Ford Falcon. Manual — part 57

205-02B-13

Independent Rear Suspension — Full Floating Axle

205-02B-13

DISASSEMBLY AND ASSEMBLY (Continued)

3. A positive (+) number on the drive pinion means

that a thinner shim should be installed to move

the pinion gear away from the ring gear. A

negative (-) number means that a thicker shim

should be used to move the drive pinion closer to

the ring gear.

4. Lubricate all differential parts with the

recommended rear axle lubricant, before they are

installed.

5. To select the correct shim thickness follow these

steps:
NOTE: The exact same rear pinion bearing that is

to be used in the vehicle, is to be used when

using the dummy pinion.

1. Install the front and rear pinion bearing cups

into the axle housing.

2. Fit the pinion bearing cone and rollers to the

dummy pinion tool. Install the dummy pinion

to the axle housing. Fit the pinion front cone

and roller to the dummy pinion. Install the tool

thrust collar and the nut to the dummy pinion.

3. Tighten the nut until a bearing preload of 1.4

to 2.4 Nm (new bearing), 0.7 to 1.2 Nm (used

bearing) is achieved while rotating the dummy

pinion back and forth to ensure correct

seating of the bearing rollers.

4. Position the depth gauge cylinder in the

carrier and fit the bearing caps, tightening

lightly. Determine the size of pinion shim that

will pass between the depth gauge and the

dummy pinion head. Examine the drive pinion

installation marking. The size of the pinion

shim should then be altered as follows:- A

positive (e.g. +0.002 inch) marking means

that this pinion has to be set at this number of

thousandths of an inch further from the drive

gear, i.e. a shim this amount thinner must be

used. A negative (e.g. - 0.002 inch) marking

means that a shim this size thicker must be

used. A zero (0) marking indicates that the

shim selected with the gauge is the correct

one for this carrier/pinion combination.

Position shims are available in .001 in (0.025

mm) increments from .008 to .030 in (0.2 to

0.75 mm).
NOTE: The marking on the pinion is in

Imperial measurement.

5. Remove the tools from the carrier.

6. Remove the rear pinion bearing cup from the

housing.

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205-05-1

Rear Drive Halfshafts

205-05-1

SECTION : 205-05 Rear Drive Halfshafts

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205-05-2

DESCRIPTION AND OPERATION

Rear Drive Halfshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . .205-05-3

Halfshaft

Handling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-05-3

DIAGNOSIS AND TESTING

Rear Drive Halfshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . .205-05-4

REMOVAL AND INSTALLATION

Halfshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205-05-5

DISASSEMBLY AND ASSEMBLY

Halfshaft Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-05-6

205-05-2

Rear Drive Halfshafts

205-05-2

SPECIFICATIONS

General Specifications

Description

Specification

Constant Velocity Joint

ESP-MIC207-A

Grease (High Temp)

E43Z-19590-A

Torque Specifications

Description

Nm

Ball joint nuts

115

Knuckle bolt

115

Rear axle wheel hut nut

290

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205-05-3

Rear Drive Halfshafts

205-05-3

DESCRIPTION AND OPERATION

Rear Drive Halfshafts

CAUTION: An inspection of the outer and

inner boots is necessary so that if damage or

grease leakage is evident, installation of a new

halfshaft can take place immediately. Continued

operation with damage or grease leakage will

result in CV joint wear and noise due to

contamination and loss of the CV joint grease.
1. Inboard and outboard CV joints connect to a

splined shaft. A circlip stopper holds the cross

groove inboard race assembly (inboard CV joint)

together.

2. An axle circlip (4B422) retains the splined inboard

CV joint to the differential side gear. Install a new

axle circlip each time the halfshaft is removed

from the vehicle.

3. A rear axle wheel hub nut secures the side shaft

assembly (interconnecting shaft and outboard CV

joint) the rear hub. Install a new rear axle wheel

hub nut each time the halfshaft is removed from

the vehicle.

Halfshaft Handling

CAUTION: Never pick up or hold the halfshaft

only by the inboard or outboard CV joint.

CAUTION: Do not over-angle the CV joints.

CAUTION: Damage will occur to an

assembled inboard CV joint if it is over-plunged

outward from the joint housing.

CAUTION: Never use a hammer to remove or

install the halfshafts.

CAUTION: Never use the halfshaft assembly

as a lever to position other components. Always

support the free end of the halfshaft.

CAUTION: Do not allow the boots to contact

sharp edges or hot exhaust components.

CAUTION: Handle the halfshaft only by the

interconnecting shaft to avoid pull-apart and

potential damage to the CV joint.

CAUTION: Do not drop assembled halfshafts.

The impact will cut the boots from the inside

without evidence of external damage.
Handle all halfshaft components carefully during

removal and installation procedures.

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