Ford Falcon. Manual — part 47

205-02A-12

Rear Drive Axle / Differential — Beam Axle

205-02A-12

DIAGNOSIS AND TESTING

Rear Drive Axle / Differential — Beam

Special Tool(s)

Axle

Knife edge puller

205-410 (1123)

Refer to Section 205-00.

Special Tool(s)

Differential Housing Spreader

E9255

Installer drive pinion rear

bearing

205-411 (E3C10AER)

Adaptors differential Housing

Spreader

E9040

Jaw remover differential side

bearing

205-410 (E1673H15)

Kit drive pinion setting gauge

205-406 (E9300A)

Installer differential side bearing

spline axle

205-412 (E3C25)

Press bolster

205-408 (E1673MT)

Installer differential side bearing

28 spline axle

205-412 (E9277)

Push - Puller, includes 6 ¼"

(158mm) legs

205-408 (927)

Base plate remove replace axle

bearing

888-300 (E1721)

Stepped plug-remover

differential side brg.

666-777 (E1673C16)

Remove installer axle bearing

and bearing retainer

(Alternate)

Jaw remover drive pinion rear

bearing

205-408-01(E1673A15)

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205-02A-13

Rear Drive Axle / Differential — Beam Axle

205-02A-13

DIAGNOSIS AND TESTING (Continued)

Special Tool(s)

Special Tool(s)

Installer drive pinion oil seal

IRS wheel bearing and hub

205-414 (E9055)

remover installer

205-446

Kit - installer drive pinion

IRS differential plugs

bearing cups

205-294

666-500 (E9271)

LSD torque check tool

Constant velocity boot clamp

888-200 (7372)

remover

666-000 (E6662B)

205-343

Half shaft removal tool

205-465

LSD spline alignment

205-415 (E9293)

Remover drive pinion bearing

cup

205-415 (E9293)

Remover pinion/flange

(E9258B)

Companion flange holder

777-111 (EN1205B)

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205-02A-14

Rear Drive Axle / Differential — Beam Axle

205-02A-14

GENERAL PROCEDURES

9. If no obvious defect is noted, check the gear tooth

In Vehicle Inspection

contact. Paint the gear teeth with suitable gear

NOTE: The differential case assembly and the drive

marking compound, such as a Henkel 39SY201

pinion should be inspected before they are removed

Yellow Gear Marking Compound or similar.

from the housing. These inspections can help to find

Too dry a mixture cannot be pressed out from

the cause of the trouble and to determine the

between the teeth. Wrap a cloth around the

corrections needed.

companion flange to act as a brake. Rotate the

ring gear back and forth (use a box wrench on the

Removal

drive gear attaching bolts for a lever) until a clear

1. Raise the vehicle on a hoist.

tooth contact pattern is obtained (approximately

three full revolutions in both directions).

2. Check for any external oil leaks. Note location and

NOTE: A mixture that is too wet will run and

replace oil seals, gaskets or breather hoses as

smear.

required to fix the leak(s).

3. Drain the lubricant by carefully removing the lower 10. Certain types of gear tooth contact patterns on

cover bolt which is the drain plug.

the drive gear indicate incorrect adjustment. Noise

Clean the area immediately around the rear cover

caused by incorrect adjustment can often be

of all loose dirt and contaminates.

corrected by re-adjusting the gears. Typical

NOTE: When replacing the drain plug, clean the

patterns and the necessary corrections are

thread of old thread sealant (Loctite Dri-Loc 202

explained in Section 308-03.

or similar) and reapply to ensure that the plug

11. Gear tooth runout can sometimes be detected by

seals correctly.

an erratic pattern on the teeth. However, a dial

indicator should be used to measure the runout of

4. Remove the rear cover. Scrape the rear cover

the back face of the ring gear, as shown. This

gasket off the carrier cover mounting surface,

runout should not exceed 0.13 mm.

making sure that no dirt is allowed to enter the

carrier housing.

Ring Gear Runout Check (Typical)

5. Wipe the lubricant from the internal working parts,

and visually inspect the parts for wear or damage.

6. Rotate the gears to see if there is any roughness

that would indicate defective bearings or chipped

gears. Check the gear teeth for scoring or signs of

abnormal wear.

7. Check the differential case and the drive pinion for

end play.

8. Set up dial indicator and check points around

drive gear. Backlash should be 0.10 to 0.18 mm

at tightest point.

Ring Gear Backlash Check (Typical)

Beam Axle Oil Change

1. Raise the vehicle so that it remains completely

level.

2. Remove the bottom rear cover flanged bolt from

the beam axle to drain oil.
NOTE: It is preferable to drain the oil while it is

warm so that any wear debris can drain out more

easily.

3. Apply thread sealant compound (eg. Loctite

Dri-Loc 211 or 202) to the cover bolt, refit and

tighten to 23-31 Nm.

4. Remove the lubrication tag, gasket and filler plug

located on the rear cover.

5. Fill the beam axle with the appropriate lubricant

(Refer to Specifications section).

6. Check the condition of the filler plug gasket to

ensure proper oil sealing function of filler plug.

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205-02A-15

Rear Drive Axle / Differential — Beam Axle

205-02A-15

GENERAL PROCEDURES (Continued)

7. Replace lubrication tag, gasket and filler plug and

Limited Slip Differential — M78 & M86

tighten to 23-31 Nm.

Check

Flange Runout Check

CAUTION: Never place the transmission in

1. Raise the vehicle on a hoist with the wheels

gear with the engine running when only one wheel

unsupported. Disconnect the drive shaft from the

of a limited slip differential equipped vehicle is

drive pinion flange after marking the drive shaft

raised. The vehicle might drive itself off the jack

and pinion flange to ensure correct radial

and cause demage or injury.

positioning on re-assembly. (Refer Section

1. The LSD construction permits differential action

205-01.)

when required for turning comers and transmits

2. Using a dial indicator mounted in the carrier

equal torque to both wheels when driving straight

housing, check the mounting face runout and the

ahead. However, when one wheel tries to spin

radial runout of the drive pinion flange. Refer to

due to leaving the ground, a patch of ice, etc., the

Specifications section for applicable runout limits.

clutch packs automatically provide more torque to

the wheel which is not trying to spin.

In Vehicle Torque Check

2. The LSD differential resists wheel spin on bumpy

1. To test the Limited Slip Differential (LSD) for

roads and provides more pulling power when one

correct operation proceed as follows:

wheel tries to slip. In many cases of differences in

Drive vehicle 10 km to warm up axle oil.

traction, pulling power will be automatically

provided until both wheels start to slip.

Chock the front wheels.

3. In diagnosis of vehicle operators’ complaints, it is

Raise the rear of the vehicle, remove one rear

important to recognise two things:

wheel and attach the Special Tool No.

E6662B.

1. If, with unequal traction, both wheels slip, the

LSD has done all it can possibly do.

Lower the rear of the vehicle to simulate

normal ride height.

2. In extreme cases of differences in traction, the

wheel with the least traction may spin after

Place the transmission in neutral and release

the LSD has transferred as much torque as

the park brake.

possible to the non-slipping wheel.

Ensure that there is no brake drag affecting

4. If noises or roughness, such as chatter, are

wheel rotation.

present during cornering, the probable cause is

Attach a torque meter to the special tool, and

incorrect or contaminated lubricant (Refer

rotate the axle.

Specification section for recommended axle

2. The torque required to rotate the axle shaft for a

lubricants and additive). Before any differential is

used LSD unit is detailed in the Specifications

removed and disassembled for chatter

section.

complaints, the correctness of lubricant can and

should be determined.

5. To confirm the problem, warm up the axle for ten

(10) kms under normal driving conditions and then

make a minimum of ten (10) figure 8 turns. If the

unit chatters then replace the axle lubricant with

new lubricant. If after changing the lubricant and

repeating the above figure 8 procedure, the

chatter continues, a complete lubricant drain,

flush and refill is required.

6. The following procedure is recommended to

ensure flushing the system of old lubricant.

1. Warm the axle lubricant for ten (10) kms

under normal driving conditions.

2. Drain lubricant while warm.

3. If the torque required to continuously rotate the

3. Refill axle with specified Limited Slip

wheel is outside the specification check the

Differential lubricant and/or additive.

differential for improper assembly and/or rework.

4. Drive the vehicle for approximately ten (10)

kms, making at least ten (10) figure 8 turns to

flush the old lubricant out of the differential.

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