Ford Falcon. Manual — part 53

205-02A-36

Rear Drive Axle / Differential — Beam Axle

205-02A-36

DISASSEMBLY AND ASSEMBLY (Continued)

3. Prelubricate the thrust face of the side gears and

the plates and discs.

7. Reposition case on bench as shown. Assemble

the adapter plate into the side gear. Apply a small

amount of grease into the centering hole of the

4. Assemble plates and discs in exactly the same

step plate.

position as they were removed, regardless of

whether they are new parts or the original parts.

Be sure lubricant that is used is of the specified

lubricant.
NOTE: Your unit may be equipped with the new

design limited slip disc and plates or your

replacement unit may contain them. If so follow

directions below. The new design can be

identified by a smooth surface. Olderdesigns have

radial grooves in plates and discs.

5. Assemble the retainer clips to the ears of the

plates. Make sure both clips are completely

assembled or seated onto the ears of the plates.

8. Assemble the other clutch pack and side gear as

shown. Make sure the clutch pack stays

assembled to the side gear splines, and that the

retainer clips are completely seated into the

pockets of the case.

6. With the differential case positioned as shown,

assemble the clutch pack and side gear into the

case. Make sure the clutch pack stays assembled

to the side gear splines, and that the retainer clips

are completely seated into the pockets of the

case. To prevent pack from falling out of the case,

it will be necessary to hold them in place by hand

9. Hold the clutch pack in position and insert the

while repositioning case on bench.

threaded adapter into top side gear, insert forcing

screw. Tighten forcing screw into bottom plate.

This will hold both clutch packs in position.

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205-02A-37

Rear Drive Axle / Differential — Beam Axle

205-02A-37

DISASSEMBLY AND ASSEMBLY (Continued)

10. With tools assembled into the case, position case 15. For snap ring retained versions, be sure the snap

onto the axle shaft by aligning the splines of the

ring grooves of the cross pin shaft are exposed to

side gear with those of the shaft.

allow assembly of the snap rings. Assemble snap

rings.

11. Loosen forcing screw slightly. Assemble both

pinion mate gears as shown. Hold gears in

16. Remove case from axle shaft. Assemble ring gear

position by hand.

to case. Line up the ring gear screw holes with

those of the case.

12. While holding gears in place, insert turning bar

NOTE: Use new ring gear screws. Assemble new

into case. Pull on bar to rotate case allowing

ring gear screws finger tight.

gears to turn. Make absolutely sure that the holes

of the pinion mate gears are in alignment with

holes of the case.

13. Prelubricate spherical washers. Torque forcing

screw until it is tight. This will collapse the

Belleville plates and allow clearance between

gears. Assemble spherical washers into case.

Use a small screwdriver to push washers into

place.

CAUTION: Be sure the holes of the

washers and gears are lined up exactly with

those of the case.

14. Remove tools.

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205-02A-38

Rear Drive Axle / Differential — Beam Axle

205-02A-38

DISASSEMBLY AND ASSEMBLY (Continued)

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

19. Reposition case onto axle shaft as shown. Torque

replace the roll pin that retains the cross shaft.

screws alternately and evenly. Torque grade 8

screws to 45-65 lb. ft. (61-88 Nm).
NOTE: If grade 9 screws are used (special for

high strength), torque 75-85 Lb. Ft. (102-115 Nm).

20. Mount spreader onto housing. Locate a dial

indicator with a magnetic base on cover face as

shown. Locate tip of indicator on housing as

shown. Set dial indicator at zero. Turn forcing

screw of spreader until indicator records .015"

(.38 mm).

CAUTION: Do not spread housing over

.015"

18. When roll pin bottoms out, stake (peen) a little

metal over the edges in two places 180’ degrees

apart.

21. Remove dial indicator.
22. Prelubricate differential bearings with the specified

lubricant. Assemble differential bearing cups to

differential cones.

23. Install differential assembly into housing. Make

sure teeth of ring gear are meshed with those of

pinion.

24. Use a rawhide hammer to seat differential

assembly into cross bore of housing. Care should

be taken to avoid nicking the teeth of the ring gear

and pinion during assembly.

25. Remove spreader.

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205-02A-39

Rear Drive Axle / Differential — Beam Axle

205-02A-39

DISASSEMBLY AND ASSEMBLY (Continued)

26. Install bearing caps. Make sure the letters

stamped on the caps correspond with those

stamped on the housing in horizontal and vertical

position.
NOTE: Torque cap screws to 70-90 Lb. Ft.

(96-122 Nm).

27. The cover face of the carrier and the flat surface

of the rear cover must be free from any oil of

foreign material. Fit the rear cover to the carrier

using silicone rubber sealant.
NOTE: Ensure that the sealant bead is laid on the

inside of the cover screw holes. The bead is not

to pass through the holes or outside of the holes.

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