Online Guide and Manuals

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.

Rear axles are hypoid design with center line of pinion set below centerline of ring gear. The axle shafts, pinion and differential assembles can be serviced without removing axle from vehicle. All differential adjustments are performed using shims. No adjustment for axle shaft end play is necessary.

Only one basic axle design is used on these models. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth.

1) With rear of vehicle raised and wheels removed, release handbrake and back off brake shoe adjuster. On models with disc wheels, remove brake drum locating screws and top drums off hubs. Remove axle shaft retaining screw and withdraw shaft from hub assembly. On models with wire wheels, remove nuts securing drum to hub and tap brake drums off hub. Remove retaining screws securing hub extension flanges to hubs. Withdraw hub extensions and axle shafts.

2) Using suitable tool, remove hub nut and lock washer. Withdraw hub complete with bearing and seal. To install, repack hub bearings with grease and press hub into position. If paper washer or "O" ring was damage on disassembly, they must be replaced. If seal was removed, drift it into position using suitable tool. Drift hub, into axle housing using suitable tools and reinstall remainder of components in reverse of disassembly procedure.

1) Mark propeller shaft and pinion flange for proper realignment and disconnect propeller shaft. Unscrew nut in center of flange, using suitable tool to prevent flange from rotating. Remove nut and washer and withdraw flange and pressed end cover from pinion shaft. Extract oil seal from axle housing.

2) Press new seal into axle housing with edge of sealing ring facing inwards. Replace flange and end cover, taking care not to damage edge of oil seal. Tighten pinion flange nut and reconnect propeller shaft, ensuring that index marks are fixed up.

Drain rear axle and remove axle shafts. Mark propeller shaft and pinion shaft for correct reassembly and disconnect shaft. Remove nuts securing differential carrier to axle housing and withdraw complete carrier. To install, reverse removal procedure.

1) Check to ensure that differential bearing caps are marked to ensure correct replacement, then remove bearing cap nuts, washers and caps. Remove differential cage. Remove differential bearings from cage, using suitable tools and not that the thrust face of each bearing is marked "THRUST" and that shims are installed between inner ring of each bearing and differential cage. Knock back tabs of locking washers and unscrew bolts securing ring gear to differential cage, remove ring gear.

2) Tap out pin locating differential pinion shaft from ring gear side of cage as tapered pins are used. Drive out differential pinion shaft and remove pinions and thrust washers from cage. Remove pinion nut, flange and pressed end cover. Drive pinion shaft towards rear through carrier. Pinion shaft will come out with inner race and rollers for rear bearing, leaving outer race and complete front bearing in position.

3) Tap out inner race of front bearing and oil seal. Withdraw outer races using suitable tools. Slide off pinion sleeve and shims. Withdraw rear bearing inner race from pinion shaft using suitable tools. Note spacing washer against pinion head. Remove rear bearing outer race using suitable tools.

Clean and inspect all components for worn or damaged parts. The ring and pinion gear must be replaced as a matched set if replacement of either is necessary.

CALIBRATING DIAL INDICATOR (TOOL 18G-191

Drive Pinion Depth - 1) Install outer bearing races in carrier using suitable tools. Smooth off pinion head with an oil-stone, taking care not to remove any markings etched on head. Assemble pinion and rear bearing with a washer of known thickness behind pinion head Position pinion in carrier without bearing spacer and oil seal.

2) Install inner ring of front bearing and pinion flange and tighten nut slowly until a bearing preload of 8-10 inch lbs. (9-12 kgcm) is obtained. Using tool 18G-191, adjust dial indicator to zero on machined step "A" of setting block (see illustration). Place dial indicator and base of tool on head of pinion and position tool so dial indicator feeler rest from zero. Now swing indicator to other bearing bore and again note variation from zero. Average the two variations together.

3) Take into consideration any variation in pinion head thickness. This will be shown as an unbracketed figure etched on pinion head and will always be minus. If no unbracketed figure is shown, pinion is of nominal thickness. Using the average dial indicator reading just obtained and the unbracketed figure from pinion head, perform the following calculation. If indicator reading is minus, add indicator reading to pinion head reading and REDUCE known washer thickness by this amount

EXAMPLE:

CHECKING BEARING THICKNESS VARIATION (TOOL 18G

    Indicator Reading...........................  -.002"

    Pinion Marking...............................  -.005"

    Variation from Nominal..................  -.007"

Reduce known washer thickness by this amount.

4) If indicator reading is plus and numerically LESS than pinion marking. REDUCE the known washer thickness by the difference.

EXAMPLE

    Pinion Marking.............................  -.005"

    Indicator Reading......................... +.003"

    Variation From Nominal............... -.002"

Reduce known washer thickness by this amount.

5) If indicator reading is plus and numerically GREATER than pinion marking, INCREASE the known washer thickness by the difference.

EXAMPLE:

    Indicator Reading........................ +.008"

    Pinion Marking............................ -.003"

    Variation from Nominal............... +.005"

CHECKING BACKLASH (TOOL 18G-191)

Increase known washer thickness by this amount.

6) The only cases where no changes are required to washer thickness are when indicator reading is PLUS and NUMERICALLY EQUAL to unbracketed pinion marking, or indicator reading is zero and there is no unbracketed marking on pinion head. Allowance should now be made as follows for mounting distance marked on pinion head in a rectangular bracket as follows.

7) If marking is a PLUS figure, REDUCE washer thickness by on equal amount. If marking is a MINUS figure, INCREASE washer thickness by an equal amount. A tolerance of .001" (.03 mm) is allowed of washer finally installed.

Pinion Bearing Period - Install washer of thickness just calculated under pinion head and assemble pinion with bearings, pinion sleeve, oil seal, flange and nut. Pinion sleeve is of collapsible design and can only be used once. Therefore the following procedure should be done with care or a new sleeve will be required. Slowly tighten flange nut to specifications while holding flange to prevent rotation. During tightening process, occasionally check pinion bearing preload. When nut is tightened to specifications, preload should be to specifications. Installation of pinion is now complete.

Side Bearing Preload - 1) The method of setting position of ring gear assembly depends on marking given on differential gear carrier and case. The dimensions to be considered are (see illustration): "A" - The dimension from center line to bearing on right side. Variation in dimension "A" is stamped on carrier adjacent to right side bearing bore. "B" - The dimension from center line to bearing on left side. Variation is stamped on left side bearing bore. "C" - Dimension from bearing on one side of cage of bearing on the other side and "D" - Dimension from rear face of ring gear to bearing on opposite side. Variations are "C" & "D" dimension are stamped on machined face of differential cage.

SIDE BEARING PRELOAD DIMENSIONS

2) It is possible to calculated shim thickness required on left side by use of following formula:

Substituting the actual variation shown, this formula gives shim thickness required to compensate for variations in machining plus the extra .002" (.05 mm) to give necessary bearing preload. In addition, allowance must be made for variations in bearing thickness in the following manner:

3) Rest bearing with inner race over recess and thrust face downwards on surface plate of tool 18G-191. Place dial indicator on surface plate and zero indicator on step "A" of gauge block of tool 18G-191. Swing indicator over until it rests on plain surface of inner bearing race. Hold inner race down against balls and note indicator reading. Indicator will normally indicate a negative reading. This negative variation should be ADDED to the shim pack previously calculated for that side of the differential.

4) To calculate the shim thickness for the right side, use the following formula:

substituting the actual values for "B" and "D" as described in 1). Again, final allowance must be made for variation in bearing thickness describe in 3) above.

5) When a framed number is marked on back of ring gear, e.g. +2, it must be taken into account before assembling shims and bearings to differential cage. If, for example, the mark is +2, then shims of .002" must be transferred from left (ring gear) side to right side. If marking is -2, shims of .002" must be moved from right to left side.

Backlash Adjustment - 1) Assemble bearing  (thrust faces outwards) and shims as calculated to differential cage. Bolt ring gear to differential cage but do not knock over locking tabs. Mount assembly on two "V" blocks and check runout by means of dial indicator. If runout exceeds specifications, remove ring gear and check joint faces on cage ring gear for any particles of dirt. If parts are thoroughly cleaned it is unlikely that ring gear will not run true. Tighten bolts and knock over locking washers.

2) Install differential to carrier. Replace bearing caps and tighten nuts. Bolt surface plate of tool 18G-191 to carrier flange and mount dial indicator in such a way that an accurate backlash figure may be obtained. Correct figure for backlash to be used with any particular ring gear and pinion is etched on rear face of ring gear. A movement of .002" (.05 mm) shim thickness from one side of differential cage to the other will produce a variation in backlash of about .002" (.05 mm). Use care to ensure absolute cleanliness during this operation as dirt can result in inaccurate readings and poor settings. Carrier may now be installed in rear axle housing.

File Size: 89 MB

File Type: PDF, ZIP

Rear axles are hypoid design with center line of pinion set below centerline of ring gear. The axle shafts, pinion and differenctial assemblies can be serviced without removing axle from vehicle. All differential adjustments are performed using shims. No adjustments for axle shaft end play is necessary.

Side Bearing Preload - 1) Install differential bearing comes in gear carrier using suitable tool. Install two differential gear carrier using suitable tool. Install two differential gears in carrier, ensuring each thrust washer is correctly positioned. Position two pinion gears, one each side of carrier and mesh them with differential gears. Using on axle shaft inserted in a differential gear, turn gears and ensure two pinions rotate into mesh and align with pinion shaft hole in carrier. Install pinion shaft.

2) Press each pinion firmly into mesh with differential gears and, asses required pinion thrust washer thickness required to achieve ZERO backlash. Remove pinon shaft and pinions and install thrust washers. Reinstall pinion gears and shfts with thrust washers and check that zero backlash exists. Lubricate components and install pinion shaft locking pin and secure by peening metal of differential carrier.

3) Clean ring gear mounting and carrier face and install ring gear, tighten bolts. Assembly carrier bearing cups to bearings and position assembly in case; do not install bearing shims. Install bearing caps in correct position. Using dial indicator and suitable adapters, ensure that ring gear runout does not exceed specifications. Remove bearing caps and press differential bearing cups onto bearings and move carrier assembly to one side of case. Zero dial indicator and move carrier assembly fully in opposit direction. The indicator reading should be noted for future references as "Total Side Floor". Remove differential assembly from case.

Drive Pinion Depth - 1) Install inner and outer pinion bearing cups to case using suitable tools. Install pinion inner bearing to dummy pinion (18G-191 M). NOTE - Dummy pinion incorporate standard pinion head washer of .077" (1.95 mm) thickness. Oil bearing and install dummy pinion, outer bearing, tool spacer, washer and nut. Tighten nut gradually until bearing preload specification is obtained. Clean dummy pinion head and position dial indicator gauge foot of tool 18G-191 on dummy head and zero indicator.

2) Move dial indicator over center of one differential bearing bore and note reading. Repeat for opposite bearing bore.

Average these two measurements and perform the following calculation.

Average of bore measurements.................. .0002" (.051 mm)

PLUS dummy pinion washer allowance..... .077"  (1.956 mm)

Required size of pinion head washer ........  .079    (2.007 mm)

If the etched marking on pinon face is "N" (normal), no change to above dimension is required. If etched marking is positive (+), reduce size of required pinion washer by amount marked. If etched marking is negative (-), increase size required pinion washer by amount marked. Remove dummy pinion and remove inner bearing from dummy pinion.

Pinion Bearing Preload - 1) Place selected pinion head washer on pinion and install inner bearing using suitable tools. Oil bearing and install pinion in case. Install bearing spacer, chamfered end towards drive vlange. Install shims, oil and install outer bearing. Install drive flange washer and nut. Gradually tighten nut, but do not exceed torque specifications, and check preload during tightening operation.

Adjusting Backlash - 1) Place bearing cups on differential bearing and install carrier in case. Position dial indicator with suitable adapters on ring gear side of case. Move ring gear fully into mesh with pinion and zero indicator on rear of ring gear. Move ring gear and carrier in opposite direction until bearing ring gear side is butted in housing. The indicated measurement should be noted as the "In-out" mesh clearance.

2) Perform the following calculation:

"In-Out" mesh clearance 1..........................   .025" (.63 mm)

MINUS Specified backlash.........................  .005" (.13 mm)

Required ring gear side shim pack.............  .020" (.50 mm)

"Total Side Floot" 2....................................  .060"  (1.52 mm)

MINUS ring gear side shim pack...............  .020" (.50 mm)

Required shim pack opposite ring gear ...  .040" (1.02 mm)

1 - Value from 2) above

2 - Value from 2) under "Side Bearing Preload".

Add a value of .002" (.51 mm) to each shim pack calculated above for preload.

3) Stretch case specified amount and from calculations made above, select required shim pack. Install differential assembly in case with shim packs. Loosen case stretcher and remove. Install bearing caps as originally marked and tighten bolts. Rotate pinion to settle differential bearings and position dial indicator using suitable adapters to measure ring gear backlash. Measure backlash at several locations, it must be to specifications. If not, interchange shims from side to side to achieve specified backlash. NOTE - A movement of .002" (.05 mm) shim thickness from one bearing to the other will vary backlash by about .002" (.05 mm). Reinstall differential assembly in rear axle housing.