Ford Falcon. Manual — part 56

205-02B-9

Independent Rear Suspension — Full Floating Axle

205-02B-9

IN-VEHICLE REPAIR

3. Lubricate the seal lips and the outside diameter

Pinion Oil Seal Replacement

with oil and install the seal, using the special tool.

Correct seal location is from flush to 0.25 mm

Removal

below the carrier surface.

CAUTION: Axles on vehicles with V8 or I6HO

4. Align the pinion flange spline mark with the pinion

engines use a synthetic lubricant that is not

shaft spline mark and install the flange with a

compatible with standard polyacrylic pinion seals.

smear of lubricant on the splines. Tighten the nut

Viton pinion seals must be used in this axle.

until the marks previously made on the pinion

Synthetic seals must not be soaked or washed in

flange and the nut are in alignment re-establishing

cleaning solvents.

the pinion bearing preload.

1. Raise the vehicle on a hoist. Disconnect the drive 5. Install the driveshaft with the marking on the drive

shaft from the drive pinion flange after marking

shaft and the pinion flange in alignment.

the drive shaft and pinion flange to ensure correct

6. Check axle lubricant level and top up if necessary

positioning on reassembly.

with specified lubricant.

2. Mark the pinion shaft and the pinion flange to

7. Remove the vehicle from the hoist.

ensure correct positioning on reassembly. Mark

the pinion flange and the pinion nut to establish

bearing preload on reassembly.

Item

Description

1

Oil Seal Tool E9055

2

Drive Pinion Oil Seal

3. Hold the pinion flange using tool EN1205B and

remove the self locking nut.

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

flange spline for correct re-alignment during

installation.

6. Clean the pinion bearing housing around the oil

seal.

7. Remove the pinion flange using tool number

E9258B. Under no circumstances should a

hammer be used.

8. Remove the pinion oil seal by prying it out with a

suitable tool.

Installation
NOTE: Refer to, Section 205-00 for Special Tool(s).

1. Check the 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.

2. Clean the oil seal seat. The lubricant return

passage must be clear.

G567885 en

205-02B-10

Independent Rear Suspension — Full Floating Axle

205-02B-10

REMOVAL AND INSTALLATION

3. Remove the differential assembly.

Half Shaft

Removal and Installation

Refer to section 205-05.

Drive Unit Assembly

Removal
1. Remove knuckle assembly, refer to Section

204-02a.

2. Remove Rear Drive Halfshafts, refer to Section

205-05.

3. Remove IRS Module, refer to Section 204-02a.
4. Unclip

handbrake

cables.

5. Remove breather tube.

Item

Description

6. With the Drive Unit Assembly supported, remove

the front and rear support bolts.

1

Tool-Push/Puller with Legs

2

Tool-Stepped Plug

3

Tool-Knife Edge Puller

Installation
1. Installation procedure is the reverse of the

Removal procedure.
NOTE: Ensure all bolts are torqued to

specifications.

Differential Assembly

Removal and Installation
1. Remove the rear cover, ABS mounts and screw

adjuster lock plates.

2. Remove the screw adjusters using special service

tool 205-463.

G567892 en

205-02B-11

Independent Rear Suspension — Full Floating Axle

205-02B-11

DISASSEMBLY AND ASSEMBLY

surface of the axle shafts on which the seal runs and

Inner Axle Shaft Seal Replacement

remove any nicks or burrs. Should this surface be

irreparable, a new half shaft should be fitted. Examine

Disassembly

the housing bore and remove any nicks and burrs.

1. Drain lubricant from unit via bottom cover bolt.

1. Lubricate the seal lips and the outside diameter

2. Remove the half shafts from the assembly. Refer

and install. The seal is to be seated on the screw

to ’Half Shaft’ in this section.

adjuster.

3. Clean around the seal area ensuring there is no

2. Install the half shafts ensuring that the splines do

ingress of dirt into the axle shaft needle roller

not come into contact with the seal lips. Refer to

bearing.

’Half Shaft’ in this section.

4. Carefully remove the seal.

3. Shafts should withstand a pull out force of 1200N.

Assembly

4. Check lubricant level, top up as required.

NOTE: Before installation of a new seal examine the

6. A pinion depth adjusting shim is installed

Pinion & Pinion Bearings

between the rear pinion bearing cup and the

axle housing. Discard damaged shims.

Disassembly and Assembly
1. Carry out the following procedure with the

differential assembly removed:

1. Mark the relationship of the companion

flange. Hold the companion flange and

remove the pinion nut.

2. Remove the companion flange.

3. With a soft hammer, drive the pinion out of

the front bearing cone and remove it through

the rear of the carrier casting.

4. Drive the pinion seal and the bearing cone out

of the carrier casting.

5. If the pinion bearing cups are to be replaced,

remove them from the carrier using the

special tool.
NOTE: It is essential to renew the cups one

after the other so that in each instance the

other cup serves as a guide for the replacer

tool.

G567889 en

205-02B-12

Independent Rear Suspension — Full Floating Axle

205-02B-12

DISASSEMBLY AND ASSEMBLY (Continued)

7. In the pinion rear bearing cone and roller is to Pinion & Ring Gear Identification

be replaced, lubricate the pinion shaft and

remove the bearing cone from the pinion.

Drive the bearing whenever it has been

removed from the pinion.

Item

Description

1

Tool-Push/Puller with Legs

2

Tool-Knife Edge Puller

Drive Pinion Selection — Shim

Selection

Disassembly and Assembly
NOTE: The drive pinion and ring gear set

identification marking (e.g. number 5K-25) is the

matching number that appears on both the drive

pinion and the ring gear. When a new gear set is

being installed in an axle, be sure that the same

matching number appears on both the drive pinion

and the ring gear.

1. The ring gear and pinion are manufactured within

a tolerance of a specified distance. On the end of

each pinion, there is etched a plus (+) number, a

minus (-) number, or a zero (0) number which

indicates the best running position for each

particular gear set. This dimension is controlled by

the shimming behind the rear pinion bearing cup.

2. When the shim thickness is decreased, the pinion

gear is moved away from the ring gear. When the

shim thickness is increased, the pinion is moved

closer to the ring gear.

G567889 en