Ford Falcon. Manual — part 52

205-02A-32

Rear Drive Axle / Differential — Beam Axle

205-02A-32

DISASSEMBLY AND ASSEMBLY (Continued)

Disassembly
1. Place one of the axle shafts, which was removed

from the assembly, into a vise. Tighten shaft in

vise firmly. The spline end of the shaft is not to

exceed 2.750" (69.85 mm) above the top of the

vise. This will prevent the shaft from fully entering

into the side gear and causing interference with

the step plate during disassembly of the pinion

mate gears, etc. Caution should be used that the

vise jaws do not locate on axle splines or any

machined surfaces.

Item

Description

1

Tool E6662 - LSD torque check

2

Axle shaft bearing

3

Differential assembly

4

Axle shaft

2. Place a few shop towels over vise to prevent any

damage during disassembly of ring gear:

Assemble the differential on the axle shaft with

the ring gear screw heads up. Assembling the

differential onto the shaft will serve as a holding

device to remove the ring gear and to

disassemble the internal parts of the case.

Remove the ring gear screws.

NOTE: 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 components appear in good condition and the

cone surfaces have a mirror like finish, then the

following rework procedure should be followed. If the

cone surfaces are scored then the components

should be replaced and the normal set up procedure

followed as in the repair manual.

Limited Slip Differential — M86

Tool Kit #C-4487

Special Tool(s)

Tool Kit

C-4487

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Rear Drive Axle / Differential — Beam Axle

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DISASSEMBLY AND ASSEMBLY (Continued)

3. Remove ring gear. It will be necessary to remove

6. It is recommended that when referring to the

the ring gear to allow clearance for the removal of

Trac-Lok, obtain the complete part number and

the cross pin. Tap ring gear with rawhide hammer

build date. To do this it will be necessary to wipe

to free it from case.

off the lubricant from the case.

NOTE: It is recommended that on spicer axles

7. Reposition differential case onto axle shaft as

whenever the ring gear screws are removed they

shown. Remove the two snap rings from the cross

are to be replaced with new ones.

pin. Use two screwdrivers and push the rings free

from the cross pin. Place a shop towel behind the

case to prevent the snap rings from flying out of

the case.

Snap Ring Retained Version

4. Remove differential case from the axle shaft and

remove ring gear.

5. All Spicer Trac-Loks are identified with a

manufacturing date and the complete part number

stamped on the barrel of the case. If the axle

8. For roll pin retainer version, use a small drift to

assembly is equipped with a Trac-Lok Limited Slip

remove the roll pin retaining the cross shaft.

Differential a special tag will be located on the

Roll Pin Retained Version

bottom right hand side of the cover plate

specifying the use of limited slip lubricant.

In this figure the Trac-Lok is identified with 0.125"

(3.17 nim) high numbers stamped on the case.

For example:

The number 1-21-77A is the manufacturing or

build date of the Trac-Lok and is interpreted

as follows. The first number is the month,

second number is the day of the month, third

number is the year, the letter is the shift. For

example: Jan. 21, 1977 first shift. The number

stamped above the manufacturing date is the

complete Trac-Lok assembly part number.

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Rear Drive Axle / Differential — Beam Axle

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DISASSEMBLY AND ASSEMBLY (Continued)

9. Remove the cross pin. Use a hammer and punch

11. Lubricate threads of threaded adapter and forcing

as shown to remove the cross pin from the case.

screw.

10. Assemble the adapter plate into the bottom side

12. Assemble threaded adapter into top side gear.

gear. Apply a small amount of grease to the

Thread forcing screws into threaded adapter until

centering hole of the adapter plate. Tool

it becomes centered into adapter plate.

#C-4487-1 (adapter plate).

Use a small screwdriver, position it in slot of

threaded adapter. This will prevent the

adapter from turning. Tools #C-4487-3

(threaded adapter), C-4487-2 (forcing screw).

13. Torque forcing screw until it becomes slightly

tight. This will collapse the Belleville plates and

allow a loose condition between the side gears

and pinion mate gears.

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Rear Drive Axle / Differential — Beam Axle

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DISASSEMBLY AND ASSEMBLY (Continued)

14. Remove both pinion mate spherical washers. Use 18. Remove top side gear and clutch pack. Keep the

a shim stock of .030" (.76 mm) thickness or an

stack of plates and discs intact in exactly the

equivalent tool to push out the spherical washers.

same position while they are being removed.

15. Relieve the tension of the Belleville springs by

loosening the forcing screw.

16. Insert small O.D. end of turning bar into cross pin

hole of case. Pull on bar and the case will rotate

until the pinion mate gears can be removed from

opening.
NOTE: It might be necessary to adjust the forcing

screw slightly to allow the case to rotate. Tool

#C-4487-4 (turning bar).

19. Remove the case from the axle shaft. Turn case

with the flange or ring gear side up and allow the

step plate, side gear and clutch pack to be

removed from the case. Remove the retainer clips

from both clutch packs to allow separation of the

plates and discs. Keep the stack of plates and

discs exactly as they were removed.

Assembly
1. Prior to assembly, prelubricate each disc and

17. Hold top clutch pack with one hand and remove

plate with Friction Modifier by presoaking for a

tools. It might be necessary to hold threaded

minimum of 20 minutes.

adapter with screwdriver.

2. After assembly into carrier housing, fill axle

assembly with the proper amount and specified

lubricant, refer to Specifications section.

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