drive shaft from differential. Place jack under rear suspension. Remove bolts and lock nuts securing crossmember mounts to frame. Lower and remove rear suspension from vehicle. To install, reverse removal procedure and note the following: Bleed brakes. Tighten radius arm nuts on lower control arm when weight of vehicle is on wheels.

1) Remove rear suspension assembly. Remove rear hub as follows: Remove fulcrum shaft grease fitting. Withdraw cotter pin and remove nut and washers from splined end of half shaft. Using suitable puller, pull hub and carrier from half shaft. Remove spacer from half shaft and examine inner oil seal track. Replace track if necessary. Remove one nut from outer suspension arm fulcrum shaft and using soft hammer, drift out shaft. Remove hub and carrier assembly from car.

2) Support suspension arm with jack and remove nut and bolt securing top of forward shock absorber. Remove nuts and washer securing shock absorber to suspension arm and remove shock. Remove four nuts securing half shaft flange to stub axle flange and brake rotor. Pull half shaft from suspension unit noting number of camber shims installed between half shaft flange and brake rotor. If necessary, remove joint shields by drilling out rivets.

3) To install, reverse removal procedure, noting the following: If necessary, replace joint shield, positioning grease nipple access hole correctly. Cover joint lines in shield with non-hardening waterproof sealing compound. Be sure to replace camber shims. To reinstall rear hub, proceed as follows: Install suitable dummy shaft (JD.14) in hub carrier fulcrum. Install carrier and suspension arm. Replace outer suspension arm fulcrum shaft, displacing dummy shaft. Secure shaft with nut and reinstall grease nipple.

4) If necessary, install oil seal track to half shaft splined flange, replace spacer. Thoroughly clean and de-grease splines of half shaft and bore of hub. Using a small brush, sparingly apply Lactite "Stud Lock" to outer two thirds of half shaft splines. Assemble hub carrier to half shaft. Install washer and tighten hub carrier assembly nut. Install new  cotter pin. Install dial indicator so it bears against hub and zero indicator. Using two levers, pry out on hub and measur hub bearing endfloat. If endfloat exceeds specifications, overhaul rear hub and carrier assembly. After installation of rear suspension in vehicle, check rear wheel camber.

1) Remove half shaft. Remove locking wire and withdraw bolts securing brake caliper to final drive unit. Remove brake rotor, noting number of shims removed between rotor and stub axle flange. Remove lock wire and five bolts securing caliper mounting bracket. Withdraw drive shaft, together with caliper mounting shims, ball bearing and oil seal. Turn down tab washer and remove nut from stub axle. Remove ball bearing and caliper mounting bracket stub axle.

2) Lightly oil new seal and position carefully in final drive case. Press seal squarely and fully seat in case groove. Do NOT remove protruding portion of seal. Coat seal with hypoid oil and place caliper mounting bracket and seal assembly over stub axle. Slide ball bearing on drive shaft followed by new tab washer and nut. Ensure bearing seats square to stub axle shoulder and tighten nut. Turn up tab on washer.

3) Lightly oil stub axle splines and install shaft in final drive housing. Install bolts securing mounting bracket finger tight. Using feeler gauges, measure dimension between inside face of mounting bracket and final drive housing. The measurement obtained determines shim thickness required. Remove stub axle and select shims of required thickness, and thinly coat mating faces and shims with suitable sealant (Hylomar). Tighten bolts in a diagonal sequence.

4) Wire lock securing bolts to tension in clockwise direction. Install brake rotors and half shaft flange, using shims removed from between rotor and flange. Install caliper on mounting bracket. Install suitable distance spacers (oversize nuts) to rotor studs and tighten nuts. Use feeler gauge to ensure that rotor is centrally located between jaws of caliper. If necessary add to or remove from shim pack between flange and disc to center rotor. Continue assembly in reverse of disassembly procedure.

1) Disconnect propeller shaft. Check and record torque required to turn drive shaft falnge clockwise (viewed from front) through backlash movement. Chock rear wheels and remove flange securing nut and washer. Remove flange. Pry oil seal out of final drive case. Lightly score oil seal recess with tang of file.

2) Ensure oil seal recess is clean and free of oil. Lightly top new oil seal into recess ensuring seal is square with case. Reinstall falnge, washer and nut. Tighten nut to 120 ft. lbs. (16.5 mkg) while rotating flange to ensure bearing seats correctly. Again check pinion preload. If preload is below specifications, continue tightening flange nut until specified preload is obtained. However, if preload exceeds maximum specified value, new collapsible spacer must be installed, see differential overhaul. Reconnect shaft and remove wheel chocks.

1) Remove rear suspension assembly and drain final drive unit. Remove final drive mounting plate and shock absorber/spring units. Remove nuts securing half shaft inner universal joint to brake rotor and disconnect half shaft, noting shims removed. Remove nut from inner suspension arm fulcrum shaft and drift out shaft. Repeat for other side of unit. Disconnect and plug brake lines. Disconnect hand brake levers from compensator.

2) Remove locking wire from final drive mouting bolts, remove bolts and crossmember by tilting forward over pinion. Remove calipers from final drive unit. Remove brake rotors, noting number of shims removed from between rotor and stub axle flange. To install, reverse removal procedure making sure brake rotor is centered between jaws of caliper and wire lock tension bolts in clockwise direction.

1) Remove rear cover and discard gasket. Remove lock wire and bolts securing caliper mounting braket. Withdraw stub axle along with caliper mounting bracket shims, ball bearing and oil seal. Turn down tab washer and remove nut, ball bearing and caliper mounting bracket from stub axle. Repeat procedure for second stub axle. Remove bolts securing differential bearing caps and lift off caps. Pry out differential assembly using two levers and taking care not to damage housing.

2) Remove drive pinion nut and washer. Mark relative positions of flange and pinion and remove flange. Using a suitable press, remove pinion from differential housing. Remove oil seal, oil thrower and outer bearing cone. Examine inner and outer bearing cups for wear. If replacement is required, extract cups, using suitable tools (SL 14 and SL 14/1). NOTE - If removal of bearing cups is difficult, gently heat final drive housing in rear of bearing cups. On "Powr-Lok" differentials only, proceed as follows.

3) Remove differential side beaings using suitable tools (SL. 14 & 14/3). If no reference marks are present, scribe a line across both halves of differential case to ensure correct reassembly. Remove bolts securing bolts halves of differential case. Split case and remove clutch discs and plates from one side. Remove differential side ring, pinion side gear and pinion cross shafts complete with gears. Remove remainin side gear and ring and extract remaining clutch discs and plates.

4) On non "Powr-Lok" differentials only, remove peening and drift pinion shaft lock pin out of carrier. Remove gears, shaft and shims from carrier.

"POWR-LOK" CASE ASSEMBLY

Case Assembly - 1) On "Powr-Lok" differentials, install clutch plates and discs alternately into flange half of case. Install two belleville clutch plates so that convex sides are against case. Install side ring and position one side gear into ring recess. Install cross shafts. Install pinion cross shafts complete with pinion gears ensuring that ramps on shafts coincide with mating ramps in case.

2) Assemble differential case halves ensuring that reference marks are lined up and clutch friction plate tongues are aligned with grooves in differential case. Install bolts but do not tighten yet. Check alignment of splines by inserting both stub axles. Tighten differential case bolts with stub axles in position. With one stub axle locked,  other axle must not turn more than .75" (.19 mm) measured on a 6" (152 mm) radius.

3) On non "Powr-Lok" differentials, install pinion shaft, shims and gears into differential carrier. Secure lock pin by peening.

MEASURING SIDE BEARING PRELOAD

Side Bearing Preload - Install differential side bearings, without shims, on differential case, making sure that bearings and housing are perfectly clean. Place differential assembly in housing. Install dial indicator with indicator leg against back face of ring gear. Using suitable pry bars between housing and bearing cups, move differential assembly fully to one side of housing. Zero dial indicator and move assembly ot other side. Record indicator reading and add .009" (.20 mm) to reading to give total shim pack required. Remove differential assembly from housing.

Drive Pinion Depth - 1) Place pinion, together with inner bearing cone, into housing. Turn housing over and support pinion. Install pinion outer bearing cone, flange, washer and nut, omitting collapsible spacer, oil slinger and oil seal, tighten nut. Using suitable dial indicator support fixture (SL3) zero dial indicator on setting block (4.H.A.). Place dial indicator fixture firmly on face of pinion and note dial indicator reading to bottom of housing bearing bore (see illustration).

2) The indicator reading shows deviation of pinion setting from zero cone setting. This value should agree with value etched on face of pinion at bottom. For example, if value etched on pinion is -2, dial indicator should read - .002". If setting is incorrect, dismantle pinion and remove pinion inner bearing cup. Add or remove shims as required, reassemble and recheck pinion depth.

3) When setting is correct, extract pinion from housing sufficiently far to remove outer bearing cone. Install collapsible spacer to pinion ensuring that it seats firmly on machined shoulder of pinion. Insert pinion into housing, install outer bearing cone, oil slinger and oil seal. Lightly grease splines of pinion shaft and install flange. Install new washer on end of pinion with convex side facing end of shaft. Install but DO NOT tighten nut.

MEASURING PINION DEPTH

Backlash Adjustment - 1) Place differential assembly, complete with side bearings but less shims, in housing. Ensure that bearings and housing are perfectly clean. Install dial indicator on housing with feeler on back face of ring gear. Pry differential case and ring gear assembly away from pinion until opposite side bearing is seated against housing. Zero dial indicator at this point.

2) Move differential assembly towards pinion until ring gear is deeply meshed with pinion. Note indicator reading and from this value, subtract the backlash allowance etched on drive gear (eg. B/L.007 denotes .007"). This result will yield the thickness of shims (in inches) to be placed between differential case and side bearing on ring gear side of differential. Install this thickness of shims, taking shims from pack determined previously under "Side Bearing Preload". Install balance of total shims required on opposite side of case. An example of calculations required as follows

EXAMPLE

     Side Bearing Preload Reading...........................   .080"

     PLUS Preload Value........................................   .009"

     Total Shim Pack.............................................   .089"

     Pinion-to-Ring Gear Clearance..........................  .042"

     MINUS Etched Backlash Value.........................  .007"

     Total Ring Gear Side Shims..............................  .035"

     Total Shim Pack..............................................  .089"

     MINUS Ring Gear Side Shims..........................  .035"

     Opposite Ring Gear Shim Pack.........................  .050"

MEASURING RING GEAR SIDE SHIM THICKNESS

3) With shims calculated installed, lower differential assembly into position, lightly tapping bearing home with soft hammer. Make sure ring and pinion gears mesh as installation proceeds. Install side bearing cap bolts. Mount dial indicator on housing with feeler against back face of ring gear. Turn pinion by hand and check ring gear run out. If run out exceeds specifications, disassemble differential, clean all mounting surface and check for burrs.

4) Now place dial indicator to measure ring gear backlash. Move ring gear and check that backlash is to specification etched on ring gear. If backlash is not to specifications, transfer necessary shims from side of differential case to the other NOTE - To increase backlash, remove shims from ring gear side and install on opposite side and visa versa. Finally, run a gear tooth contact pattern and adjust shims as necessary.

Pinion Bearing Preload - Install pinion and stub axle oil seals. Install stub axles following procedure give under stub axle removal and installation. Tighten flange to ensure correct seating of taper roller bearings. Use care not to overtighten nut. If not is overtighten, install a new collapsible spacer as pinion bearing preload will otherwise be incorrect. Install final drive rear cover using new gasket and suitable sealer (Hylomar).

MEASURING RING GEAR BACKLASH

Rear axle assembly is semi-floating, hypoid gear type with centerline of pinion set below centerline of ring gear. Axle shafts have integral wheel hubs and are supported in the differential case by side gears and in the axle housing by ball bearings. Service of these assemblies, with exception of axle housing, may be performed without removing complete rear axle assembly from vehicle

The semi-floating, hypoid gear type rear axle assembly with separate housing is used on all Fiat 124 models. The basic difference in rear axles from one vehicle model to another is the axle ratio. The Fiat 124 Sedan axle ratio is 4.3 to 1, and the Fiat 124 Sedan Special is 4.1 to 1.

Removal - 1) Raise vehicle and remove rear wheels and disc brake front shield. Remove caliper support bracket mounting bolt and remove caliper (without disconnecting brake lines). Remove bolts attaching brake disc to axle shaft hub and remove brake dis and plate.

2) Remove snap ring securing bearing dust shield. Attach slide hammer and withdraw axle shaft assembly. Inspect axle shaft, bearing, dust shield and bearing retaining collar for wear or damage and replace as necessary.

Disassembly - Using suitable arbor press (A. 74108/1/2), press bearing retaining collar off axle shaft and discard collar. NOTE - Retaining collar must never be reused; replace with new collar. Remove ring, dust shield, and bearing. If axle shaft is scored or damaged, replace shaft.

Reassembly - 1) Install snap ring, dust shield, and bearing onto axle shaft held vertically on solid plate of arbor press (A. 74107/1). Insert new collar into suitable holder. (A. 74107/4), place in oven and place on axle shaft. Press axle into collar using 13,000 lbs (6000 kg) maximum pressure.

2) Place axle shaft assembly in tool A. 9560. Rotate axle by applying 58 to 61.5 ft. lbs. (8 to 8.5 mkg) of torque then check dial indicator reading at opposite end of axle shaft. Reading should remain at zero rotation of axle shaft.

3) Remove load from axle and recheck dial indicator to zero reading. This will insure that collar has not moved on axle shaft.

Reinstallation - Install new oil seal and "O" ring and complete installation by reversing removal procedure.

Removal - Drain fluid, raise vehicle, and remove wheels. Withdraw axle shafts for enough to disengage from side gears. Disconnect propeller shaft, support differential and remove attaching bolts. Remove differential assembly from axle housing.

Installation - Thoroughly clean oil residue from axle housing. Position new gasket in place and reverse removal procedure.

Disassembly - 1) With differential secured in suitable holding fixture, remove two bolts and spring washers from caps and remove lock plates. Remove bolts and spring washers securing case bearing caps, and remove caps, adjuster rings and roller bearing cups. Remove differential case from carrier.

2) Turn differential carrier upside down and lock bevel pinion shaft and remove sleeve. Remove pinion, thrust ring, rear roller bearing cone and collapsible spacer from inside housing. Remove oil seal, oil slinger, and front bearing cone from carrier.

3) Slide collapsible spacer off pinion, then draw off rear roller bearing. Thrust washer can then be removed from pinion. Using a suitable puller, remove differential case roller bearings. Remove screws holding ring gear to differential case then use drift to remove pinion gear from case. Remove pinion gears, side gears and thrust washers.

Case Assembly - 1) Install thrust washers on differential side gears and position gears in differential case. Insert pinion gears in case and engage them with side gears. Align holes in pinion gears through openings in case and insert pinion shaft. Check axial play in each side gear.

2) Axial play should not exceed .004" (0.10 mm). If play exceeds specification, replace side gear thrust washers. These washers are available in various thicknesses. If correct clearance cannot be obtained, gears must be replaced. Assemble ring gear to differential case and torque to specification. Using suitable driver (A. 70152), install both roller bearings on differential case.

Drive Pinion Depth - 1) Fit front and rear roller bearing cups of bevel pinion in position using suitable driver. Using same driver, attache cone of rear roller bearing to dummy pinion (A. 70184) then position in differential carrier.

2) Install cone on front roller bearing and place nut on dummy pinion. Turn pinion to seat bearing cones and tighten nut.

3) Zero dial indicator (A. 95690) on a surface plate then attach to dummy pinion. Position dial indicator to allow plunger to contact roller bearing seat in differential case. Obtain minimum reading on dial indicator by moving plunger from right to left. Record reading and repeat procedure on opposite side.

4) Determine an average from the two readings, then from this average, subtract the value stamped on bevel pinion to be used. This will give correct thickness of thrust washers to be inserted between the head of the pinion and the shoulder of rear roller bearing.

5) If the number stamped on the pinion is preceded by a plus sign, the thickness of the washer to be used is derived by subtracting this number from dial gauge reading. If the number stamped on the pinion is preceded by a minus sign, the thickness of the washer is obtained by adding this figure to the dial gauge reading.

6) Place thrust washer (correct thickness) on bevel pinion, then rear roller bearing cone followed by collapsible spacer. Install pinion assembly in carrier and attach the front roller bearing cone, oil slinger, oil seal and "U" joint sleeve. Install washer and self-locking nut on tail of pinion.

Pinion Bearing Preload - Secure pinion to keep it from turning. Gradually tighten nut on tail of pinion shat to B7-166 ft. lbs. (12-23 mkg). Check turning torque of pinion shaft using dynamometer (A. 95697) and adapter (A.55075) fitted to pinion nut and set to 17 INCH lbs. (20 cmkg). If turning torque is less than 14 INCH lbs. (16 mkg), pinion nut must be tightened (without exceeding maximum torque). If turning torque is more than 17 INCH lbs. (20 cmkg), pinion must be removed and collapsible spacer changed.

Backlash and Side Bearing Preload - 1) Place differential side bearing cups on side bearings and place differential assembly into carrier. Fit two bearing retaining and adjusting rings, install caps and torque to specifications.

2) Attach suitable tool (A. 95688) (see illustration), to differential carrier. Adjust backlash between ring gear and pinion to .0031-.0051" (0.08-0.13 mm). Insure that bearings are not preloaded.

3) Set preload by tightening two bearing adjusting rings alternately with equal number of turns until dial indicator "A" (see illustration), shows an increase of .0055-.0071" (0.14-0.18 mm). After preload is set, check backlash of bevel gears.

4) To check backlash, set dial indicator "B" (see illustration), so that plunger rests against tooth of bevel gear. Rotate ring gear to obtain maximum reading. Backlash must be .031-.0051" (0.08-0.13 mm).

Final Inspection and Assembly - With pinion bearing and ring gear backlash properly adjusted, make a tooth pattern contact check. NOTE - Check gear tooth contact using point impression mothod described at beginning of this section. When pattern is satisfactory, install axle shafts, brake drums, wheels and tires, propeller shaft and refill with suitable gear lubricant.

Rear axle is of the banjo type, utilizing the removable carrier style differential. Light weight construction joins split tubular housing for each side with center covers welded to axle 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.

Removal - 1) Raise and suitable 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 and 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.

FIG. 1 MEASURING AXLE SHAFT DEFLECTION

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

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

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

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

FIG. 2 EXPLODED VIEW OF AXLE SHAFT ASSEMBLY

                                               (0-2.0 mm)..............................(2.0 mm)

4) Rear axle bearing should be replaced when bearing noise is detected, when bearing axial play exceeds .014-.016" (.36-.41 mm) or if bearing axial 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 parts as necessary.

Installation - 1) Fit outer bearing retainer for sie 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 at oil seal and using suitable oil seal installer (DT-10078 and CT-1008) fit axle shaftt oil seal in rear axle housing.

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

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.

FIG. 3 REMOVING DIFFERENTIAL GEAR HOUSING

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.

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 and lever gear case assembly form housing. Using suitable puller tool (C-293-P & C-293-39) pull differential side bearing. Keep right and left bearings and shim in sequence for reassembly.

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 same position.

FIG. 6 REMOVING DRIVE PINION FRONT BEARING OUTER RACE

Drive Pinion Assembly - 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 rce, spacer and preload adjusting shim.

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

Check differential gears for correct tooth contact and replace gears if 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.

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

FIG. 7 EXPLODED VIEW OF COLT SEPARATE HOUSING REAR AXLE ASSEMBLY

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 pinions 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 bearings are scheduled to be reused, shims should be replaced with new ones of same 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 washer in order of removal. fit pinion shaft retaining nut and slowly tighten nut, continously 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 block 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 hundredth 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.

FIG. 9 MEASURING CLEARANCE BETWEEN SIDE BEARING AND GEAR CARRIER

Side Bearing Preload - Fit each side bearing into differential case leaving shims out; use suitable tool (CT-1102) for this procedure. Ensure side bearings are completely seated before proceeding. Install differential case assembly on gear carrier, then calculate the clearance bwetween 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.

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 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 four different spots on ring gear with drive pinion securely fixed in final position. Set up a dial indicator on ring gear teeth edges. If measured backlash is greater than .005-.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 at beginning of this section.

Final Inspection and Assembly - Lightly coat each gear and bearing before and during reassembly with gear oil. After installing each component, ensure all 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.