Ford Falcon. Manual — part 44

205-01-10 Driveshaft 205-01-10

DISASSEMBLY AND ASSEMBLY (Continued)

4. Using bearing puller (tool number ?) press CV

CV Joint Replacement

joint from shaft.

NOTE: To maintain balance mark all bolts and

5. Remove boot from shaft.

weights in reference to the companion flange.

Assembly

Disassembly

1. Inspect boot for damage and/or holes.
2. Take care whilst sliding boot onto stub shaft. A

small amount of CV joint grease may be used as

a lubricant.

3. Place metal sealing gasket inside boot can, keep

bolt holes aligned.

4. Press CV onto stub shaft using unique tool (tool

number ?), push on CV joint inner race. Ensure

double grooves on CV joint body are toward the

boot can.

5. Seat retainer circlip.
6. Pack joint with 60g of lubricant (supplied with CV

kit) throughout cage and races.

7. Seat CV boot can onto CV joint body, ensuring

bolt, and metal sealing gasket hole alignment, and

Item

Description

relieve any twist in the boot.

1

CV

8. Remove backing and place self-adhesive cork

gasket (supplied with CV kit) into stepped recess

2

Companion flange

on CV joint face, aligning bolt holes. Placing bolts

3

Bolt

through CV Joint as a guide to gasket alignment.

Gasket alignment is critical to sealing integrity.

9. Seat rear can onto CV again ensuring bolt holes

are aligned.

10. Clamp boot in location as shown in figure.
11. Bolts to be torqued to 72Nm (+/- 13Nm). Opposite

bolts to be torqued until all reach spec.

Item

Description

1

Stub Shaft

2

Boot Clamp

3

Boot Asy

4

Grease

5

Steel Gasket

6

CV Joint Asy

7

Cork Gasket

8

Circlip

9

Grease Cover

1. Follow steps to remove drive shaft.
2. Remove end cap from CV joint, grease can and

remove retaining clip.

3. Using a hammer and soft punch remove the boot

can forwards from the CV joint.

G96429 en

205-02A-1

Rear Drive Axle / Differential — Beam Axle

205-02A-1

SECTION : 205-02A Rear Drive Axle / Differential —

Beam Axle

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...205-02A-2

DESCRIPTION AND OPERATION

Rear Drive Axle / Differential — Beam Axle . . . . . . . . . . . . . . . . . . 205-02A-3

Beam Axle Final Drive Identification . . . . . . . . . . . . . . . . . . . . ..205-02A-3

Conventional

Differential

. . . . . . . . . . . . . . . . . . . . . . . . . 205-02A-3

Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . ..205-02A-3

Differential Assembly and Pinion Bearings . . . . . . . . . . . . . . . . . ...205-02A-4

Wheel

Bearings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .205-02A-4

DIAGNOSIS AND TESTING

Rear Drive Axle / Differential — Beam Axle . . . . . . . . . . . . . . . . . ..205-02A-12

GENERAL PROCEDURES

In Vehicle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .205-02A-14

Beam Axle Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . .205-02A-14

Flange Runout Check . . . . . . . . . . . . . . . . . . . . . . . . . . 205-02A-15

In Vehicle Torque Check . . . . . . . . . . . . . . . . . . . . . . . . ...205-02A-15

Limited Slip Differential — M78 & M86 Check . . . . . . . . . . . . . . . . .205-02A-15

Limited Slip Differential Torque Check . . . . . . . . . . . . . . . . . . . ..205-02A-16

Limited Slip Differential — M86 Inspection for Wear . . . . . . . . . . . . . . .205-02A-16

Limited Slip Differential — M78 . . . . . . . . . . . . . . . . . . . . . . .205-02A-17

IN-VEHICLE REPAIRS

Pinion Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . .205-02A-18

REMOVAL AND INSTALLATION

Axle Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . ..205-02A-19

M86 Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . ..205-02A-20

Axle Housing and Differential Assembly . . . . . . . . . . . . . . . . . . ...205-02A-21

DISASSEMBLY AND ASSEMBLY

Rear Axle Wheel Bearing and Seal Replacement . . . . . . . . . . . . . . . .205-02A-24

Differential and Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . ..205-02A-26

Differential Bearing Preload Spacer Selection . . . . . . . . . . . . . . . . ..205-02A-27

Drive Pinion Position — Shim Selection . . . . . . . . . . . . . . . . . . . 205-02A-28

Drive Pinion and Bearings . . . . . . . . . . . . . . . . . . . . . . . . .205-02A-29

Differential Installation and Backlash Check . . . . . . . . . . . . . . . . . .205-02A-30

Differential Case — Conventional Type M78 and M86 . . . . . . . . . . . . . .205-02A-30

Limited Slip Differential — M78 . . . . . . . . . . . . . . . . . . . . . . .205-02A-31

Limited Slip Differential — M86 . . . . . . . . . . . . . . . . . . . . . . .205-02A-32

205-02A-2

Rear Drive Axle / Differential — Beam Axle

205-02A-2

SPECIFICATIONS

General Specifications

Description

Specification

Description

Specification

Backlash between ring gear

0.13 to 0.18 mm

and pinion.

Rear Axle Lubrication

(Level with bottom of filler plug hole with vehicle at

Backlash variation between

0.05 mm max.

curb height.)

teeth.

Model 78

Maximum ring gear run out

0.13 mm

(assembled)

CONVENTIONAL

Limited slip differential torque

Grade

SAE 90 Hypoid

Model 78

New:

80-140 Nm

Ford Specification

ESW-M2C108-A

(cone clutch type)

Used:

50-130 Nm

Capacity

1.70 litre

Model 86

New:

100-300 Nm

LIMITED SLIP

(plate clutch type)

Used:

50-150 Nm

Grade

SAE 90 EP

Ford Specification

ESW-FM2C-1006-B

Torque Specifications

Capacity

1.60 litre + 100ml

Description

Nm

Sturaco 7098

Ring gear bolts (L.H. Thread)

140

Additive

Bearing cap bolts

55

Model 86

Differential case bolts (L.S.D.)

40

CONVENTIONAL

Rear cover bolts

30

Grade

Mobilube SHC ID

Axle bearing retainer plate bolts

45

Ford Specification

ESZ-FM2C190-A

Spring ’U’ bolt nuts (Wagon)

60

Capacity

1.9 litre

* Track arms to body

75

LIMITED SLIP

* Track arms to pivot link

75

Grade

Mobilube SHC ID

* Pivot link to axle housing cover

15

Ford Specification

ESZ-FM2C190-A

* Suspension arms to axle housing

75

Capacity

1.86 litre + 40ml

* Suspension arms to body

75

Duraphos Mobil

* Shock absorber to spring plate

75

M3022

Caliper to bracket pin nuts

20

BEARING PRELOADS

Splash shield screws

10

New Bearings Nm

Shock absorber to spring plate nut

45

Differential

Stabiliser bar clamp bolt

20

— Measured without axle

0.6-1.9

shafts or pinion

Universal joint bolts

10

Pinion

Vent - Rear axle housing

15

— With oil seal

1.5-2.1

Pinion flange nut

—

— Without oil seal

1.5-1.9

Filler Plug

30

Used Bearings

Drain Plug

30

Differential

* Items marked thus are to be tightened with the

vehicle in the curb load position.

— Measured without axle

0.4-1.1

shafts or pinion
Pinion
— With oil seal

0.7-1.2

— Without oil seal

0.7-1.0

ADJUSTMENTS
Pinion bearing preload

Collapsible spacer

adjustment.
Differential bearing preload

Selective spacer

adjustment.
Pinion depth of mesh

Selective shim

adjustment.

G98770 en

205-02A-3

Rear Drive Axle / Differential — Beam Axle

205-02A-3

DESCRIPTION AND OPERATION

Limited Slip Differential

Rear Drive Axle / Differential — Beam

Axle

This axle is a hypoid type of unitised carrier

construction. The two pinion differential case and the

Beam Axle Final Drive Identification

drive pinion are mounted in opposed tapered roller

bearings in the carrier. Differential bearing preload

A label identifying the beam axle assembly part

adjustment is provided by varying shim thicknesses

number, serial number, and final drive ratio is fixed to

behind the bearing cups. Pinion bearing preload is

the axle tube adjacent to the rear cover.

regulated by a collapsible spacer and adjusted using

Two different model beam axles are used on wagon

the pinion nut.

and utility vehicles:

Torque is transferred from the propshaft to the final

1. M78 beam axles are fitted with 3.23 or 3.45 7.75" drive assembly via the companion flange that is

(197mm) diameter gear sets, with or without ABS splined to the hypoid pinion. Torque is then

and with or without LSD’s. All M78 beam axles

transferred from the pinion through the ring gear,

whould be filled with lubricant as per the

differential case, differential pinion cross shaft,

Specifications. M78 LSD differentials are fitted

differential pinions and side gears to the axle shafts.

with a metal tag marked "SPIN RESISTANT DIFF.

For M78 Limited Slip Differentials (LSDs), the

USE APPROVED LUBRICANT ONLY".

differential case houses two cone type clutches

2. M86 beam axles are fitted with 3.23 or 3.46 8.6"

behind the side gears. These cones are splined to the

(220mm) diameter gear sets, with or without ABS axle shafts, their tapered faces bearing on the

and with or without LSD’s. M86 axles are fitted to differential case. Thrust springs pre-load the gears

all vehicles powered by a V8 or turbo I6 engine.

and cones, forcing the tapered face of the cones into

All M86 beam axles should be filled with lubricant contact with the differential case. The partial locking

as per the Specifications. Conventional M86

action, due to the spring load on the cones is

differentials are fitted with a metal tag marked

automatically increased by the inherent separating

"HIGH PERFORMANCE. USE APPROVED

forces between the side gears and pinion. This

LUBRICANT ONLY". For LSD units, a metal tag

locking action directs a portion of the driving force to

marked "LSD - HIGH PERFORMANCE. USE

the wheel with the greatest traction.

APPROVED LUBRICANT & FRICTION

M86 LSDs transfer torque in a similar manner as M78

MODIFIER" is attached under the filler plug on the

LSDs, except that a multiplate oil bath type design is

rear cover.

utilised where alternate plates are splined to the

NOTE: Upgrading the lubricating oil to synthetic type

differential case and side gear. Preloading of the

is recommended for vehicles fitted with a M86 beam

plates provides frictional resistance to rotation,

axle where the vehicle will be regularly used for

providing torque transfer to the rear wheel with the

towing. Refer to Specifications section for the

greatest traction.

recommended synthetic lubricant.

The axle shafts are mounted using tapered roller

bearings and held by retainer plates at the outer ends

Conventional Differential

of the axle housing. Axle shaft end play is pre-set and

This axle is a hypoid type of unitised carrier

is not adjustable. Oil seals are located between the

construction. The two pinion differential case and the

retainer plates and the bearing.

drive pinion are mounted in opposed tapered roller

With the conventional differential, when the rear

bearings in the carrier. Differential bearing preload

wheels are subject to highly unbalanced tractive

adjustment is provided by varying shim thicknesses

conditions such as one wheel on dry road and the

behind the bearing cups. Pinion bearing preload is

other in mud or ice, wheel spin will occur if over

regulated by a collapsible spacer and adjusted using

acceleration is attempted. However, with the limited

the pinion nut.

slip differential, when the tendency for wheel spin

Torque is transferred from the propshaft to the final

occurs, the friction generated between the cones and

drive assembly via the companion flange that is

the differential case (M78) or between the friction

splined to the hypoid pinion. The torque is then

plates (M86) transfers a portion of the driving torque

transferred from the pinion through the ring gear,

to the non-spinning wheel.

differential case, differential pinion cross shaft,

NOTE: (For M78 LSDs) In the event of continued

differential pinions and side gears to the axle shafts

spinning a whirring sound is produced due to

for conventional differentials.

over-running of the cones; such a condition or sound

The axle shafts are mounted using tapered roller

does not indicate failure of the unit.

bearings and held by retainer plates at the outer ends

of the axle housing. Axle shaft end play is pre-set and

is not adjustable. Oil seals are located between the

retainer plates and the bearing.

G98771 en