Group 3 - Rear Axle
Contents
1. RETAINER NK967B Fig 1 8 3 4 Rear Axle Assembly 3 6 REAR AXLE SHOULD THE REAR AXLE BECOME SUBMERGED IN WATER THE LUBRICANT MUST BE CHANGED IMMEDIATELY TO AVOID THE POSSIBILITY OF A EARLY AXLE FAILURE RESULTING FROM CON TAMINATION OF THE LUBRICANT BY WATER DRAWN INTO THE VENT SERVICE PROCEDURES AXLE SHAFTS AND BEARINGS CAUTION it is absolutely necessary that anytime an axle assembly is serviced and the axle shafts are loosened and removed the axle shaft gaskets and inner axle shaft oil seals must be replaced The service procedures for the removal and in stallation of the axle shaft bearings and collars differ on the Imperial due to a change in the material hard ness of the collar It will be necessary that this pro cedure be followed to assure that axle shaft is not damaged in any way during the servicing Removal All models 1 With wheels removed remove clips holding brake drum on axle shaft studs and remove brake drum 2 Using access hole in axle shaft flange remove retainer nuts the right shaft with threaded adjuster in retainer plate will have a lock under one of the studs that should be removed at this time 3 Attach axle shaft remover Tool C 3971 Fig 3 use Too C 3971 and adapter SP 5168 on Imperial only to axle shaft flange and remove axle shaft Remove brake assembly and gaskets 4 Remove axle shaft oil seal from axle housing using Tool C 637 Fig 4 5 Wipe axle hou2. 10 Inspect differential carrier for cracks or other visible damage which would render it unfit for further service Raised metal on the shoulder of bear ing cup bores incurred in removing pinion cups should be flattened by use of a flat nose punch 11 Inspect drive pinion for damaged bearing journals and mounting shim surface or excessively worn splines If replacement is necessary replace both the drive pinion and drive gear as they are available in matched sets only 12 Inspect companion flange for cracks worn splines pitted rough or corroded oil seal contacting surface Repair or replace companion flange as neces sary ASSEMBLY LUBRICATE ALL PARTS BEFORE ASSEMBLY WITH LUBRICANT AS SPECIFIED IN LUBRICATION GROUP 0 1 Install thrust washers on differential side gears and position gears in case 2 Place thrust washers on both differential pin ions and through large window of differential case mesh the pinion gears with the side gears having pinions exactly 180 degrees opposite each other 3 Rotate side gears 90 degrees to align pinions and thrust washers with differential pinion shaft holes in case 4 From pinion shaft lock pin hole side of case insert slotted end of pinion shaft through case and the conical thrust washer and just through one of the pinion gears 5 Install thrust block through side gear hub so that slot is centered between the side gears 6 While keeping all of these parts in
3. Fig 26 Tool C 758 D4 Installed in Housing 8 3 4 Large Stem Pinion position in bearing cup Install tool spacer tool thrust washer and tool nut on shaft 3 With nose of carrier up place flange holding Tool C 3281 on compression sleeve Allow assembly to rotate while tightening nut to not more than 25 50 foot pounds Always make sure bearing cones are lubricated with hypoid gear lubricant 4 Turn tool several complete revolutions in both directions to permit bearing rollers to seat After bearing rollers are properly seated check bearing preload by rotating tool with an inch pound torque wrench The correct bearing preload should be from 20 30 inch pounds for new bearings 5 With proper bearing preload set invert carrier in stand and install gauge block SP 528 or SP 3250 to the main screw attaching it with Allen screw securely Fig 27 The flat portion of gauge block should be facing differential bearing pedestals 6 Position tool arbor SP 561 in differential bear ing pedestals of carrier Fig 28 Center the arbor so that an approximate equal distance is maintained at both ends Position differential bearing caps and at taching bolts on carrier pedestals and insert a piece GAUGE BLOCK TOOL Fig 27 installing Gauge Block on Tool patie nage GAUGE BLOCK TOOL Fig 28 Installing Arbor in Carrier of 002 inch shim stock between arbor and each cap Tighten cap bolts to 10 foot pounds
4. mark drive gear Do not rotate drive gear from point of least backlash until all adjustments have been completed 3 Using Tool C 406A spanner wrench turn both bearing adjusters equally in same direction until backlash between drive gear and pinion is 0005 to 0015 inch This backlash variation is given to permit alignment and installation of the bearing adjuster lock lockwasher and attaching screw The adjuster must only be turned in a clockwise direction and under no circumstances should be backed off 4 Install adjuster lock on bearing cap back face side of drive gear Tighten lock screw to 15 to 20 foot pounds Differential Bearing Preload 1 Turn bearing adjuster tooth side of drive gear Fig 32 in a notch at a time notch referred to is the adjuster lock holes until backlash between drive gear and pinion is a minimum of 006 to 008 inch This will preload differential bearings and establish cor rect backlash KP 21 Fig 31 Measuring Backlash between Drive Gear and Pinion REAR AXLE 3 17 PATTERN CLOSE TO CENTER HEEL END DRIVE cee HEEL END COAST SIDE CONVEX SIDE CONCAVE SIDE CONCAVE NR198 Fig 32 Desired Tooth Contact Under Light Load 2 Tighten the remaining two differential bearing cap bolts to 85 90 foot pounds 3 Install remaining adjuster lock lockwasher and attaching screw Tighten to 15 20 foot pounds GEAR TOOTH CONTACT PATTERN The gear tooth contact
5. flanged axle drive shafts with related parts Fig 2 differential with drive gear drive pinion with carrier and the axle housing Servicing of the above mentioned subassemblies with exception of the axle housing may be performed without removing the complete rear axle assembly from the vehicle Gear ratio identification numbers will be stamped on a metal tag and attached by means of the rear axle housing to carrier bolt Some 8 3 4 large stem differential and carrier as semblies have incorporated a collapsible spacer which bears against the inner races of the front and rear bearing This collapsible spacer is used to establish BUMPER HOUSING CARRIER AND CAP preload on the pinion bearings Adjustment of pinion depth of mesh is obtained by placing a machined shim between the pinion head and the rear pinion bearing cone The differential bearings are larger on both the con ventional and Sure Grip Differentials and are not in terchangeable with previous years bearings The Sure Grip Differential is available as optional equipment in the 8 3 4 rear axle assembly The new Sure Grip Differential is of a two piece construction similar to the old type and is completely interchange able with the previous type and will be serviced as a complete assembly only Refer to the Sure Grip Dif ferential Section of the Axle Group for the servicing procedure ADJUSTER OIL SEAL RETAINER GASKET COLLAR GASKET
6. Axle Shaft Oil Seal SLEEVE SP 5041 Lees Fig 6 Notching B Retainer Collar sible and cut with a pair of side cutters and remove Fig 10 5 Remove roller bearing cup and protective sleeve SP 5041 from axle shaft CAUTION Sleeve SP 5041 should not be used as a protector for the seal journal when pressing off the bearing cone as if was not designed for this purpose 6 To avoid scuffing seal journal when bearing earing SLEEVE t SP 5041 3 4 i NK356 Fig 7 Removing Roller Retainer REAR AXLE 3 7 f SLEEVE SLEEVE SP 5041 BEARING ROLLER Fig 9 Removing Bearing Rollers cone is being removed it should be protected by single wrap of 002 thickness shimstock held in place by a rubber band Fig 11 7 Remove the bearing cone using Tool C 3971 Fig 3 Tighten bolts of tool alternately until cone is removed Fig 12 SLEEVE SP 5043 Fig 10 Cutting Out Roller Bearing Retainer 3 8 REAR AXLE Fig 11 Seal Journal Protection 8 Remove seal in bearing retainer plate and re place with new seal Assembly 1 Install retainer plate and seal assembly on axle shaft 2 Lubricate wheel bearings with Multi Purpose Grease NLGI Grade 2 EP 3 Install a new axle shaft bearing cup cone and collar on shaft using Tool C 3971 Fig 13 and tighten bolts of tool alternately until bearing and collar are seated properly 4 Inspect axle shaft seal journal
7. RE TIGHTENED UNTIL PROPER PRELOAD IS OB TAINED DEPTH OF MESH Without Using Tool C 758 D4 If the differential assembly was satisfactorily quiet before being disassembled the drive pinion must be assembled with new pinion bearings If replace ment parts are installed a complete readjustment is necessary the proper thickness shim must be selected and installed The drive gear and pinion are manufac tured and lapped in matching sets and are available in matched sets only The adjustment position in which the best tooth contact is obtained is marked on the end of the pinion head To obtain the proper pinion setting in relation to the drive gear the correct thickness mounting shim must be selected before the drive pinion is installed in the carrier The pinion bearing mounting shims are available in one thousands increments from 020 038 inch To select the proper thickness shim proceed as follows It will be noted that the head of the drive pinion is marked with a plus or minus sign followed by a number ranging from 1 to 4 or zero 0 marking If the old and new pinion have the same marking and if the original bearing is being reused use a mounting shim of the same thickness But if the old pinion is marked zero 0 and the new pinion is marked 2 try a 002 inch thinner shim If the new pinion is marked 2 try a 002 inch thicker shim Pinion Bearing Preload Large Stem After selecting the correct pinion bea
8. Remove the assembly from vehicle installation 1 With body of vehicle supported at front of rear springs position the rear axle assembly spring seats over the spring center bolts 2 Install spring U bolts and tighten nuts to 45 foot pounds and install shock absorbers on spring plate studs DO NOT OVER TIGHTEN U BOLT NUTS 3 Install propeller shaft match scribe marks on propeller shaft universal joint and pinion flange Tighten clamp screws to 15 foot pounds 4 Connect parking brake cable 5 Connect hydraulic brake hose bleed and adjust brakes 6 Install rear wheels 7 If carrier was removed from axle housing dur ing the removal operation fill axle with proper amount and type of lubricant see Specifications in Lubrication section Group 0 Welding Rear Axle Housing The axle housing should be completely disassem bied if it is to be welded with arc welding equip ment It is also possible to weld the assembled hous ing with gas welding equipment if precaution is taken to protect gaskets and heat treated parts DIFFERENTIAL AND CARRIER Removal 1 Remove flanged axle drive shafts 2 Disconnect rear universal joint and support propeller shaft up and out of the way to prevent dam age to the front universal joint 3 Remove the rear axle lubricant 4 Loosen and remove the carrier to housing at taching nuts and lift the carrier assembly from axle housing Disassembly
9. Side play and runout check taken during disassem bly will be very useful in reassembly 1 Mount carrier in Stand DD 1014 and attach dial indicator Tool C 3339 to differential carrier flange in a position so pointer of indicator squarely contacts back face of ring gear Fig 16 With a screw driver positioned between bearing cap and differential case flange then using a prying motion determine if side play is present If side play is evident remove adjuster lock and loosen adjuster slightly and retighten ad juster sufficiently to eliminate side play KP19 Fig 16 Checking for Runout and Zero End Play 2 Rotate drive gear several complete revolutions while noting total indicator reading Mark drive gear and differential case at point of maximum runout The marking of differential case will be very useful later in checking differential case runout Total indicator reading should be no more than 005 inch If runout exceeds 005 inch the differential case may be dam aged and a second reading will be required after drive gear has been removed This operation is cov ered during Differential Disassembly Remove dial indicator 3 With Tool C 3281 hold companion flange and remove drive pinion nut and Belleville washer 4 Install companion flange remover Tool C 452 and remove flange Fig 17 5 Using a screwdriver and hammer remove the drive pinion oil seal from the carrier 6 While holding one hand over nose
10. flange for cracks worn splines pitted rough or corroded oil seal contacting surface Repair or replace companion flange as neces sary 10 Apply a light coat of sealer in seal bore of car rier and install drive pinion oil seal into carrier using Tool C 4109 or C 3980 Double lip synthetic rubber oil seal or Tool C 3656 single lip leather oil seal The proper tool must be used in order to properly position the seal the correct depth into the carrier casting 11 Position companion flange on pinion stem be ing careful to match scribe marks made previously before removal 12 Install companion flange with installing Tool C 496 or DD 999 and holding Tool C 3281 13 Remove tool and install Belleville washer con vex side of washer up and pinion nut 14 Hold universal joint flange with holding Tool C 3281 and tighten pinion nut to 170 foot pounds Ro tate pinion several complete revolutions to assure that bearing rollers are properly seated Using an inch pound torque wrench C 685 measure pinion bearing preload Continue tightening pinion nut and REAR AXLE 3 19 PATTERN MOVES INWARD AND UP TOE HEEL END DRIVE SIDE CONVEX HEEL END COAST SIDE CONCAVE NR202 Fig 36 Effect on Tooth Contact Pattern as Spacer Thickness is Decreased checking preload until preload is at the original es tablished setting you found in step 4 Under no cir cumstances should the preload be more than 5 inch pounds over th
11. result in a premature failure of the axle 1 Raise vehicle on hoist and make scribe marks on propeller shaft universal joint drive pinion flange and end of pinion stem 2 Disconnect propeller shaft at pinion flange and secure in an upright position to prevent damage to front universal joint 8 Remove the rear wheels and brake drums to prevent any drag or a possible false preload reading could occur THINNER SPACER NEEDED HEEL END DRIVE HEEL END COAST SIDE CONCAVE SIDE CONVEX NR201 Fig 35 Incorrect Tooth Contact Pattern Decrease Spacer Thickness A 4 Using inch pound torque wrench C 685 measure pinion bearing preload by rotating pinion with handle of wrench floating read the torque while wrench is moving through several complete revolutions and re cord This operation is very important because pre load must be carefully reset when reassembling 5 With Tool C 3281 hold companion flange and remove drive pinion nut and Belleville washer 6 Install companion flange remover Tool C 452 and remove flange Lower rear of vehicle to prevent lubricant leakage 7 Using a screwdriver and hammer remove the pinion oi seal from the carrier and clean the oil seal seat 8 Check splines on pinion shaft stem to be sure they are free of burrs or are not worn badly If burrs are evident remove them using crocus cloth by work ing in a rotational motion Wipe the pinion shaft clean 9 Inspect companion
12. the same direction simultaneously the vehicle is equipped with a Sure Grip Differential Another means of identification is by removing the filler plug and using a flashlight to look through the filler plug hole to identify the type of differential case SERVICE PROCEDURES SURE GRIP DIFFERENTIAL NOISE Chatter Moan Noise complaints related to rear axles equipped with cone clutch SURE GRIP should be checked to determine the source of the noise If a vehicle ride check produces the noise in turns but not straight ahead the probable cause is incorrect or dissipated rear axle lubricant The following draining and flush ing procedure has been established for the Sure Grip Differential before it is removed from the vehicle and replaced CAUTION When servicing vehicles equipped with Sure Grip differentials do not use the engine to rotate axle components unless both rear wheels are clear off the ground Sure Grip equipped axles can exert a significant driving force if one wheel is in contact with floor and could cause the vehicle to move 1 With lubricant of rear axle assembly at operat ing temperature raise car on hoist so rear wheels are free to turn 2 Loosen and remove fill plug and using a suction gun remove as much of the old lubricant as possible 3 Fill axle to proper level with multi Purpose Hy poid Gear Lubricant Part Number 2933565 or equiva lent Reinstall fill plug and tighten 4 Start engine of vehicle an
13. 5 Remove wooden block from under brake pedal and bleed and adjust brakes PATTERN MOVES TOWARD CENTER AND DOWN TOE HEEL END DRIVE HEEL END COAST SIDE CONVEX SIDE CONCAVE NR200 Fig 34 Effect on Tooth Contact Pattern as Spacer Thickness is Increased A 6 Install rear wheels and tighten to 65 foot pounds LUBRICATION Refill axle assembly with Multipurpose Gear Lubri cant as defined by MIL L 2105B API GL 5 should be used in all rear axles with conventional differentials Chrysler Hypoid Lubricant part number 2933565 is an oil of this type and is recommended or an equivalent be used In Sure Grip axles on al 1970 Vehicles it is recom mended that only Chrysler Hypoid Lubricant part number 2933565 or an equivalent be used This lubri cant recommended for conventional differentials too contains special additives to provide proper differen tial durability and performance Anticipated Temperature Range Viscosity Grade Above 10 F SAE 90 As low as 30 F SAE 80 Bleow 30 F SAE 75 REMOVAL AND REPLACEMENT OF DRIVE PINION FLANGE AND OIL SEAL IN VEHICLE On large stem carriers which use the collapsible spacer to obtain pinion bearing preload the following procedure for the removal and replacement of the drive pinion flange and pinion oil seal must be fol lowed to assure that the proper bearing preload is maintained in the axle assembly If this procedure is not followed it could
14. 7 Select a rear pinion bearing mounting shim which will fit between cross arbor and gauge block This fit must be snug but not too tight similar to the pull of a feeler gauge Fig 29 This shim is then used in determining the correct thickness shim for installation 8 To select a shim for installation read the mark ing on end of pinion head 0 1 2 1 2 etc When marking is minus add that amount to the thickness of shim selected in step 7 When the marking is plus subtract that amount Example With a shim 036 inch thick and a pinion marked 2 install a shim 038 inch thick 036 002 038 Example With a shim 036 inch thick and a pinion marked 2 install a washer 034 inch thick 036 002 034 or when a shim 036 inch thick is too loose and 038 inch too thick use 036 inch shim Treat other pinion markings in a similar manner Shims are available in one thousands of an inch increments 9 Remove differential bearing caps and remove tool arbor from carrier Fig 29 Determining Spacer Thickness REAR AXLE 3 15 10 Reverse carrier in stand so nut of tool is in up right position Loosen compression nut and support lower portion of tool in carrier with one hand re move tool nut centering washer and compression sleeve Lower tool down and out of carrier 11 Remove front pinion bearing cone from car rier housing 12 With stem of drive pinion facing up add rear pi
15. EFT HAND THREAD With a non metallic hammer tap drive gear loose from differential case pilot and remove 3 If drive gear runout exceeded 005 inch in step 2 under Carrier Disassembly recheck the case as follows Install differential case and respective bearing cups in carrier 4 Install bearing caps cap bolts and bearing ad justers Tighten bearing cap bolts down lightly and screw in both adjusters with spanner wrench Tool C 406A 5 Tighten cap bolts and adjusters sufficiently to prevent any side play in bearings 6 Attach a dial indicator Tool C 3339 to carrier flange so pointer of indicator squarely contacts drive gear surface of differential case flange between outer edge flange and drive gear bolt holes Fig 20 7 Rotate differential case several complete revo jutions while noting total indicator reading This reading must not exceed 003 inch runout If runout is in excess of 003 inch differential case must be re placed In a case where the runout does not exceed 003 inch it is often possible to reduce the runout by positioning the drive gear 180 from point of maxi mum runout when reassembling drive gear on dif ferential case 8 With a flat nose drift and hammer remove dif ferential pinion shaft lock pin from back side of drive gear flange The hole is reamed only part way through making it necessary to remove lock pin from one direction 9 With a brass drift and hammer remove dif ferent
16. ON Never exert pressure against the bearing cage since this would damage the bearing PINION BEARING CUP INSTALLATION 1 Position pinion bearing cups squarely in bores of carrier Assemble Tool C 758 D4 Fig 24 by plac ing spacer SP 5387 followed by rear pinion bearing cone over main screw of tool and inserting it into carrier from gear side 2 Place front pinion bearing cone over main GAUGE BLOCK 5P 528 OR SP 3250 83 4 SLEEVE SP 2920 AND 9 AXLE WRENCH CROSSBORE ARBOR LN AU SP 561 B 4 AXLE f SP 5183 994 AXLE SPACER SCREW WASHER lt COMPRESSION SP 538 SLEEVE SP 535 MAIN BODY i SP 526 j SPACER SPACER T 2 a WASHER WASHER A EON SP 1371 SP 3639 SLEEVE SP 1370 SP 2921 OR 5387 CENTRALIZING y WASHER O 8 AXLE Sp 53d SP 5184 934 AXLE v PINION ma COMPRESSION m a LOCATING NUT SP 533 SLEEVE SPA ER ae T SPACER SPACER sp 1682 SP SP 539 EEN Fig 24 Rear Axle Setting Gauge Tool C 758 D4 3 14 REAR AXLE screw of tool followed by compression sleeve SP 535 centralizing washer SP 534 and main screw nut SP 533 Hold compression sleeve with the companion flange holding Tool C 3281 and tighten nut Fig 25 allowing tool to rotate as nut is being tightened in order not to brinnel bearing cone or cups Do not remove tool after installing cups PINION BEARING PRELOAD AND DEPTH OF MESH SETTING USING TOOL C 758 D4 The 8 3 4 large stem differential and carrier as sem
17. Page REAR AXLE ASSEMBLY 834 RING GEAR 5 SPECIFICATIONS REAR AXLE NOISE DIAGNOSIS SERVICE DIAGNOSIS Condition REAR WHEEL NOISE SCORING OF DIFFERENTIAL GEARS AND PINIONS TOOTH BREAKAGE RING GEAR AND PINION REAR AXLE NOISE SERVICE DIAGNOSIS REAR AXLE CONTENTS wich a ei 2 Possible Cause a Wheel Loose b Spalled wheel bearing cup or cone c Defective brinelled wheel bearing d Excessive axle shaft end play e Bent or sprung axte shaft flange a insufficient lubrication b Improper grade of lubricant c Excessive spinning of one wheel a Overloading b Erratic clutch operation c Ice spotted pavements d Improper adjustment a Insufficient lubricant b Improper ring gear and pinion adjust ment c Unmatched ring gear and pinion d Worn teeth on ring gear or pinion GROUP 3 Page gules oh Bees Hines a oes 23 SURE GRIP DIFFERENTIAL 19 1 TIGHTENING REFERENCE 23 Correction a Tighten loose wheel nuts b Check rear wheel bearings If spalled or worn replace c Defective or brinelled bearings must be replaced Check rear axle shaft end play Readjust axte shaft end play Replace bent or sprung axle shaft d e a Replace scored gears Scoring marks on the pressure face of gear teeth or in the bore are caused by instan taneous fusing of the mating surfaces Scored gears should be replaced Fill rear ax
18. R CLEARANCE With Gauge RAET Getic tie dt caida ne ead eared ete we wad oad eis diene 001 to 012 WHEEL BEARINGS TY DO beetle os tek Sie Bais wate bed bade oar eae le SEE PRESS Slew wat ene Tapered Roller Adjustment roesini Se ek reste cede a DAE EEN ee Wiel ES Adjusting Nut End Play sient wie that di Ghee ca ot oye bigs bale an eee Gia EA whe 008 018 LUBPICAIOMN a cine bee kia s dpierech apts ieee ota anne Wea 7 tee aa wie Automotive Multi Purpose Grease NLGI grade 2 LUBRICATION Capacity gt nv S EA card E tae 4 oe Gas deat ce E E 4 4 Pints 3 1 2 Pints Imp Meas Type Multi Purpose Gear Lubricant as defined by MIL L 2105B API GL 5 should be used on all rear axles such a lubricant is available under Part No 2933565 Chrysler Hypoid Gear Lubricant or an equivalent be used TIGHTENING REFERENCE 8 3 4 Axle Pounds Foot Inch Differential Bearing Cap Bolts 0 cc ccc ccc cece reece eee nee ree tere e beeen eee 90 Ring Gear to Differential Case Bolts Left Hand Thread ccc cece ence eee e eee 55 Drive Pinion Flange Nut 0 enpr ce ee cee eee enter eN large Stem ie cd see ea hs alo oes casas oa eave Wale Wea a DN big hve Sly STE te aa tat la day rele 170 Min Carrier to Axle Housing Bolt Nuts cece eee eee ee eee e eee e eee ne eesrenaenes 45 Axle Shaft Retainers Nuts sceoin a eenaa Raw Soba dh tae o oio a AEO O DTE wal E EAS 35 Propeller Shaft Bolts Rear 20 0 c
19. and tooth contact pattern and these results recorded and analyzed It is felt that these measurements and their results will aid you in making the necessary repairs to the axle assembly BEARING NOISE DRIVE FINION AND DIFFERENTIAL Defective or damaged bearings generally produce a rough grow or grating sound that is constant in pitch and varies with the speed of the vehicle This fact will allow you to diagnose between bearing noise and gear noise 3 4 REAR AXLE Drive pinion bearing noise resulting from defective or damaged bearings can usually be identified by a constant rough sound Front pinion bearing noise is usually most pronounced on coast whereby rear pinion bearing is loudest on drive Pinion bearings are rotating at a higher rate of speed than the differ ential side bearings or the axle shaft bearings These particular noises can be picked up best by road testing the vehicle in question on a smooth road black top However extreme caution should be taken not to con fuse tire noise with bearing or gear noise If doubt should exist tire treads should be examined for irregu larities that will often produce such noise Differential bearing noise will usually produce a constant rough tone which is much slower than the noise caused by the pinion bearings REAR WHEEL BEARING NOISE Defective or damaged rear wheel bearings produce a vibration or growl which continues with car coasting and transmission in neutra
20. bly has incorporated a collapsible spacer which bears against the inner races of the front and rear bearings This collapsible spacer is used to establish pinion bearing preload The large stem pinion requires the depth of mesh adjustment first while pinion bear ing preload is the last operation performed The position of the drive pinion with respect to the drive gear depth of mesh is determined by the loca tion of the bearing cup shoulders in the carrier and by the portion of the pinion in back of the rear bear ing The thickness of the rear pinion bearing mount ing shim suitable for the carrier can be determined by using Tool C 758 D4 DEPTH OF MESH Large Stem Pinion Inspect differential bearing cups and cones carrier for grit and dirt or other foreign material Clean all parts in fast evaporating mineral spirits or a dry cleaning solvent and with the exception of bearing cones dry with compressed air Front Pinion Bearing Cone and Cup Must Never Be Reused Under Any Cir cumstances 1 Assemble spacer SP 5387 to main section of tool followed by spacer SP 1730 Install rear pinion bearing cone over spacer SP 1730 and against spacer SP 5387 Fig 26 2 Insert assembly into carrier and install front pinion bearing cone over tool shaft and in its proper Fig 25 Seating Bearing Cup in Carrier Housing A SP 561 PINION LOCATING WASHER A SP 3250 7 OR Q NO WASHER OR SPACER A ASSEMBLY OF Ni NY168C
21. c ccc cece eee eee eee ee ee beeen ete sete eeeenenes 15 Spring Clip U Bolt Nuts io i eea aa wee Se Wie EEE A vlnig beryl elas ove aie wie ain gees 45 Wheel Stud NUtS sinc ier ks pennig cared ae AAE det be 4 oe See Ne eyes Geared RAA 65 Shock Absorber Stud Nuts Lower 0 0 ccc ce eee ce cen ee tence cence tener etre eeeeteeee 50
22. ct pattern increase the thickness of the rear pinion bearing mounting spacer Fig 34 which will cause the high heel contact on drive side to lower and move toward the toe the high toe con tact on coast side will lower and move toward the heel 3 18 REAR AXLE THICKER SPACER NEEDED Ngai ow HEEL END DRIVE HEEL END COAST SIDE CONVEX SIDE CONCAVE NR199 Fig 33 Incorrect Tooth Contact Pattern increase Spacer Thickness 4 If after observing the contact pattern you find it resembles that in Fig 35 the drive pinion is too close to the ring gear the pattern will appear low on the toe on drive side and low heel contact on coast side To correct this type tooth contact pattern de crease the thickness of the rear pinion bearing mount ing spacer Fig 36 which will cause the low toe contact on drive side to raise and move toward the heel low heel contact on coast side will raise and move toward the toe DIFFERENTIAL AND CARRIER Installation 1 Thoroughly clean the gasket surfaces of the car rier and rear axle housing 2 Using a new gasket install the carrier assembly into the axle housing Tighten the carrier to axle hous ing nuts to 45 foot pounds 3 Refer to Installation of Rear Axle Shaft when installing and setting axle shaft end play 4 Install propeller shaft match scribe marks on propeller shaft universal joint and pinion flange Tighten clamp screws to 15 foot pounds
23. d engage in gear and run on hoist with rear wheels free to turn at approx imately 40 MPH for ten 10 minutes This thoroughly circulates the lubricant and brings it to operating tem perature 5 Stop vehicle and remove the fill plug and using a suction gun remove as much of the lubricant as pos sible A REAR AXLE 3 21 DIFFERENTIAL PINIONS SIDE GEARS CONE CLUTCH COIL SPRING E LUBRICATION GROOVES NU405 Fig 2 Sure Grip Differential Schematic 6 Refill axle to proper level with multi Purpose Hypoid Gear Lubricant Part Number 2933565 or equivalent Reinstall fill plug and tighten 7 Lower vehicle on hoist and return to customer to drive and evaluate for approximately 100 miles to determine if lubricant corrects the noise complaint If after the vehicle is driven approximately 100 miles and the noise condition is still evident remove the differential and carrier assembly and replace the Sure Grip Differential The Sure Grip Differential and the internal parts are serviced as an assembly only TESTING SURE GRIP DIFFERENTIAL The Sure Grip differential can be checked to deter mine if its performance is satisfactory without remov ing the differential and carrier assembly from the ve hicle 1 Position vehicle on hoist with engine off and the transmission selector lever in park if automatic or in low gear if manual 2 Attempt to rotate wheel by applying turning force with hands gripping tire tread area Fi
24. e established setting found at time of checking in step 4 of procedure Bearing preload should be uniform during a com plete revolution A preload reading that varies during rotation indicates a binding condition which has to be corrected The assembly is unacceptable if final pinion nut torque is below 170 foot pounds or pinion bearing preload is not within the correct specifications CAUTION Never back off the pinion nut to lessen pinion bearing preload If the desired preload is ex ceeded a new collapsible spacer must be installed and nut retightened until proper preload is obtained In addition the universal joint flange must never be ham mered on or power tools used 15 Install propeller shaft match scribe marks on propeller shaft universal point and pinion flange Tighten clamp screws to 15 foot pounds 16 Install the rear brake drums and wheels and tighten nuts 65 foot pounds 17 Raise the vehicle to a level position so axle as sembly is at correct running position and check lubri cant level Add the correct type of lubricant required to bring lubricant to proper level SURE GRIP DIFFERENTIAL INDEX Page Page Installing Sure Grip Differential and Sure Grip Differential 0 0 cece 21 Carrier Assembly 2 0200 eee 22 Removal einen cceucadataosadunlvet we ewe tess 22 LUD riCation sia desanar AT EEA 22 Cleaning amp Inspection 008 22 Sure Grip Differential Identificatio
25. en 1 Differ ential pinion shaft to differential case 2 Axle shaft to differential side gear splines 3 Differential side gear hub to differential case counterbore 4 Differen tial side gear to pinion 5 Worn thrust washers 6 Drive gear backlash Measure and inspect components and replace as required and or adjust to proper speci fications ENGINE AND TRANSMISSION NOISE Sometimes noises which seem to originate in the rear axle are actually that of the engine or transmis sion To diagnose which unit is actually causing the noise observe the approximate vehicle speed and con ditions under which the noise is most pronounced stop the vehicle in a quiet place to avoid any interfer ing noises With engine running and transmission in neutral run engine slowly up and down through en gine speeds corresponding to approximate car speed at which the noise was most pronounced If a noise similar is produced in this manner it usually can be assumed that the noise was caused by the engine or transmission and not that of the rear axle PROPELLER SHAFT VIBRATION Objectional vibrations at high speed 65 MPH or higher may be caused by a propeller shaft that is out of balance or worn universal joints Out of balance may be due to a damaged or bent shaft To determine whether propeller shaft is causing the vibration in question road test the vehicle through speed range and note speed at which vibration is most pronounced Shift tran
26. end of car rier invert carrier in stand The front pinion bearing cone shim pack and bearing spacer where used will drop from carrier 7 Apply identifying punch marks on differential bearing pedestals of carrier differential bearing caps and bearing adjusters for reassembly purposes Fig 18 Fig 17 Removing Companion Flange A SCRIBE MARKS PUNCH MARKS S KPI Fig 18 Marking Bearing Caps and Adjusters 8 Remove both differential bearing adjuster lock screws and locks 9 With a 3 4 inch socket loosen bearing cap bolts one on each side and back off bearing adjusters slightly using spanner wrench Tool C 406A to re move differential bearing preload Remove bearing cap bolts caps and bearing adjusters 10 Remove differential and ring gear assembly with bearing cups Differential bearing cups must be kept with respective bearing cones 11 Remove drive pinion and rear bearing assem bly from carrier Rear Pinion Bearing Removal 1 Remove drive pinion rear bearing from large stem pinion with Tool C 293 and four 4 No 37 plates Fig 19 2 Using a flat end brass drift remove front and rear pinion bearing cups DIFFERENTIAL CASE Disassembly i 1 Mount differential case and ring gear assembly KD 374B Fig 19 Removing Drive Pinion Rear Bearing REAR AXLE 3 11 in a vise equipped with soft jaws brass 2 Remove drive gear bolts BOLTS ARE L
27. etallic mallet to seat right wheel bearing cup against adjuster and rotate axle shaft several revolu tions so that a true end play reading is indicated 3 Remove one retainer plate nut install adjuster lock If tab on lock does not mate with notch in ad juster turn adjuster slightly until it does Install nut and tighten 30 35 foot pounds 4 Recheck axle shaft end play If it is not within the tolerance of 008 018 inch then repeat adjust ment procedure 5 Remove dial indicator and install brake drum drum retaining clips and wheel REAR AXLE HOUSING Removal 1 Raise vehicle and support body at front of rear springs 2 Block brake pedal in the up position using a wooden block 3 Remove rear wheels 4 Disconnect hydraulic brake hose at connection on left side of underbody 5 Disconnect parking brake cable To maintain proper drive line balance when reas sembling make scribe marks on the propeller shaft universal joint and the pinion flange before removal 6 Disconnect propeller shaft at differential yoke ee Thy Je manatee SR SOMBER me Nr n a oad Oy o oa 7a A ai k NK128 i Fig 15 Measuring Axle Shaft End Play 3 10 REAR AXLE and secure in an upright position to prevent damage to front universal joint 7 Remove shock absorber from spring plate studs and loosen rear spring U bolt nuts and remove U bolts 8
28. for scratches and polish with 600 crocus cloth if necessary Disassembly Imperial CAUTION Under no circumstances should axle shaft collars or bearings be removed using a torch The use of a torch in the removal of the axle shaft collars or bearings is an unsafe practice because heat is fed into the axle shaft bearing journal and thereby weakens this area 1 Slide protective sleeve SP 5041 over the seal Fig 12 Removing Bearing Cone with Tool C 3971T Fig 13 Installing New Bearing and Collar surface next to bearing collar and tape in place This will prevent the possibility of seal surface being damaged during the cutting of roller retainer grind ing of collar and inner bearing race and splitting of collar 2 Remove bearing roller retainer flange by cutting off lower edge with a chisel Fig 7 3 Grind axle shaft collar in one position to ap proximate thickness of protective sleeve SP 5041 At same time grind a portion of inner bearing race so bearing rollers can be removed Fig 14 4 Position axle shaft bearing retaining collar on a heavy vise or anvil and using a chisel cut a groove into collar at position that you previously ground Collar should split and which in turn will enlarge bore and permit collar to be driven off of axle shaft 5 Remove bearing rollers at ground section of inner bearing race Fig 9 6 Pull bearing roller retainer down as far as possible and cut with a pair of side cutte
29. g 3 3 If you find it extremely difficult if not impos sible to manually turn either wheel you can consider the sure grip differential to be performing satisfac torily If you find it relatively easy to continuously turn either wheel smoothly then the differential is not performing properly and should be removed and re placed The Sure Grip Differential and internal parts are serviced as a complete assembly only Under no circumstances should the differential be removed and disassembled and reinstalled SURE GRIP DIFFERENTIAL CAUTION During removal and installation of axle shafts DO NOT rotate one axle shaft unless both are Fig 3 Testing Sure Grip Differential Effectiveness 3 22 REAR AXLE in position Rotation of one axle shaft without the other in place may result in misalignment of the two spline segments with which the axle shaft spline en gages and will necessitate difficult realignment pro cedures when shaft is installed Removal Follow the same procedure outlined under conven tional differential removal Cleaning and Inspection 1 Clean the Sure Grip differential assembly in a fast evaporating mineral spirits or a dry cleaning sol vent and with exception of bearings dry with com pressed air 2 Inspect differential bearing cones cups and roll ers for pitting spalling or other visible damage If replacement is necessary remove bearing cones from differential case using Tool C 293 and adapter
30. g preload g Sure Grip Differential moan and chat g Drain and flush lubricant See pro ter LOSS OF LUBRICANT b Worn axle shaft oil seals c Cracked rear axle housing d Worn drive pinion oil seal e Scored and worn companion flange f Clogged breather g Loose carrier housing bolts or hous ing cover screws OVERHEATING OF UNIT a Lubricant level too low b Incorrect grade of lubricant c Bearings adjusted too tightly d Excessive wear in gears a Lubricant level too high Soe in Sure Grip section of Group a Drain excess lubricant by removing filler plug and allow lubricant to level at lower edge of filler plug hole b Replace worn oit seals with new ones Prepare new seals before replace ment c Repair or replace housing as required d Replace worn drive pinion oil seal with a new one e Replace worn or scored companion flange and oil seal f Clean breather thoroughly g Tighten bolts or cover screws to spec ifications and fili to correct level with proper lubricant a Refill rear axte b Drain flush and refill rear axle with correct amount of the proper lubri cant See Specification Section c Readjust bearings d Check gears for excessive wear or scoring Replace as necessary e Insufficient ring gear to pinion clear e Readjust ring gear and pinion back ance REAR AXLE NOISE DIAGNOSIS Most rear axle failures are relatively s
31. gaging and disen gaging clutch transmission in neutral to determine if noise can only be isolated by removing propeller shaft and operating transmission in high TIRE NOISE Tire noise is often mistaken for rear axte noise even though the noisy tires may be located on the front wheels Tires that are unbalanced or worn unevenly or have surfaces of non skid type design or worn in a saw tooth fashion are usually noisy and often produce noises that seem to originate in the rear axte Tire noise changes with different road surfaces but rear axle noise does not Inflate all tires to approx imately 50 pounds pressure for test purposes only This will materially alter noise caused by tires but will not affect noise caused by rear axle Rear axle noise usually ceases when coasting at speeds under 30 miles per hour however tire noise continues but with lower tone as car speed is reduced Rear axle noise usually changes when comparing drive and coast but tire noise remains about the same Distinguish between tire noise and differential noise by noting if noise varies with various speeds or sudden acceleration and deceleration exhaust and axle noise show variations under these conditions while tire noise remains constant and is more pronounced at speeds of 20 to 30 miles per hour Further check for tire noise by driving car over smooth pavements or dirt roads not gravel with tires at normal pressure If noise is caused by tires it wi
32. ial pinion shaft and axle drive shaft thrust block 10 Rotate differential side gears until each dif ferential pinion appears at large opening of case Fig 20 Checking Drive Gear Mounting Flange Face Runout 3 12 REAR AXLE A SHAFT THRUST WASHER BOLT AND LOCKWASHER DIFFERENTIAL CASE EAS LOCK BEARING CONE FLANGE ane COLLAPSIBLE ADJUSTER SPACER SEAL BOLT N CARRIER i BEARING CONE 2 DRIVE GEAR M A 7 i rw I w gM gi A E RIS N lt ot R S a l Fi w J vV Y j E Po j i j nea GEA WASHER j l THRUST WASHER THRUST BLOCK ne THRUST WASHER SIDE GEAR THRUST WASHER BEARING CONE 3 AND sot TA WASHER T Sh ADJUSTER BOLT y hock BOLT AND LOCKWASHER KPID Fig 21 Differential Carrier Assembly Large Stem Tapered Pinion Remove each pinion and thrust washer at that time 11 Remove both differential side gears and thrust washers Cleaning and Inspection Fig 21 1 Clean all parts in a fast evaporating mineral spirits or a dry cleaning solvent and with the excep tion of bearings dry with compressed air 2 Inspect differential bearing cones cups and rollers for pitting spalling or other visible damage If replacement is necessary remove bearing cones from differential case with Tool C 293 and adapter plates No 43 Fig 22 3 Inspect differential case for elongated or en larged pinion shaft hole The machined thrust washer surface areas and coun
33. imple to locate and correct although rear axle noise is a little more difficult to diagnose and make the necessary re pairs The most essential part of rear axle service is proper diagnosis of the problem All rear axles are noisy to a certain degree Gear noise is usually associated with older axles but this is not always true New axles can also be noisy if they are not properly adjusted or lack lubrication Usually when new improperly set gears are noisy the disturb ing noise cannot be adjusted out once the gears are broken in Recent experience has shown that axle gears can often be readjusted to reduce excessive gear noise if they have been operated at normal break in speeds for less than 500 miles Regardless of what you ve heard to the contrary noisy gears will not get quieter with added mileage they will stay the same or get worse Slight axle noise heard only at certain speeds or under remote conditions must be considered normal Axle noise tends to peak at varying speeds and the noise is in no way indicative of trouble in the axle If axle noise is present in an objectionable form loud or at all speeds an effort should be made to iso late the noise as being in one particular unit of the ve lash and check gears for possible scoring hicle Many noises reported as coming from the rear axle actually originate from other sources such as tires road surfaces wheel bearings engine transmis sion exha
34. ing gear with those in differential case flange 5 Insert drive gear screws left hand threads through case flange and into ring gear After all cap screws are properly started tap ring gear against dif ferential case flange with a non metallic mallet 6 Position differential case unit between brass jaws of a vise and alternately tighten each cap screw to 55 foot pounds NOTE Before installation of differential case into car rier lubricate the inside of differential assembly with Multi Purpose Hypoid Gear Lubricant Part Number 2933565 or equivalent Do not use any other lubricant other than this special lubricant 7 Follow procedure outlined in conventional axle assembly for setting drive pinion depth of mesh drive gear backlash adjustment and bearing preload adjust ment INSTALLING SURE GRIP DIFFERENTIAL AND CARRIER ASSEMBLY 1 Using a new gasket install carrier assembly in axle housing Tighten mounting nuts to 45 foot pounds 2 Refer to Installation of Rear Axle Shaft when installing axle shafts 3 Connect the rear universal joint 4 Before lowering the rear wheels of the vehicle to the floor adjust rear brakes CAUTION Both rear wheels must be raised off the floor when adjusting brakes LUBRICATION Every six months check the fluid level in the axle through the filler plug hole When checking the level be sure the vehicle is in a level position on an axle or drive on type hoist See Lubricat
35. ion Section for proper level of specific axle assembly In Sure Grip Differentials use only the Multi Pur pose Hypoid Gear Lubricant Part Number 2933565 or equivalent Do not use any other lubricant other than this special lubricant AN nnn TIGHTENING REFERENCE 3 23 SPECIFICATIONS 8 3 4 Axle TYPE Sesh si cleated edt Behe ecto Madi LB eed ba hercules teste Davee Semi Floating Hypoid Ring Gear Diameter 0 cc ccc cece cece eee eee teen eee ae eeeee 8 750 PINION BEARINGS TY PO esis ots E EAEN eos ae sa ais to este ERO WS he ee UN aye ere ak eee es Tapered Roller Number WS d cnc ie orka Seo Sk WA Rie Alp ee oe HR Aaa ot see 2 Adjustment e ecce cee bos ereunna eek bee ate eee Mada els RAOR wa We Large Stem cnc ied tel Melee A aa ae vans ition acne anes tay cae ey Collapsible Spacer Pre Load Torque Sea Removed 0 cece ence e etree eee 20 to 30 inch pounds DIFFERENTIAL BEARINGS WN DOs eer alt a cous inte ees cba wea tanta Re ASL AMES RR Wels eee Baoan We Tapered Roller NumberUSOd sis cae betes Bs ens s e urA a Se enh nee lee SS WS sel ae a aan gars 2 ACjUStMO Nt k ea eced tenim a s Recess did cheats wave DES wis acing EE A EEO SEE A Adjusting Nut RING GEAR AND PINION Serviced IN eree Sts wae es Vea A E ESE A ERA Rie alee EA Matched Sets Ring Gear RUNQUE cies 6 hobs oe hae BNR oS Ae oak CLES eRe Cee ee eT G s 005 Max Back Lash oraaa En EEr woe Gal ET AERENCA EOE EES 006 to 008 DIFFERENTIAL SIDE GEA
36. l A brinneled rear wheel bearing causes a whirring noise Spalled rear wheel bearings normally produce a noise similar to a growl created from either flaked or pitted rollers or bearings races Unless the damage is severe rear axle bearing noise is seldom heard above 30 mph To differentiate between wheel bearings and gear noise road test the vehicle on a smooth road black top at medium and low speed With traffic permitting swerve the vehicle sharply right to left If the noise in question is caused by wheel bearings it will usually increase when the vehicle is swerved and will prob ably be coming from the bearing on the loaded side If the noise in question cannot be isolated an inspec tion of bearings will be necessary KNOCK AT LOW SPEEDS Low speed knock is usually caused by brinneled universal joints or differential side gear hub to coun terbore clearance being too great Inspect and replace universal joint or differential case and side gear as required DRIVE LINE SNAP A snap on a sudden start either forward or reverse may be caused by a loose companion flange Remove the propeller shaft and flange and reinstall 180 de grees from original position Pinion bearing preload A and pinion nut torque must be reset to original set tings upon reinstallation BACKLASH CLUNK Excessive clunk on acceleration and deceleration can be caused by anyone of the following items or a combination excessive clearance betwe
37. le to required capacity with proper lubricant See Specification section Replace scored gears Inspect all gears and bearings for possible dam age Clean out and refill axle to re quired capacity with proper lubricant See Lubrication section Replace scored gears Inspect all gears pinion bores and shaft for scoring or bearings for possible dam age Service as necessary b c a Replace gears Examine other gears and bearings for possible damage Replace parts as needed Avoid Over loading Replace gears and examine remain ing parts for possible damage Avoid erratic clutch operation c Replace gears Examine remaining parts for possible damage Replace parts as required d Replace gears Examine other parts for possible damage Make sure ring gear and pinion backlash is correct b a Refill rear axle with correct amount of the proper lubricant See Specifica tion section Also check for leaks and correct as necessary b Check ring gear and pinion tooth contact c Remove unmatched ring gear and pinion Replace with a new matched gear and pinion set d Check teeth on ring gear and pinion for contact If necessary replace with new matched set 3 2 REAR AXLE Condition e End play in drive pinion bearings f Side play in differential bearings Possible Cause Correction e Adjust drive pinion bearing preload f Adjust differential bearin
38. ll noticeably change or disappear and reappear with changes in road surface FRONT WHEEL BEARING NOISE Loose or rough front wheel bearings will cause noise which may be confused with rear axle noises however front wheel bearing noise does not change when comparing drive and coast Light application of brake while holding car speed steady will often cause wheel bearing noise to diminish as this takes some weight off the bearing Front wheel bearings may be easily checked for noise by jacking up the wheels and spinning them also by shaking wheels to determine if bearings are loose Rear suspension rubber bushings and spring insula tors help to dampen out rear axle noise when properly and correctly installed Check to see that no metallic interference exists between the springs and springs hangers shackles or U bolts Metal to metal contact REAR AXLE 3 3 at those points may result in telegraphing road noise and normal axle noise which would not be objection able if properly installed and tightened to specifica tions GEAR NOISE Abnormal gear noise can be recognized easily be cause it produces a cycling tone and will be very pronounced through the speed range in which it oc curs Gear noise may be developed under one or more of the following conditions drive road load float or coast Gear noise usually tends to peak in a narrow speed range or ranges Gear noise is more prominent between 30 t
39. n 20 Assembly 0 cece cece rere eee nee 22 Sure Grip Differential Noise 20 Testing Sure Grip Differential 21 GENERAL INFORMATION A new Sure Grip differential being offered as a special equipment option in the 8 3 4 rear axles Fig 1 The Sure Grip differential design is basic and sim ple and consists of a two piece case construction and is completely interchangeable with the conventional 3 20 REAR AXLE NU404 Fig 1 Sure Grip Differential differential and also the previous type Sure Grip dif ferential Fig 2 A conventional differential allows the driving wheels to rotate at different speeds while dividing the driving torque equally between them This function is ordinarily desirable and satisfactory However the total driving torque can be no more than double the torque at the lower traction wheel When traction con ditions are not the same for both driving wheels a portion of the available traction cannot be used The SURE GRIP differential allows the driving wheel with the better traction condition to develop more driving torque than the other wheel so that the total driving torque can be significantly greater than with a conventional differential SURE GRIP is not a locking differential In normal driving conditions the controlled internal friction is easily overcome during cornering and turning so that the driving wheels can turn at different speed
40. ng cones care fully install the assembly into carrier 2 Install differential bearing caps on respective sides making certain that identification marks on caps correspond with those on carrier Install cap bolts and tighten bolts of each cap by hand 3 Install differential bearing adjusters on respec tive sides making certain that identification marks correspond Screw adjuster in by hand No attempt should be made to apply any excessive pressure at this time 4 Using spanner wrenches Tool C 406A to square bearing cups with bearing cone turn adjusters IN until cups are properly square with bearings and end play is eliminated with some backlash existing be tween the drive gear and pinion Fig 30 Fig 30 Adjusting Differential Bearings A 5 Tighten one differential bearing cap bolt on each side to 85 90 foot pounds DRIVE GEAR AND PINION BACKLASH Correct drive gear and pinion backlash when properly set is 006 to 008 inch at point of minimum backlash Rotate drive pinion and ring gear several revolutions in both directions in order to seat the bear ing rollers This is necessary before setting backlash 1 Attach a dial indicator Tool C 3339 to carrier flange so pointer of indicator is squarely contacting one drive gear tooth drive side Fig 31 2 Measure backlash between drive gear and pin ion at four positions approximately 90 degrees apart After point of least backlash has been determined
41. nion bearing mounting shim you selected on pinion stem PINION BEARING PRELOAD Large Stem Pinion 1 Position rear pinion bearing cone on pinion stem small side away from pinion head Make cer tain that the contacting surfaces of selected shim rear bearing cone and pinion head are perfectly clean and free of any foreign particles 2 Lubricate front and rear pinion bearing cones with hypoid gear lubricant Install rear pinion bearing cone onto pinion stem using Tool C 3095 press bear ing cone into place An arbor press may be used in conjunction with tool 3 Insert drive pinion and bearing assembly up through carrier and install collapsible spacer followed by front pinion bearing cone on pinion stem Install companion flange using Tool C 496 or DD 999 and holding Tool C 3281 This is necessary in order to properly install front pinion bearing cone on stem due to interference fit Remove tool from pinion stem CAUTION During the installation of the front pinion bearing be careful not to collapse the spacer 4 Apply a light coat of sealer in seal bore of car rier casting and install drive pinion oil seal into carrier using Too C 4109 or C 3980 double lip synthetic rub ber oil seal or Tool C 3656 single lip leather oil seal The proper tool must be used in order to position the seal the proper depth into the carrier casting 5 With pinion supported in carrier instal anti clang washer on pinion stem Install compani
42. o 40 mph and 50 to 60 mph Abnormal gear noise is quite rare and if present it usually originates from scoring of the ring and drive pinion gear as a result of insufficient or improper lubrication of the axle assembly The differential side gears and pinions very seldom cause trouble as they are only under loads when the rear wheels travel at different speeds such as when turning corners When objectionable axle noise is heard note the driving condition and speed range Remove the differ ential and carrier from the axle housing on the 8 3 4 axle Perform a tooth contact pattern check to deter mine if the best possible pattern has been obtained If pattern is found to be unacceptable reshim and adjust to obain the best possible pattern If after read justment noise still persists replace with new gear set PRE DISASSEMBLY INVESTIGATION A close examination of the rear axle assembly prior to disassembly can reveal valuable information as to the extent and type of repairs or adjustments neces sary This information coupled with the road test re sults will provide a basis for determining the degree of disassembly required Since the most frequent causes of axle noise are improper backlash or differen tial bearing preload or both a few simple adjust ments may be all that is necessary to correct the com plaint Therefore before disassembly the following checks should be made drive gear and pinion backlash pinion bearing preload
43. oating of Multi Purpose Grease NLGI Grade 2 E P or equivalent to the outside diam eter of the bearing cup prior to installing in the bear ing bore This operation is necessary as a corrosion preventative 3 Install foam gasket on the studs of axle housing and carefully slide axle shaft assembly through oil seal and engage splines in differential side gear 4 Tap end of axle shaft lightly with a non metallic mallet to position axle shaft bearing in hous ing bearing bore Position retainer plate over axle housing studs Install retainer nuts and tighten 30 35 foot pounds Start by tightening bottom nut 5 Repeat step 1 for right side of axle housing 6 Back off threaded adjuster of right axle shaft assembly until inner face of adjuster is flush with inner face of retainer plate Carefully slide axle shaft assembly through oil seal and engage splines in dif ferential side gears 7 Repeat step 4 AXLE SHAFT END PLAY CAUTION When setting axle shaft end play both REAR AXLE 3 9 rear wheels must be off the ground otherwise a false end play setting will occur 1 Using a dial indicator mounted on the left brake support Fig 15 TURN THE ADJUSTER CLOCKWISE UNTIL BOTH WHEEL BEARINGS ARE SEATED AND THERE IS ZERO END PLAY IN THE AXLE SHAFTS BACK OFF THE ADJUSTER COUN TERCLOCKWISE APPROXIMATELY FOUR NOTCH ES TO ESTABLISH AN AXLE SHAFT END PLAY OF 008 018 INCH 2 Tap end of left axle shaft lightly with a non m
44. on flange with installing Tool C 496 or DD 999 and holding Tool C 3281 6 Remove tools and install Belleville washer con vex side of washer up and pinion nut 7 Hold universal joint flange with holding Tool C 3281 and tighten pinion nut to remove end play in pinion while rotating the pinion to insure proper bearing seating 8 Remove holding tool and rotate pinion several complete revolutions in both directions to permit bear ing rollers to seat 9 Tighten pinion nut to 170 foot pounds and meas ure pinion bearing preload by rotating pinion using an inch pound torque wrench The correct preload specifications are 20 35 inch pounds for new bear 3 16 REAR AXLE ings or 10 inch pounds over the original if the old rear pinion bearing is being reused Cor rect bearing preload readings can only be obtained with nose of carrier in upright position Continue tightening of pinion nut in small increments and checking pinion bearing preload until proper preload is obtained Bearing preload should be uniform during complete revolution A preload reading that varies during rotation indicates a binding condition which has to be corrected The assembly is unacceptable if final pinion nut torque is below 170 foot pounds or pinion bearing preload is not within the correct speci fications NOTE UNDER NO CIRCUMSTANCES SHOULD THE PINION NUT BE BACKED OFF TO LESSEN PRE LOAD IF THIS IS DONE A NEW COLLAPSIBLE SPACER MUST BE INSTALLED AND NUT
45. pattern will disclose whether the correct rear pinion bearing mounting shim has been installed and the drive gear backlash set prop erly Backlash between the drive gear and pinion must be maintained within the specified limits until correct tooth contact pattern is obtained 1 Apply a thin film of red or white lead on both the drive and coast side of the drive gear teeth Ro tate drive gear one complete revolution in both direc tions while load is being applied with a round bar or screwdriver between the carrier casting and differen tial case flange This action will leave a distinct con tact pattern on both the drive and coast side of the drive gear teeth 2 Observe the contact pattern on the drive gear teeth and compare with those in figures 32 33 and 35 to determine if pattern is properly located With pinion depth of mesh and gear backlash set properly your contact pattern should resemble that in Fig 32 Notice that the correct contact pattern is well centered on both drive and coast sides of the teeth When tooth contact patterns are obtained by hand they are apt to be rather small Under the actual operating load however the contact area increases 3 If after observing the contact pattern you find it resembles that in Fig 33 the drive pinion is too far away from centerline of the ring gear the contact pattern will appear high on the heel on drive side and high on toe on coast side To correct this type tooth conta
46. plates No 43 3 Visually inspect differential case for cracks or other visible damage which might render it unfit for further service Assembly If during cleaning and inspection the differential bearings were found to be unfit for further use and were removed follow this procedure for installation of new bearings 1 Position each differential bearing cone on hub of differential case taper away from drive gear and with installing Tool C 4086 install bearing cones An arbor press may be used in conjunction with installing tool CAUTION Never exert pressure against the bearing cage since this would damage the bearing 2 If the ring gear was removed from the sure grip differential case or is being replaced with a new ring gear for any reason new nylok drive gear screws must be installed IMPORTANT The procedure for installing the ring gear on differential case must be followed so the ring gear seats on the differential case properly 3 Using an Arkansas stone relieve the sharp edge of the chamfer on the inside diameter of the ring gear Fig 23 in 8 3 4 Axle section of this group This is very important otherwise during the installa tion of ring gear on differential case the sharp edge A will remove metal from the pilot diameter of case and can get imbedded between differential case flange and gear causing gear not to seat properly 4 Position ring gear on differential case pilot aligning threaded holes of r
47. proper alignment push pinion shaft into case until locking pin hole in pinion shaft is in exact alignment with its respective hole in case install pinion shaft lock pin through hole in case from pinion shaft side of drive gear flange The contacting surfaces of the drive gear and differential case flange must be clean and free of all burrs 7 Using an Arkansas stone relieve the sharp edge of the chamfer on the inside diameter of the ring gear Fig 23 This is very important otherwise during the installation of ring gear on differential case the sharp edge will remove metal from the pilot diameter of case and can get imbedded between differential case flange and gear causing gear not to seat properly 8 Position drive gear on differential case pilot aligning threaded holes of drive gear with those in differential case flange 9 Insert drive gear screws LEFT HAND THREADS through case flange and into drive gear REAR AXLE 3 13 NU403 Fig 23 Stoning Chamfer on Ring Gear After all cap screws are properly started tap drive gear against differential case flange with a non metallic mallet 10 Position unit between brass jaws of a vise and alternately tighten each cap screw to 55 foot pounds 11 Position each differential bearing cone on hub of differential case taper away from drive gear and with installing Tool C 4086 install bearing cones An arbor press may be used in conjunction with in stalling tool CAUTI
48. ring mounting shim and installing it behind the rear pinion bearing cone proceed as follows Install the pinion assembly into the carrier Install the new collapsible spacer fol lowed by new front pinion bearing cone on pinion stem Press front pinion bearing cone on pinion stem being careful not to collapse the spacer Apply a light coat of sealer to drive pinion oil seal and carrier casting bore and install drive pinion oil seal with Tool C 4109 or C 3980 synthetic rubber seal or Tool C 3656 leather seal Install anti clang washer and universal joint flange Belleville washer convex side of washer up and nut Tighten the pinion nut to 170 foot pounds and using an inch pounds torque wrench rotate the pinion to determine preload The correct preload specifications are 20 30 inch pounds for new bearings or 10 inch pounds over the original if the old rear pinion bearing is being reused If pre load is not correct continue to tighten pinion nut in small increments and checking preload until preload on pinion bearings is correct A minimum of 170 foot pounds of torque is required on pinion nut Under no circumstances should the pinion nut be backed off to lessen preload If this is done a new pinion bearing collapsible spacer must be installed and nut retight ened until proper preload is obtained installation of Differential and Ring Gear in Carrier 1 Holding differential and ring gear assembly with bearing cups on respective beari
49. rs and re move Fig 10 Fig 14 Collar and inner Race Ground Prior to Removal Imperial A 7 Remove roller bearing cup and protective sleeve SP 5041 from axle shaft CAUTION Sleeve SP 5041 should not be used as a protector for the seal journal when pressing off the bearing cone as it was not designed for this purpose 8 To avoid scuffing seal journal when bearing cone is being removed it should be protected by a single wrap of 002 thickness shimstock held in place by a rubber band Fig 11 9 Remove bearing cone using Tool C 3971 and adapter SP 5168 Tighten bolts of tool alternately until cone is removed Fig 12 10 Remove seal in bearing retainer plate and re place with new seal Assembly imperial 1 Install retainer plate and seal assembly on axle shaft 2 Lubricate wheel bearings with Multi Purpose Grease NLGI Grade 2 E P or equivalent 3 Install a new axle shaft bearing cup cone on axle shaft using Tool C 3971 and adapter SP 5168 Fig 13 and tighten bolts of tool alternately until bearing is seated properly Repeat same step for installing the collar 4 Inspect axle shaft seal journal for scratches and polish with 600 crocus cloth if necessary installation 1 Clean axle housing flange face and brake sup port plate thoroughly Install a new rubber asbestos gasket on axle housing studs followed by brake sup port plate assembly on left side of axle housing 2 Apply a thin c
50. s Ex A treme differences in traction conditions at the driving wheels may permit one wheel to spin SURE GRIP has been engineered to perform its specialized functions with minimum effect on normal vehicle operations The cone clutch SURE GRIP differentials are similar to corresponding 8 3 4 conventional differentials ex cept for the incorporation of the helix grooved cones that clutch the side gears to the differential case The grooves assure maximum lubrication of the clutch surface during operation The cone brakes and side gears are statically spring preloaded to provide an internal resistance to the differential action within the differential case itself This internal resistance as sures an adequate amount of pull while under ex tremely low tractive conditions such as mud snow or ice when encountered at one of the rear wheels During torque application to the axle the initial spring loading of the cone brakes is supplemented by the gear separating forces between the side gears and differential pinions which progressively increases the friction in the differential It should be remembered that the Sure Grip differential is not a positive lock ing type and will release before excessive driving force can be applied to one wheel SURE GRIP DIFFERENTIAL IDENTIFICATION Identification of sure grip differential assembly can easily be made by lifting both rear wheels off the ground and turning them If both rear wheels turn in
51. sing seal bore clean and install a new axle shaft oil seal using Tool C 839 Fig 5 Disassembly All Models except Imperial CAUTION To prevent the possibility of damaging axle shaft seal surface slide protective sleeve SP 5041 over the seal surface next to bearing collar CAUTION Under no circumstances should axle shaft collars or bearings be removed using a torch The FLANGE GASKETS ADJUSTER SHARI AA RIGHT LOCK SEAL BEARING NK59A Fig 2 Axle Shaft Disassembled use of a torch in the removal of the axle shaft collars or bearings is an unsafe practice because heat is fed into the axle shaft bearing journal and thereby weak ens this area 1 Position axle shaft bearing retaining collar on a heavy vise or anvil and using a chisel cut deep grooves into retaining collar at 90 intervals Fig 6 This will enlarge bore of collar and permit it to be driven off of axle shaft 2 Remove bearing roller retainer flange by cutting off lower edge with a chisel Fig 7 3 Grind a section off flange of inner bearing cone Fig 8 and remove bearing rollers Fig 9 4 Pull bearing roller retainer down as far as pos BLOCKS BEARING ADAPTER REMOVING SP 5020 SP 5021 7 TSR SCREWS At N A SP 5026 Euf AA Ja id ADAPTER SP 5015 OR SP 5168 o 7 oo we a ere o7 P RING BLOCK HOLDING SP 5017 SLEEVE SP 5041 NK360A Fig 3 Tool Set C 3971 NK56 Fig 4 Removing
52. smission into lower gear range and drive car at same engine speed as when vibration was most pronounced in direct drive and note any effect on vibration If the vibration is still present at the same engine speed whether in direct drive or in the lower gear since the propeller shaft speed varies this cannot be the fault If the vibration decreases or is eliminated in the lower gear then propeller shaft is at fault and should be rebalanced or replaced REAR AXLE 3 5 REAR AXLE ASSEMBLY 834 RING GEAR INDEX Page Page Axle Shafts and Bearings 04 Pinion Bearing Preload and Pinion Depth of Axle Shaft End Play 2 00 0 eee 9 Mesh Setting Using Tooli C 758 D4 14 Differential and Carrier Removal 10 Large Stem Pinion Depth of Mesh 14 Differential and Carrier installation 18 Depth of Mesh Differential Case 0 2 ccc ce eee ee 11 Setting Without Using Too C 758 D4 16 Drive Gear and Pinion Backlash 17 Rear Axle Housing c cece eee eee eees 9 Gear Tooth Contact Pattern 4 17 Removal and Replacement of Drive Pinion PUDKICAON se rhea a a een E a AE 18 Flange and Oil Seal in Vehicle 18 Pinion Bearing Cup Installation 13 GENERAL INFORMATION The 8 3 4 Rear Axle Assembly shown in Fig 1 is a semi floating type and may be divided into four subassemblies
53. terbores must be smooth and without metal deposits or surface imper fections If any of the above conditions exist satisfac tory correction must be made or the case replaced Inspect case for cracks or other visible damage which might render it unfit for further service 4 Inspect differential pinion shaft for excessive wear in contact area of differential pinions Shaft should be smooth and round with no scoring or metal pickup 5 Inspect differential side gears and pinions they should have smooth teeth with a uniform contact pat tern without excessive wear or broken surfaces The differential side gear and pinion thrust washers should be smooth and free from any scoring or metal pickup 6 Inspect axle shaft thrust block for excessive wear or visible damage The wear surface on the opposite ends of the blocks must be smooth 7 Inspect differential pinion shaft lock pin for damage or looseness in case Replace pin or case as necessary 8 Inspect drive gear and pinion for worn or chipped teeth or damaged attaching bolt threads If replacement is necessary replace both the drive gear and drive pinion as they are available in matched sets only 9 Inspect drive pinion bearing cones cups and rollers for pitting spalling excessive wear or other PLATES TOOL Fig 22 Removing Differential Bearings A visible damage If inspection reveals that either are unfit for further service replace both cup and cone
54. ust propeller shaft vibration universal joint noise or body drumming A thorough and careful check should be made to determine the source of the noise before any disassembly and teardown of the rear axle is attempted The complete isolation of noise in any one unit re quires considerable skill and previous experience Eliminating certain type noises often baffle even the most experienced personnel Often such practices as raising tire pressures to eliminate tire noise listening for the noise at varying speeds under different load conditions such as drive float and coast and under certain highway conditions turning the steering wheel from left to right to detect wheel bearing noise will aid even the beginner in detecting certain alleged axle noises Axle noises normally fall into two categories gear noise and bearing noise To make a good diagnostic check for rear axle noise a thorough road test is necessary Select a level smooth blacktop or asphalt road This will reduce tire noise and body drumming Drive the car far enough to thoroughly warm up the axle to normal operating temperature Drive the car and note speed at which noise occurs A Then stop car and with clutch disengaged or auto matic transmission in neutral run engine slowly up and down through engine speeds corresponding to car speed at which noise was most pronounced to de termine if it is caused by exhaust roar or other en gine conditions Repeat while en
Download Pdf Manuals
Related Search