Ford Falcon. Manual — part 48

205-02A-16

Rear Drive Axle / Differential — Beam Axle

205-02A-16

GENERAL PROCEDURES (Continued)

5. Repeat Steps 2, 3, and 4.

2. Side gears and pinion mate gears — The gear

teeth of these parts should be checked for

6. It is possible that slight chatter, requiring

extreme wear and possible cracks. The external

additional vehicle operation may remain after

teeth of the side gear, which retain the concentric

Step 5. If chatter still persists after one

groove discs, should also be checked for wear or

hundred (100) kms of vehicle operation, or

cracks.

remains severe after Step 5 above,

disassembly and repair will be necessary.

3. If replacement of one gear is required due to

Follow procedures for disassembly and

wear, etc., then both side gears, pinion mate

assembly as illustrated in the manual.

gears, and washers are to be replaced.

4. Cross Pin - If excessive wear is evident, the cross

Limited Slip Differential Torque Check

pin should be replaced.

1. Clamp Special Tool or an axle shaft in a vice with 5. Clutch Retainer Clips — If wear is evident on any

approximately 75mm of the splined end extending

one of the retainer clips, all four clips must be

above the vice jaws.

replaced.

2. Place the differential unit on its end with the

6. Differential Case — If scoring, wear or metal

flange section above the cap section. Place over

pick-up is evident on the machined surfaces, then

the extended tool/ axle shaft spline.

replacement of the case is necessary.

3. Install the remaining part of Special Tool or an

axle shaft, into the flange section of the case.

4. Using Special Tool E6662 check that the torque

required to continuously rotate the side gears is

as per the values listed in the Specifications.

Item

Description

1

Concentric groove disc

2

Radial groove plate

Item

Description

1

Tool E6662-LSO Torque check

2

Axle shaft bearing

3

Differential assembly

4

Axle shaft

NOTE: LSD units that operate smoothly but with

excessively low torque should be checked as per the

Inspection for Wear sections.

Limited Slip Differential — M86

Inspection for Wear

1. Plates and discs — If any one member of either

stack shows evidence of excessive wear or

scoring, the complete stack is to be replaced on

both sides.

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205-02A-17

Rear Drive Axle / Differential — Beam Axle

205-02A-17

GENERAL PROCEDURES (Continued)

Item

Description

1

Plate

2

Disc

3

Dished spacer

4

Side gear

Limited Slip Differential — M78

LSD units that operate smoothly but with excessively

low torque should be checked as follows.
With the limited slip differential unit fully dismantled

examine the parts for wear and general condition. If

the cone surfaces have a mirror like finish, then the

following rework procedure should be followed. If the

cone surfaces are scored then components should be

replaced and the normal set up procedure followed as

in the repair manual.
1. Mark the cones to ensure they are reassembled

to the original differential cases.

2. Using P800 grade wet and dry abrasive paper,

rub the tapered surfaces in the differential

direction by hand, in order to remove the glazed

coating from the surfaces. Give the surfaces a

final rub using oil on the wet and dry to produce a

fine finish. The abrasive paper must be rubbed

around the surfaces in a uniform manner to avoid

creating hollows in the cone surfaces.

3. Thoroughly clean debris from all components.
4. Use new spring washers.
5. Prior to reassembly coat all surfaces with an

approved LSD lubricant.

6. Reassemble.
7. Check friction torque of unit as in the Torque

Check procedure.

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205-02A-18

Rear Drive Axle / Differential — Beam Axle

205-02A-18

IN-VEHICLE REPAIR

7. Continue to tighten the nut until the marks

Pinion Oil Seal Replacement

previously made on the pinion flange and the nut

are in alignment to re-establish the pinion bearing

NOTE: Refer to Special Tools in this section.

preload.

Removal

8. Install the driveshaft with the marking on the drive

1. Raise the vehicle on a hoist. Disconnect the drive

shaft and the pinion flange in alignment. (Refer to

shaft from the drive pinion flange after marking

Section 205-11.)

the drive shaft and pinion flange to ensure correct

9. Check axle lubricant level and top up if necessary

radial positioning on re-assembly. (Refer to

with specified lubricant.

Section 205-01.)

10. Remove the vehicle from the hoist.

2. Mark the pinion flange and the pinion nut to

establish bearing preload on re-assembly.

3. Hold the pinion flange using tool EN1205B and

remove the self locking nut. As Loctite is used on

the pinion nut, the torque required to release the

nut will be greater than 200Nm.

4. Place a drain pan beneath the pinion housing.
5. Mark the ends of the pinion shaft and a pinion

flange spline for correct re-alignment during

installation.

6. Clean the pinion bearing housing around the oil

seal to remove loose dirt and oil so that it does

not fall into the front of the carrier housing during

the removal or replacement procedure.

7. Remove the pinion flange using tool number

Item

Description

E9258B. Under no circumstances should a

hammer be used.

1

Oil seal installation Tool E9055

8. Remove the pinion oil seal by carefully prying it

2

Drive pinion oil seal

out with a suitable tool.

Installation
NOTE: All hardware must be correctly installed and

torqued to specification.

1. Check the mating splines on the pinion shaft and

pinion flange for burrs and if necessary clean up

with fine crocus cloth. Wipe the flange and shaft

clean. Remove any Loctite thread locking

compound from the pinion nut of flange thread.

2. Clean the oil seal seat. The lubricant return

passage in the axle housing must be clear.

3. Lubricate the seal lips and the outside diameter

with oil and install the seal, using the correct

special tool. Seal location is from flush to 0.25

mm below the machined carrier face.

4. Align the pinion flange spline mark with the pinion

shaft spline mark and start the flange onto the

pinion splines by hand. A smear of lubricant on

the pinion splines will assist in installation.

5. Install the pinion nut onto the pinion thread

(without Loctite) and wind the nut down to pull the

flange onto the pinion spline until no axial end

play can be detected by hand in the pinion

assembly. Remove the pinion nut.

6. Apply Loctite 262 Liquid Threadlocker to the

pinion thread and reinstall the nut, tightening to

100Nm.

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205-02A-19

Rear Drive Axle / Differential — Beam Axle

205-02A-19

REMOVAL AND INSTALLATION

Axle Shaft Assembly

Removal
1. Raise the vehicle and remove the road wheel.

(Refer to Section 100-02.)

2. Disconnect the park brake cable from the park

brake and remove from axle. (Refer to Section

206-05.)

Remove the caliper.

Remove ABS sensor (if ABS fitted).

Remove the disc from the axle flange.
NOTE: If ABS is fitted, take care not to damage

tone wheel.

3. Working through the access hole in the axle

flange using an allen key to remove the four

bearing retainer plate bolts.

4. Withdraw the axle shaft and bearing assembly.

NOTE: The bearing cup typically may be loose in

the axle housing or may fall out on axle

disassembly. Friction surfaces of brake parts must

be kept contamination free.

Item

Description

1

Seal

2

Bearing assembly

3

Bearing retaining collar

4

Axle housing

5

Brake anchor bracket

6

Bearing retaining plate

Item

Description

7

Tone wheel (ABS)

1

Score - M6

2

Shield

Installation

3

Bolt - M12

NOTE: All hardware must be correctly installed and

torqued to specification.

4

Caliper

5

Rotor

NOTE: Friction surfaces of brake parts must be kept

contamination free.

6

Asle Assy.

1. If the bearing cup was previously removed install

the bearing cup in the axle housing.
NOTE: A new bearing should always be used if

the axle oil seal, retaining collar, retaining plate or

tone wheel have been replaced. Ensure that the

cup back face is seated against the back shoulder

in the housing. The bearing must be lubricated

with axle lubricant before installation. Also, apply

a film of MIC75B Grease to the outside diameter

of the seal prior to installation. Refer to Rear Axle

Bearing And Seal Replacement section for how to

service the axle assembly once removed from the

tube housing.

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