Ford Falcon. Manual — part 49
205-02A-20
Rear Drive Axle / Differential — Beam Axle
205-02A-20
REMOVAL AND INSTALLATION (Continued)
2. Start the splined end of the shaft into the
3. Remove cover plate screws, cover plate. Clean
differential and start the bearing cone assembly
sealant from cover faces.
and seal into the housing.
3. Line up the retaining plate to the retaining plate
bolts and push the axle into the housing as far as
possible.
4. Start the bolts onto the tube flange holes and
tighten to finger tight only. Then tighten the bolts
to 20 Nm in a diagonal sequence. The bolts
should be tightened in such a manner to assure
that the seal and bearing cone assembly are
drawn evenly against the cup in the housing.
Refer to Specifications section for tightening
torque required on retaining plate bolts.
5. Install the disc on the axle flange.
Install the brake caliper.
Route the park brake cable and connect to park
4. Remove differential bearing caps. Note letters
brake. (Refer to Section 206-05.)
stamped on the bearing caps and the cover face
Replace ABS sensor (if fitted).
of the housing. Letters are to correspond in
horizontal and vertical positions. This is very
6. Replace the road wheel and lower the vehicle.
important at time of assembly.
7. Tighten the wheel nuts. (Refer to Section 204-04.)
8. Check the park brake adjustment. (Refer to
Section 206-05.)
M86 Limited Slip Differential
Special Tool(s)
Spreader
E9255
Indicator Set or Equivalent
5. Mount spreader to housing. Locate a dial indicator
with a magnetic base on cover face as shown.
Removal
Locate tip of indicator on housing as shown.
NOTE: On Dana Spicer axles it is recommended that
6. Set dial indicator at zero ("0"). Turn forcing screw
the complete axle assembly be removed from the
of spreader until indicator records .015" (.38 mm).
vehicle when it becomes necessary to remove the
M86 LSD from the housing.
CAUTION: Do not spread carrier in
1. Remove wheels, brake drums, brake backing
excess of 015" (.38 mm).
plate screws and axle shafts. Brake backing
7. Remove
Indicator.
plates can normally be wired to frame without
loosening the hydraulic brake line connection at
the wheel cylinder if desired. Use caution to avoid
damage to brake line.
2. Remove axle assembly and place in rack or stand
to serve as a holding device.
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205-02A-21
Rear Drive Axle / Differential — Beam Axle
205-02A-21
REMOVAL AND INSTALLATION (Continued)
8. Remove differential using two pry bars as shown.
Use caution to avoid damage to ring and pinion. It
will not be necessary to remove the differential
bearings at this time, however, the bearing cups
should be marked or tagged to indicate from
which side of the case they were removed. After
differential case has been removed, remove
spreader.
Axle Housing and Differential
Assembly
Removal
1. Loosen the rear wheel nuts.
2. Raise the vehicle and support it on the axle.
3. Remove the rear wheels.
4. Detach the shock absorbers from the spring
plates as follows. (Refer to Section 204-02B.)
5. Support the vehicle on the underbody. (Refer to
Section 100-02.)
6. Mark the relationship of the driveshaft and the
pinion flanges and disconnect the driveshaft from
the pinion flange. (Refer to Section 205-01.)
7. Detach the park brake cable from the drum (park)
brake and remove from rear axle
Remove the calipers and suspend from the
underbody. Leave the hydraulic lines attached.
Remove the discs.
Remove ABS sensor (if ABS fitted).
Remove the splash shields. (Refer to Section
206-04.)
Remove the axle shafts as described in this Part.
NOTE: Do not strain the brake lines and/or hoses.
(Refer to Section 206-04.)
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205-02A-22
Rear Drive Axle / Differential — Beam Axle
205-02A-22
REMOVAL AND INSTALLATION (Continued)
8. Remove the ’U’ bolts, spring plates and the lower
spring insulator. (Refer to Section 204-02B.)
9. Remove the axle housing from the vehicle.
10. Drain the oil from the axle housing through an
axle tube.
Installation
1. Position the axle housing on the springs. Ensure
that the insulators are correctly located on the
springs. Install the ’U’ bolts, lower insulator,
spring plate and ’U’ bolt nuts. (Refer to Section
204-02B.)
2. Install the axle shafts as described in this Section.
3. Install the splash shields.
Item
Description
4. Install ABS sensor (if ABS fitted).
1
Screw (Torque to 6Nm)
Install the discs.
Install the calipers.
2
Tube - Rear axle housing vent
Route the park brake cable and connect to rear
3
Clip
drum (park) brake.
4
Screw
5. Align the marks on the driveshaft and the pinion
5
Clip
flanges and connect the driveshaft. (Refer to
6
Clamp
Section 205-01.)
7
Tube assy. - Brake fluid
6. Raise the rear axle and install the lower shock
absorber to the spring plate (Refer to Section
204-02B.). Install the rear wheels.
7. With the vehicle in the curb load position fill the
axle to the bottom of the filler plug hole with the
correct oil.
CAUTION: Use of unspecified lubricant
may lead to premature gear failure.
8. Lower the vehicle and tighten the wheel nuts.
(Refer to Section 204-04.)
9. Check park brake adjustment. (Refer to Section
206-05.)
Item
Description
1
Screw - M6
2
Shield
3
Bolt - M12
4
Caliper
5
Rotor
6
Axle Assy.
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205-02A-23
Rear Drive Axle / Differential — Beam Axle
205-02A-23
REMOVAL AND INSTALLATION (Continued)
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