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4 Pages Wiring Diagrams 

-Engine Compartment

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-Rear Compartment

The differential assembly is of hypoid design with centerline of drive pinion gear set below centerline of ring gear. A collapsible spaer is used to set drive pinion bearing preload and all other differential adjustments are accomplished using shims. Stub axles transmit power out of differential, through independent rear suspension, to drive wheels. A clutch pack limited slip unit, "Powr-Lok", is available as an option.

Jaguar uses only one basic rear axle design, however, unit 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 determined owner inquiry or test.

NOTE - This procedure is provided since many operations on the final drive require removal of rear suspension assembly before starting work on 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 and radius arm from body mounting post. Disconnect and plug brake lines at 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 on suspension arm, installing shims removed from between carrier and suspension arm. Replace outer suspension arm fulcrum shaft, displacing dummy shaft. Secure shaft with nut and reinstall grease nipple.

Fig. 1 Exploded view of Jaguar "Power-Lok" Differential Assembly

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 measure 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 nut from stub axle. Remove ball bearing and caliper mounting bracket from stub axle.
2) Lightly oil 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 gauge, measure dimension between inside face of mounting bracket and final drive housing. The measurement obtained determines shim thickness required, 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 gauges 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 flange clockwise (viewed from front) through backlash movement. Check 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 flange, 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 propeller 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 mounting 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.

Fig. 2 Exploded View of Limited Slip Differential Clutch Pack and Side and Pinion Gears

1) Remove rear cover and discard gasket. Remove lock wire and bolts securing caliper mounting bracket. Withdraw stub axle along with caliper mounting brracket shims, ball bearing and oil seal. Turn down tab washer and remove nut, ball bearing and caliper mounting bracket from stub axle. Repeat procedure fro 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 fro 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 caps. On "Powr-Lok" differentials only, proceed as follows:
3) Remove differential side bearings using suitable tools (SL.14 and 14/3). If no reference marks are present, scribe a line across both halves of differential case to ensure correct reassembly. Remove bolts securing both 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 remaining side gear and ring and extract remaining clutch discs and plates.
4) On non "Powr-Lok" differential only, remove peening and drift pinion shaft lock pin out of carrier. Remove gears, shaft and shims from carrier.

Fig. 3 Measuring Side Bearing Preload

Case Assembly - 1) On "Powr-Lok" differentials, install clutch plates and disc alternately into flange half of case. Installtwo 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.
Side Bearing Preload - Install differential side bearing without shims, on differential case, making sure that bearing and housing are perfectly clean. Place differential assembly in housing. Install dial indicator with indicator leg against back face of ring gear. Using sutiable pry bars between housing and bearing cups, move differential assembly fully to one side of housing. Zero dial indicator and move assembly to other side. Record indicator reading and add .009" (.20 mm) to reading to give total shim pack required. Remove differential assembly from housing.

Fig. 4 Measuring Drive Pinion Gear Installed Depth

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 not 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 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 fro 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 shat. Install but DO NOT tighten nut.
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 dones .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 (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 follows
EXAMPLE:

Fig. 5 Measuring to Determine Ring Gear Side Shim Thickness

     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"
3) With shims calculated installed, lower differential assembly into position, lightly tapping bearings home with a soft hammer. Make sure ring and pinion gears mesh as installation proceeds. Install side bearing cups, ensure proper cup is placed in proper bearing. Tighten cup 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 surfaces and check for burns.

Fig. 6 Measuring  Ring Gear-to-Drive Pinion Gear  Backlash

4) Now place dial indicator to measure ring gear backlash. Move ring gear and check that backlash is 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 vise versa. Finally run a gear tooth contact pattern and adjust shims as necessary.
Pinion Bearing Preload - Install pinion and stub axle of seals. Install stub axles following procedure given under stub axle removal and installation. Tighten flange nut to specified torque. During tightening process rotate flange to ensure correct seating of taper roller bearings. Use care not to over tighten nut. if nut is overtightened, 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).

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Rear axle assembly uses an integral carrier type differential having hypoid type ring and drive pinion gear set. Drive pinion bearing preload is maintained by a collapsible spacer and differential bearing preload is obtained through the use of shims between the bearings and rear axle housing. Semi-floating axles use ball bearings retained on the axle by a press fit retaining ring and the axle is secured in the housing with a retaining flange. A removable rear cover permits inspection and service of differential assembly.

The fiat 131 uses only one rear axle assembly. The axle ratio is 4.44-1; a nine tooth drive pinion with a forty tooth ring gear.

FIG. 1  SECTIONAL VIEW OF AXLE SHAFT AND BEARING ASSEMBLY

Removal - 1) Raise and support vehicle. Remove rear wheels and brake drums. Remove bolts retaining axle shaft retaining flange to brake backing plate.

2) Attach slide hammer to axle flange and pull axle from housing using care to guide the brake backing plate off the axle as if it is extracted.

3) Remove axle bearing from shaft using an arbor press and suitable support tools. Discard axle shaft bearing retainer. Inspect retainer seat on axle shaft and if seat is scored or damaged, replace axle shaft.

Installation - 1) Place retainer flange and bearing on axle shaft. Heat bearing retaining ring to about 600°F (300°C) and place heated retainer on axle shaft.

2) Using an arbor press and appropriate support tools, press bearing retainer onto shaft until bearing is locked between retainer and shoulder on axle shaft. NOTE - Do not exceed 13,000 lbs. force with press as damage to axle shaft assembly may occur.

3) If axle is to be installed at this time, replace oil seal inside axle housing (if required), and install axle in reverse order of removal.

Removal - Raise and support vehicle. Release parking brake and remove spring from parking brake bracket and support. Pull cable housings away from bracket and remove cables from bracket and support. Remove propeller shaft from drive pinion flange and stabilizer bars from rear axle housing. Remove brake hose from "T" connector and slip link out of slot in bracket on axle housing. Support rear axle assembly floor jack(s), remove shock absorber-to-axle housing bolts and lower and remove axle assembly.

Installation - Reverse removal procedure then bleed the brake system and check for proper operation of parking brake.

FIG. 2 REMOVING DIFFERENTIAL BEARINGS FROM CASE

NOTE - Overhaul of differential assembly can be accomplished with rear axle assembly installed in vehicle

Differential Case Assembly - 1) Raise and support vehicle, remove axle shafts as previously described, and separate propeller shaft from drive pinion flange. Remove cover from rear of housing and drain lubricant.

2) Install spreader (8064), on housing, mark differential bearing caps for reference at time of reassembly, the remove bearing caps. Spread housing and remove differential case along with bearings and shims, noting position of bearing outer race and shims and keeping all left and right side components separated.

3) Using a puller, remove differential bearings from case. Keep bearings separated with other components. Put locating reference marks on ring gear and case, then removing eight ring gear-to-case retaining bolts and remove ring gear. NOTE - Drive ring gear from case (if required) using a soft headed mallet.

FIG. 3 EXPLODED VIEW OF FIAT 131 DIFFERENTIAL ASSEMBLY

4) Using a soft drift, drive differential pinion gear shaft out of case. Remove pinion gears, side gears, and side gear thrust washers.

Drive Pinion Gear - Hold drive pinion flange and remove flange nut and flange from drive pinion gear. Remove oil seal and dust shield from pinion shaft then push dive pinion gear out of rear housing. Remove drive pinion  bearing outer races from housing. Using an arbor press, remove rear bearing from drive pinion shaft and retain shims found between bearing and gear.

FIG. 4 REMOVING REAR BEARING FROM DRIVE PINION GEAR

Drive Pinion Gear - 1) Install pinion bearing outer races in rear axle housing. Before installing rear bearing on drive pinion gear, establish pinion depth adjusting shim thickness as follows (all values given are in hundredths of a millimeter):

NOTE - If the original ring and pinion gears will be used for reassembly, and right-to-drive pinion gear tooth contact pattern is satisfactory, use original shim(s).

Note marking on original drive pinion shaft. Measure original shim thickness and add it to the value give on the pinion shaft to establish the nominal dimension.

Example: Pinion marking is +10 and original shim thickness is 2.90. Nominal dimension is 3.00 (2.90 plus +10).

Note marking on new pinion gear and subtract this value from the established nominal dimension and this will give you the new required shim thickness.

EXAMPLE: Nominal dimension is 3.00 and marking on new drive pinion is +20, then new shim thickness is 2.80 (3.00 minus +20, then new shim thickness is 2.80 (3.00 minus +20).

2) Place new (or original) pinion depth adjusting shim on drive pinion gear, and using a press install rear bearing on drive pinion gear. Lubricate bearing and install drive pinion and bearing in housing. Install new collapsible spacer, front pinion bearing, dust shield, new oil seal, and pinion flange in housing.

3) Start pinion flange nut on shaft and as nut is tightened, keep checking rotating torque of pinion shaft (pinion bearing preload) using an inch pound torque wrench. Tighten nut until pinion bearing preload is within specifications. NOTE - If pinion bearing preload torque is exceeded, do not back off nut to obtain preload. Install new collapsible spacer and repeat procedure.

Differential Case Assembly - 1) Place thrust washers on side gears and install side gears in case. Install pinion gears by rolling them into position and install pinion shaft. Check rotating torque is not to specification, install new thrust washers on side gears. NOTE -Thrust washers are available in thicknesses from .0709" (1.80 mm) to .0817" (2.10 mm) in increments of .002" (.05 mm).

2) Install ring gear on case and tighten bolts to specified torque. Press differential bearings onto case, and if using original bearings, spread housing and install case using original shims. If using new bearing or case, install case in housing and insert enough shims equally on both sides to eliminate any end play.

3) Install bearing caps and bolts and tighten bolts. Measure ring gear backlash using a dial indicator mounted to hoousing ring gear backlash using a dial indicator mounted to housing with plunger contacting ring gear at right angel to the gear teeth. Block drive pinion flange from turning. Zero dial indicator. Rotate ring geaer back as far as possible and note backlash reading on indicator. If backlash is not within specification, adjust backlash by changing size of shims. To increase backlash, increase size of shim on pinion side of carrier, and to decrease backlash, increase size of shim on ring gear side of carrier. When changing shims, be sure to install shims of equal size to opposite side of carrier.

4) After determining correct shims to be used, add .002" (.05 mm) more shim thickness to each side. Install spreader on housing, spread housing and install bearing outer races and shims. Remove spreader and install bearing caps and tighten bolts. With differential completely assembled, check ring-to-pinion gear tooth contact pattern to ensure all adjustments are correct.

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File Type: PDF, RAR

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 models, The axle ration is 4.3-1.

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 disct to axle shaft hub and remove brake disc 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 snap ring, dust shield and bearing. If axle shaft is score 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 heat to 571°±18°F (300°±10°C). Remove unit from oven and plae on axle shaft. Press axle shaft into collar using 13,000 lb (6,000 kg) maximum pressure.

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 in place. Loosen self-locking nut securing sleeve to 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 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.

FIG 3. CHECKING FOR CORRECT THICKNESS OF WASHER FOR DRIVE PINION DEPTH ADJUSTMENT

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" (.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, attach cone  of rear roller bearing to dummy pinion (A. 70184) then position dummy pinion in differential carrier.

FIG. 4 LOCATION OF STAMPED NUMBER ON DRIVE PINION GEAR

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 on 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 the 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.

FIG. 5 CHECKING DIFFERENTIAL BEARING AND RING GEAR BACKLASH

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 87-166 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 cmkg), pinion nut must be tightened (without exceeding maximum torque). If turning torque is more than 17 INCH lbs. (20 cmkg), pinion must be removed an 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 to "B" (see illustration), so that plunger rests against tooth of bevel gear. Rotate gear to obtain maximum reading. Backlash must be .0031-.0051" (0.08-0.13 mm).

Final Inspection and Assembly - With pinion bearing and ring gear backlash properly adjusted, make a tooth contact pattern check. NOTE - Check gear tooth contact using paint impression method 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.

Axle housing is banjo type with removable differential carrier and semi-floating axle shafts. Ring and pinion are hypoid type in which centerline of pinion is set below centerline of ring gear. Differential case may be either two pinion or four pinion design. The axle shafts are retained in housing by ball bearings and bearing retainers at axle housing outer ends.

All Mazda models use one basic 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 (All. Exc. Pick-Up) - Remove wheel and tire assembly and brake drum. Remove brake shoe return springs and brake shoes. On RX-4 models, remove center cap adapter from axle shaft flange. On all models, withdraw nuts attaching retainer and backing plate to axle housing, then use a suitable puller (49 0259 631 and 49 0223 630A) to remove axle from housing.

Bearing Replacement (All Exc. Pick-Up) - Remove axle bearing and collar using a press and a suitable bearing adapter (49 0259 745). NOTE - If pressure necessary to remove bearing exceeds 10 tons, or if bearing adapter is not available, grind bearing retaining collar down and cut with a chisel to remove. To reassemble, apply a light coat of oil to axle shaft and place bearing retainer and spacer on shaft. Position bearing on shaft with sealed side toward axle shaft flange, then press bearing on shaft until spacer contacts shaft shoulder. Next, press bearing retaining collar on shaft until it seats firmly against bearing. NOTE - Do not press bearing and collar on shaft at the same time. In addition, if collar is installed with less than 3 tons of pressure, replace a new part.

AXLE SHAFT ASSEMBLY (EXCEPT PICK-UP)

Installation (All Exc. Pick-Up - 1) Apply a light coat of grease to oil seal in axle housing. Check axle shaft end clearance as follows. Install backing plate and gasket temporarily and measure depth of bearing seat in axle housing. Then measure width of axle bearing outer race. The difference between the two measurements indicates the required thickness of shim.

2) Shims are available in thicknesses of .004" (.1 mm) and .016" (.4 mm). After selecting correct shim pack, apply sealant to shims and position brake backing plate and shims on axle housing. Install axle shaft assembly in housing using a new gasket, then install and tighten retainer bolts. At this time, recheck end play, maximum end play allowable is .004" (.1 mm). Install brake shoes, return springs, brake drum and wheel and tire assembly.

AXLE SHAFT ASSEMBLY (B1600 & RE PICK-UP)

Removal (B1600 and Pick-Up) - Remove wheel and tire assembly, then remove brake drum and brake shoes. Remove parking brake cable retainer and disconnect brake lines at wheel cylinders. Remove nuts attaching backing plate and bearing housing to axle housing, then pull axle shaft, backing plate, bearing housing assembly, and shims off axle housng.

Bearing Replacement (B1600 and RE Pick-Up) - Straighten tools of lock washer, and using a suitable spanner wrench (49 0603 621A), remove lock nut and lock washer. Using a puller withdraw bearing and housing assembly from axle shaft, then remove backing plate. Remove bearing and oil seal from housing. To reassemble, reverse disassembly procedure.

Installation (B1600 and RE Pick-Up) 1) Install axle shaft, backing plate, and bearing housing to rear axle housing, temporarily attaching with two bolts and nuts. Mount a dial indicator on backing plate and check axle shaft end play. End play should be .002-.006" (.05-.15 mm).

2) NOTE - If both axle shafts were removed, a special procedure must be followed: The end play for the first axle shaft installed should be set to .026-.033" (.65-.85 mm). The second axle shaft installed should be set to the normal end play of .002-.006" (.05-.15 mm).

Removal and Installation - Raise vehicle until rear wheels are clear of ground. Remove drain plug and drain rear axle lubricant, reinstall plug and tighten. Remove axle shafts. Mark propeller shaft and pinion flange for reassembly reference, then disconnect propeller shaft. Remove carrier attaching nuts and withdraw carrier from axle housing. To install, reverse removal procedure, making sure to refill axle with lubricant.

MEASURING PINION HEIGHT

1) Mount carrier in a suitable repair stand. Attach a dial indicator to carrier (with button of indicator contacting backface of ring gear) and check ring gear deflection. Maximum allowable deflection is .004" (.1 mm); replace ring and pinion if above specification. Punch identification marks on side bearing supports of carrier, differential bearing caps, and side bearing adjusters. Remove adjuster lock plates, loosen bearing cap attaching nuts or bolts, and slightly back off adjusters to relieve preload.
2) Remove bearing caps and adjusters, then withdraw differential assembly from carrier, making sure side bearing races remain with their respective bearings. If necessary for replacement, use a suitable puller and remove side bearings from gear case. Straighten lock tabs, remove ring gear attaching bolts, and separate ring gear from gear case.
3) On all models except RX-4, drive out differential pinion shaft lock pin with a punch and remove pinion shaft. Rotate pinion gears 90 degrees and remove gears, thrust washers, thrust block (if equipped), and differential side gears. On RX-4 models, remove bolts joining differential case halves and separate case. Remove side gears, thrust washers, pinion gears, and spider.
4) On all models, remove pinion nut and pinion flange. Remove drive pinion and rear bearing assembly, adjusting shims (if equipped), spacer and bearing collar if used). NOTE - It may be necessary to top end of pinion with soft hammer to remove from carrier. Remove front oil seal and withdraw front pinion bearing. Using a press, remove rear bearing from drive pinion, then lift off pinion adjusting shim. If necessary for replacement, use a drift punch and remove pinion bearing races from carrier.

MAZDA REAR AXLE ASSEMBLY

REASSEMBLY AND ADJUSTMENT
Drive Pinion Depth - 1) NOTE -The use of a suitable dial indicator assembly (49 0727 570) and pinion gauging set (49 0305 555, all exc. pick-up; or 49 0603 555A, B1600 and RE pick-up) is required for this procedure. Install dial indicator on gauge body, place gauge body on a surface plate, and preload indicator .040-.120" (1-3 mm). When preloaded, turn outer ring of indicator assembly to "zero" gauge.
2) Make sure differential bearing bores are free of dirt and burrs, then install drive pinion, dummy bearing, and original pinion depth shim into carrier. Place gauge block on pinion and position indicator assembly on block so button of indicator contacts lowest portion of differential bore.
3) Record the amount indicator moves in a "+" (plus) or "-" (minus) direction from zero. Remove gauging assembly and pinion from carrier. Check rear face of pinion for the machining correction figure. If pinion is marked "+" (plus), SUBTRACT amount specified on pinion from dial indicator reading; if marked "-" (minus), ADD amount to indicator reading. NOTE - Figures on pinion are hundredth millimeters.
4) Place dummy pinion and rear pinion bearing on surface plate and compare heights. If pinion bearings is higher than dummy bearing, SUBTRACT difference from dial indicator reading, if pinion bearing is lower than dummy bearing, ADD amount to indicator reading.
5) Select correct pinion depth adjusting shim to be used for reassembly by adding or subtracting the amount determined in steps 2), 3), and 4) from the thickness of the original pinion depth shim used during gauging process. Position correct shim on pinion and install pinion bearing. Shims are available in the following thicknesses for all models except RX-4:
Identification Mark                              Thickness In. (mm)
08.......................................................   .121 (3.08)
11.......................................................   .122 (3.11)
14.......................................................   .124 (3.14)
17.......................................................   .125 (3.17)
20.......................................................   .126 (3.20)
23.......................................................   .127 (3.23)
26.......................................................   .128 (3.26)
29.......................................................   .130 (3.29)
32.......................................................   .131 (3.32)
35.......................................................   .132 (3.35)
38.......................................................   .133 (3.38)
41.......................................................   .134 (3.41)
44.......................................................   .135 (3.44)

SOLID BEARING PRELOAD SPACER AND SHIMS

47.......................................................   .137 (3.47)
For RX-4 models, the following thickness shims are available
Identification Mark                             Thickness In. (mm)
52.......................................................   .139 (3.52)
55.......................................................   .140 (3.55)
58.......................................................   .141 (3.58)
61.......................................................   .142 (3.61)
64.......................................................   .143 (3.64)
67.......................................................   .145 (3.67)
70.......................................................   .146 (3.70)
73.......................................................   .147 (3.73)
Pinion Bearing Preload (W/ Solid Bearing Spacer) - 1) Position drive pinion and rear bearing assembly into carrier, then install bearing spacer and preload shims onto pinion. Install front pinion bearing and pinion flange (do not install oil seal at this time). Install pinion nut and tighten to 110 ft. lbs. (15 mkg) on 1200 models or 130 ft. lbs. (18 mkg) on R-100 models.
2) Using a torque wrench installed on pinion nut, measure turning torque of drive pinion through at least one full revolution. If preload is greater than specified (see Axle Assembly Specifications), a thicker shim or longer bearing spacer is required; if preload is less than specified, a thinner shim or shorter bearing spacer is required. Shims and spacer are available in the following thicknesses and lengths:
Identification Mark                               Thickness/Length In. (mm)

INSTALLING COLLAPSIBLE BEARING SPACER

Shims
   4.....................................................   .013 (.34)
   6.....................................................   .014 (.36)
   8.....................................................   .015 (.38)
Spacer (1200 Model Only)
   10...................................................   1.658 (41.10)
   18...................................................   1.661 (41.18)
   26...................................................   1.664 (41.26)
   34...................................................   1.668 (41.34)
Spacer (R-100 Model Only)
   60...................................................   2.149 (54.60)
   68...................................................   2.152 (54.68)
   76...................................................   2.155 (54.76)
   84...................................................   2.159 (54.84)

INSTALLING PINION SHAFT & LOCK PIN

3) After obtaining correct preload shim pack, remove pinion flange, install pinion oil seal, and reinstall pinion oil seal, and reinstall pinion flange. Tighten pinion nut to specification.
Pinion Bearing Preload (W/Collapsible Bearing Spacer) - 1) Position drive pinion in carrier and install bearing spacer. Place front pinion bearing in position on pinion gear, hold gear fully forward, and drive bearing over pinion until seated. Apply grease to lip of pinion by tapping with a soft hammer. Install pinion washer and nut. Before tightening nut (when pinion preload is zero), check oil seal drag using a torque wrench. Tighten pinion nut as follows:
Application                                       Ft. Lbs. (mkg)
808 (W/1300 cc)...................................   87 (12)

INSTALLING DIFFERENTIAL ASSEMBLY

RX-4....................................................  101(14)
B1600, RE (Rotary Pick-Up)...................  145(20)
All Others..............................................   94(13)
2) With nut tightened, check preload using a torque wrench mounted on pinion nut. If preload is not as specified (see Axle Assembly Specifications), continue tightening nut and checking preload until specified preload is obtained. CAUTION - Preload builds quickly. Nut should be tightened a little at a time and preload checked after each slight amount of tightening.
Case Assembly - 1) On all models except RX-4, install a thrust washer on each differential side gear and install into case. Through openings in gear case, insert pinion gears exactly 180 degrees opposite each other. Rotate pinion gears 90 degrees so holes in gears line up with pinion shaft holes in gear case. Insert pinion shaft through case and pinion gears.

ADJUSTING BEARING PRELOAD (CASE SPREAD)

2) On RX-4 models, install a thrust washer on each differential side gear and install into case halves. Position pinion gears on spider and install spider into differential case half. Align identification marks, mate case halves, and install and tighten retaining bolts.
3) On all models, check backlash between side gears and pinion gears. Backlash should be less than .004" (.1 mm); if not, install selective thrust washers to bring backlash within specifications. Washers are available in thicknesses of .063" (1.6 mm), .067" (1.7 mm), .071" (1.8 mm), .079" (2.0 mm), .083" (2.1 mm), and .087" (2.2 mm). NOTE - Always use some thickness thrust washer for both side gears.
4) If equipped with thrust block, remove pinion shaft, install thrust block, and reinstall pinion shaft. On all models except RX-4, drive lock pin into case to secure pinion shaft. Using a punch, shake lock pin into case to secure pinion shaft. Using a punch, stake lock pin hole to prevent pin from working loose. On all models, mount ring gear on case, then install and tighten ring gear attaching bolts. If removed, instal differential side bearings.
Backlash & Side Bearing Preload - 1) Place differential case assembly into carrier making sure timing marks on ring and pinion gears are aligned. Install bearing adjusters and bearing caps, then tighten bearing cap nuts or bolts finger tight. Turn adjusters with a suitable spanner wrench (49 0259 720) until bearing end play is eliminated and some backlash exists between ring gear and pinion. Slightly tighten one bearing cap nut or bolt on each side carrier.
2) Mount a dial indicator to carrier flange so button of indicator contacts of the ring gear teeth at a right angle then check backlash between ring and pinion gears. Using the spanner wrench, turn both bearing adjusters equally until backlash is as specified in Axle Assembly Specifications.
3) Differential bearing preload (case spread) is obtained by tightening both bearing adjusters equally.  Tighten adjusters until the distance between pilot section of side bearing caps in as specified in Axle Assembly Specifications. Tighten bearing cap nuts or bolts, then recheck backlash adjustement. Make a gear tooth pattern check to insure correct assembly, then install adjuster lock plates on bearing caps.