Professional Documents
Culture Documents
Repairsand Maintenance
Rearaxle
1976-
Contents
Specifications Specialtools Sparepartsillustrations
Rear axleassembly Differential
Limitedslip differential
Page 1 2
6 7 B
Descriptions
Flearaxle
Serviceprocedutes
On vehiclerepairs - C h e c k i nl gm i t e s l i pd i f f e r e n t i . . l. . . . i d a - C h e c k i n g n df l o a o f a x f e f r " f U e " r i n g . . . . . . . . . e t s t . pi'1ron Beplacrng seal R e p l a c i n g l e h a f b e a r i na n ds e a . . . . . . . . . . . . . . ax s l g | Removing rearaxle O i s a s s e m b l irn g ra x l e. . . . . . . . . . . . . . . . . . . . . . . . . ea - D i f f e r e n t i a l w i t hl om t t e s l i p. . . . . . . . . . . . . . . . . . i ui d D i f f e r e n tw i l hl i m i t e s l i p. . . . . . . . . . . - . . . . . . . . . . . iat d - C l e a n i n ig , s p e c t i o n n -.. -.. . Assemblingdillerenlial - Differential without i m i t e d s l i p . - . . . . . . . . . . . . . - . . l . - Differential limi t e d s | i p. . . . . . . . . . . . . . . . . . . . . . with . - Installing pinion . . Installingdifferential Inslalling rearaxle
c1-c7
D1-D21
14
34
40
TP 30039/2
3000.06.81 Printed USA in
Specilications
Specifications
Rearaxle
qear ax e. type Track . . Finaldrive
USmeasurements 53.1s',
Tvpe
Reduction ratio Type1030 Type1031 Wa p. ringgea' Backlash............
Pre-loading pinionbearings on n e wb e a f l n g s . . . . . . . . . used bearings P.e-loading oifferenLial on bearngs Lubricant OLa iry.standarddi'fere'rial . . I m.reds ip oiffprentral Viscosrly rormal opa'arirg co'1ditiors. . is when temperature steadiy below l 5 " F - 1 0 " Cu s e
Hypoid
3 . 7 3 : 1 , 9 11 4 . 1 0 : 1 3. : , 3.54:1,3.73:1 mm max.0.08 0 . 1 3 - 0 . 1m m 8
0.0032' 0.005-0.007'
( L A P tG L - 5 M i r - 2 1 0 5 - B ) (l\lilL-2105-B) additive with APIGL-5 for limited differential slip SAE 90 SAE BO 1.3lrters 1.6liters Nm 50 70 70-80 90 110 1 0 01 4 0 240-300 200-250 2A0 250 '1.35 qts US 1 . 7U Sq t s ft.lbs. 35-50 50-58 65-80 70-100 175-220 145-180 145-180
Tighlening torques
Caps
Ring gear:standardbolt heads flangedbolt heads. Wheelruls.. F l a n g e u t s .8 8 6 2 6 3 / 4 " N F ) . . . ( n U (3/4"UNF) . . 946831 (M20| l5) 947855
Gtoup46
Specialtools
Special tools
1801 Slandard handle 1845 Press tool3/4'-16 UNF installing drive flange 2261 Pullel round drive flange 2284 Dialgauge holder adjusting finaldrive 2337 Tool removlng carrrer 2392 Puller rearpinionbearing 2393 Measuring tool pinion at 2284) adjusting (ill. 2394 Expanding tool removing/installing limited slip differential 2395 Drift installing pinion rear bearing 2404 Wrench installing frontpinion bearing (ill.at 1845) 2483 Puller differential carrier bearings 2524 Workstand 2522 Fixture 2595 Adlusting rings differential 2598 Dritt removing pinion tear bearing outer r i n g( i l l a t 1 8 0 1 ) . 2599 Drilt r e m o v i n g ' r op itn i o n e a n go u l e r n b ringand installing differential carrier bearings 2600 Measuring fixture for adjusting rings 2595, 2685, 2687, 2689and 2840 260'1Relainer torexpanding 2394 at 2394) tool (ill. 2685 Adlusting ring ptnton 2686 Presstool pinionbearing instalJing outerrings 2709 Extractor drive shaft 2714 Fixlure removing/installing axle rear 2779 Socket propeller removing shaft 2806 Drift insialling on drive ange seal f 2809 Holder plate anddialgauge 2838 Presstool rernoving/installing shaltbearing drive andsnapflng 2840 Adlusting ring pinion height at 2685) (ill. 2841 Wrench for adjusting rings 2840, 2685 and 2689 at 2685) (ill. 2842 Sleeve installing pinion rear bearing outer ring(ill.at 2395) 2843 Otill removing pinion rear bearing outer r i n g i l l . t1 8 0 1 ) ( a 2844 Puller pinionbearing at 2392) rear (ill. 2845 Presstool install pinron ng bedri']q ourer'rngs (ir.at 2686) 2846 Socket propeller removing (ill. shaft at 2779) 2917 Extractor pads brake 4112 Drilt instalingdifferential carrier bearings 5009 Drift installing drive shaftinner seal 5010 Ring install bearing snapringon ng and drive shaft(ill.at 2838) 5069 Puller Pinion seal 5149 Wrench instaliing/removing f lange drive 5156 Press tool instal drive (ill. ing flange at 1845) 5157 Wrench for adjusting (ill.at 2685) ring 5214 Ring (fortool 521515216) 5 2 1 5P u l t e r p i n i o n e a r i n (1030 b g axle) 5216 Puller pinionbearing (103'1 axle)
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Group46 Rearaxle
Speclal ioo/s
1801Siandard handle 2598 Drift bearing removing Pinion rear outerrrng 2843 Drilt removing Pinion rear bearing outerring
1845Piesstool3/4'-16UNF installing drive flange 2404 wrench inslalling frontpin on beanng 5156 Press tool installlng ilange drive
\ holder 2284 Dialgauge finaldrive adjusting 2393Measuringtool pinion adjusting 2337 Tool removtng carner (1030) new 5215 Puller rearpinion bearing (1031) new 5216 Puller rearpinion bearing 5214 Ring
2395 2842
2483
2394 Expanding tool removing/installing limited slipdifferential 2601 Holder forexpanding tool2394
2395 Drift installing pinion rear lreanng 2842Sleeve installing pinion rear bearing outerring
Specla/tools
2520Worksland 2522Fixture
2685 Adiustingring prnron 2840 Adlustingring pinion eight h 2600Measuring tixture 2841Wrench for adjusting rings 2595, 2685, g for adjustin rings 2840, 2685 2687 26A9and 2840 , and2689 5157Wrench for adjusting ring
2686 Press tool pinionbearing installing outer flngs 2845 Press lool pinionbearing lnstalling outer rings
g"
2709 Exlractor driveshaft 2/14 Fixlure rear removlng/installing axle
2779 Socket
Grouq46 Reataxle
Specia/ tools
2838 Press tool removlng/installing shaf drive t bearing snapring and 5 0 1 0R i n g installing bearing snapring and on drive shaft
o
112
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lr,rl
Extractor paos 0raKe Drift installing ferential dif carrier oearngs 5009 Drift installing drive shafiinner seal
SparePartslllustration
ALTI ALT 2
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Rearaxleassembly
Gtoup46 Reataxle
SparePartslllustration
Differential (Finaldrive)
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Gtoup46
SparcPaftslllustrction
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DescrtPtton
2. Tralingarm 5. Stabilizer
The rearaxle is connected the body by 1wo to (2).Longitudinalforces transfer trailing arnrs are redby tworeaction rods{3)and transversal torces by a track rod (Panhard rod) (4).Trailng arms, reaction rodsand trackrod areattached body to andrearaxleby replaceable rubber bushings. (notwagons), equipped llost vehicles are with a rearstabilizer fittedbetween trailing (5) the arms.
0
TheoLiter endsoi ihe driveshaftsarejournaled In raoe-oller beaflngs, rs Bea-_g crearance n o l a d t u s l a b la _ d i s d e t e r m e d b y o e a r i n g 1 e design, see Fig. lett. Oil sealsare provided on the outsideof the driveshaft bearings.
Dfiveshafliournaling
Graup46
Description
Description, ditferential
differential gears s h r m s a d j u s tb a c k l a s h ,
I 20
nnggearteeth,
s h i m s ,a d j u s t i x i a l o c a i l o n i lhe rlnqgear
nnggear
3 0 iu
oeannq
,',
only) {produclion
Thefinaldriveis of the hypoid type, whichmeans that the drivepinionliesbelowthe center rne oT rrng gear-lt consists pinion,ring gear and of gear.Gearbacklash differential and diiferenta carrier bearir1g lension adjusted shimsinare by sidethedifterential carrier bearings. Differential carrierand ring gear assembly are journaled the finaldrivehousing iwo taper in by rollerbearings. ring gearis attached the The to differeniial carrier bolts. by Thedifferentialgears in the diiferential carrierconsistof two oevel 46 Group
p nions on a trunnionand two side gears in whichdr ve shaitsarecarried internal by splines. gearsarejournaled thai they The differential so can rotate and permit drive the shafts rotate to at d fierentspeeds whenlhe car is beingdnvenin curvesThereis a thrustwasherundereachof thediffereniia gears. Thepinon bearings laperro er bearings. are The axial locaton oi the p nion relative the ring to gear s adjusled shimsunder outerraceof by the the rearp n on bearings.
Descrtptlon
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1 2 3 4 D i f f e r e n t i a a f i i e r ,s m a e r s e c t i o n c D i s c si n t e r n a l t e e t h D i f f e r e n i i as i d eg e a rr e i a l n e r l D i f f e r e n l l ap i n l o nq e a r l 5 6 7 8 Spider D i f f e r e na l c a r r i e r l a r g e r s e c l i o n t D i l f e r e n i i as i d eg e a r l D l s c s , x t e r n a, t e e t h e
tr
Twoshalts makeup ihe spider the differential for plniongears. the sidewhereit is against On the ditferential carrier,each shaft has a V-shaped bevel. Thedifferential is carrier correspondingly designed. WhenpowerfroTn engine the starts to (A) drive vehicle, shafts g ideup the bevelthe the lod re.es. in rhe differerrial carrer. lhis compresses frictionplates the behind differential the sidegearsso that the ditferential assembly brak e s T h eb e v ea n g r e r l h ed ' r e ' e r r i ac a r , r ei.s l l o designed chosen sucha waythatthediffeand in rental gearsare not entirely locked,but max. 75% of enginetorquecan be transmitted a to drive shaft.
Group46
11
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On-vehicle rcpairs - Limitedslipdilfercntial-
Onvehicle repairs
limitedslip differential Checking
Fabricale tool As shownin illustration of 3/16" out steelstock. Specialtool 2709can be used after modif ications. necessary
A2
A3
Checktorque
Thefrictiontorqueof the limited slip differeniial should be: minimum Nm = 40ft.lbs 55 m a x i m u m5 0N m = 1 1 0 f t . l b s 1 Notethe torquereading whenthe wheelrotares (rotational friction).lf torque readingis below minimum, replace discs.
GtouP46
a
Checking floaton axleshaftbearing end
?i::nl:::::::; _ ",.u
Theendfloatfor the axleshafts cannotbe adjusreo. However, it may be necessaryto determine whether endf loatiswithinacceptable the limits. B1
B2
Installmeasuring equipmenl,
a. Usetool 2809to clampan iron plateagainst
ih6 hr.l6 ^.lin6r'< h^<c
b. Usea dabof grease place steelballin the to a center holeof the axleshaft. c. Place standtor the dialgaugeon the iron the plate.Placethe dial gaugemeasuring point (whichmust havea flat surface) against the steelball.
B3 mm = 0.004 The end float shouldbe 0.01-{.35 -0.0'i4". To obtain total end float, the axle shaft must be rotated least in at onerevolution bothdirections. NOTE: Priorto installation, bearings the axleshafts for have considerablygreater clearance.lt is reduced installation. at procedure otheraxleshaft. Repeai for
Gtoup46 Rearaxle
13
on-vehiclerepairs
pinionseal(onvehicle) Replacing
Remove flangenut,
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R e m o v el a n g e . l
b
2261
p Use uller2261.
Removeeal. s
UseextractorS069. protecting ield. Alsoremove sh
5069
Group46
14
On vehiclerepairs
2806
Installnew seal
Usedrift2806. Packthe newsea springwith 9rease. Otherwise j n t h es p r i n g i g h t u m po u l o f p o s i t i o o u n n gI n m grease seallips. stalat on.Also the ll ustration:
I = Seal
Installllange.
Use tool1845 5156. or Torques:
1845 5156
(3/4" nut88626 UNF): 24H00 Nm = 175 220ft.lbs. nut946831 (3/4" UNF): 20G-250 Nm = 150-185 ft.lbs. (M20 1.5): nut947855 x 20G-250 Nm = 150-185 ft.lbs.
Reconnect driveshaft.
tJse tool 2779or 2846.
46 Group
tc
rcpairc On-vehicle
Preparations.
Jackupvehicle. Remove rearwheel. guard. USAN,4odels: remove collision
Remove brakepalts.
fromrearaxle. Detach brake andbracket line Remove Hangit out ol waywith a brakecaliper. lengthof steelwire to prevent damage brake to pipe.
Remove brakediscs,
position. Parking brake mustbe in thefull release Bemove two Phillips the headscrews and lift off the brake discs. Tapon the inside the discwith of a plastic hammer similar or tool if necessary.
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parkingbrakeshoes Remove
Unhookand removethe springsusing brake pliers. spring
an vehiclereqatrs
parkingbrakecables. Disconnect
the Press the lock pin securing brakecabes out to the levers. 3mm punchif the pin doesnot Use faLlout.
r:.try
t' Freebearingretainers.
D6
D7
D8
Remove innerseal.
Use tool2337. D9
2838 a R e m o v i nc i r c l i pb e a r i n g n db e a r i n g g , reiainerplate.
a Placetoo 2838in a v se. F x shaft n tool. b; Adjust too so that jaws come between NOT come bearingand seal The seal l\,4UST too and bearrng. between oii c. Press circlip and bearing. d. Opentoo . Removeparts. o e Drscar( rc p ll VUS NOI be'eu.ed.
Gtoup46
17
On vehicle repairs
Dl0
2838
I n s t a l l i nb e a r i n g e t a i n e r , e a r i n g n d g r b a circliD.
LJse tool5010to presson the bearinq.
D12
D13
I n s t a liln n e rs e a l .
Usetools5009and 1801. ( D14
Install axle shaft. Install screws bearing for retainer. Torque:30-50Nm = 22-36tt.lbs. Insta brake I shoereiaining springs
46 Graup
'18
on-vehiclerepais Dl5
Attachbrakecablesto levers.
Lubrlcate joints and shoe contactsurfaces all graphite grease. withheatresistant Press pinsecuring in brake to cables levers.
D16
Installparkingbrakeshoes.
Inspect appropriate mabrakelining.Reference nualforderaledoroceduTes neuessarv as
D17
lnstallbrakediscs.
Installdiscs and secure with two Phillips head
D18
Adjustparkingbrake.
Loosen cableat parkingbrakeleverto remove anytension cables. on The adjusting throughash screw is accessible trayhousing. Use17 mm socketand extension. Adjustso that brakeis fully appliedbetween 2-3 notchesof brake lever movernent. Gtaup46
19
I
on vehiclerepairs D19
Installblakecaliper.
Attach line to brake andbracket rearaxle. Usenewscrews brake for caliper. D20
guard. Installcollision
tJSA models. D21
Installwheels.
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20
46 Group
Removing rearaxle
Removing rearaxle
Raisevehicle on lift and remove real wheels. pipe the axle, remove Withexhaust below rear pipefrom front to rear intermediate exhaust muftler.
E2
E4
Remove
g Removeollision uards. c
Group46
21
On rearaxle.
Disconnect venti ation hose. the Remove clampsho ding brakepipes. Djsconnectthe brake pipes from rear axle and secureout ot way to prevent darrageto pipes.
Remove brakecalipers.
Remove two bolts (hex 17mm)and free the brake ca ipers(leftand rrght). Removebrake I ne clamp to allow some freedom ol movement the caliper. for Hook the brake calipers to their respective s o ri n g sr o o r e v e ntlh e b r a l . er r e s ' r o n b e c o m i a g l drstorted.
E8
Remove brakediscs.
Parkingbrakemust be ln the fu I release position. Removethe two Phillipshead screws and lifi off the brakediscs Tap on the insideof the disc with a plastc hammeror simi ar tool ii necessary.
0 0
E9
parkingbrakeshoes. Remove
lJnhookand removethe springs using brake sPring Pllers.
Grcup46
22
rearaxle Removing
parkingbrakecables. Disconnect
Press the lock pin securing brakecables out the to the evers. 3 mm ounchif the oin doesnot Use fallout.
E12
23
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E16
ol
E17
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24
GtouP46 Reataxle
I I
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Bearing caps.
Checkthat bearingcapsare markedlor proper alignment with carrier.lf Ta'ks are'nissingor difficult see,markbothsides ensure to to correct reinstallation. Remove four screws (hex'16 mm)to freebearing caps.
Disassemblingrcat axle
Installtool2394.
Placelool 2394w|lh rera.ners 2601or hoLsrng. Alignpinson tool with holesin housing. Screw retainer boltsinlohousing. Tighten the tensioningscrew until tool fits securely holes. in Thentighten screwslowly until thedifferential assembly be removed. can DONOT exceed 1/2turnson thescrew. 3
F6
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Remove flangenut.
Usewrench5149and suitabe socket.
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Remove flange.
Usetool2261.
Group46
T
pinion. Remove
F9
Use plaslic a hammer knock the pinron. to out To preventdamage, hod the pinion wrth one handas it isdriven out.
D
pinionbearing. Remove
F10
I
It necessary: Remove pinionbearing. rear
Bearaxle type 1030: use tool 5215 Rear axletype1031 :|rse 52'16 tool andtool52'14. See nextpagefor instructions howto applythe on tool.(Superseded illuslrated). tool
Group46
27
F13
1. Pushpuller overrollers and pressdownthe lock nng. 2. pullerscrewsuntil rollers flushwith Tighten are edgeof inner raceandpuller. 3. Drive lockring. out
Differential withoutlimitedslip
Remove erentialcarlierbearing.' diff
Use tool2483. Care should takennot to damabe ge shimpack. it aside Put withremoved bearing. '1. Placepullerover bearingon ring gear side of carrier.IVlake certainthat groovein tool catches on rollers. Press lockringdownon tool. 2. puller Tighten untilbearing off carrier. is 3. Use hammer knockoutihe lockringa to Repeatfor other bearing.Record positjonof bearings and shimsto facjlitate installation on
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F15
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lf ring gearis tight, threadscrewsin partway.Tap screwstopushring gearoff. Discardthe screws.New screws MUST be used whenassembling_
Group46 Rearaxle
2A
F1B
Group46
Markposilionot parts.
gear shafts Draw line-upmarkson differential and differential carrier that partsare installed so position in thesame whenreassembled.
Remove bolts.
Remove boltswhichholdthe differential the carnertogether. NOTE: Rear axle type 1030 has bolts with left-hand Inreaos.
F21
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seizure Gear
Gtoup46
30
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ul Y
Checkthe different gearsfor tooth damage. al lf anygearis damaqed, complete of four the set gearsmust be repaced, malched Washersfor the differential gears (flat or thrust) shouldbe replaced. the largedifferential For side gears ythrustwashers, 1232436-4, used. on P/N are
)f
p r n t o nu t drive flange
The p nion nut loses its self-lockingcapacityafter be ng removeda couple of iimes. Replaceas A I sealsshould be replacedany time the differentialis disassembled.
I
,' !-t I
Check rearaxle the carrierfor cracks. Check brackets trailing for armsandtrackrodfor llroken ds and/ordamages. we
Graup46
31
r
Assembling differential
Bearings mustbe oiledand rotated severaltimes underloadbeforemeasuring bearingclearance or pretoao.
The utmostcleanliness mustbe observed when assembling finaldrive. the Dirtin a tapered roller bearing can resultin enlirely incorrect measurements.
Ditlerential withoutlimitedslip
Construct tool.
Bolts,nutsand washers according the folloto wing Iisting recommended helpinstall are to the gears. difterential Two bolts Two nuts Fourwashers 1/2"x3-1/2"(M12x90) 1/2"(M12) 1-3l8"x1/8"(34x3 rnm)
o( o(
Cut two washers shownso that they can be as fitted overthe bolts.
G2
o( e{
G3
1 I
Compress.
Tighten nutsto compress thrustwashers. the the
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GrouP46 Bearaxle
32
g I n s t a ls m a l ld i f f e r e n t i a le a r sa n d l thrustwashers.
gearsand thrust washers Roll n smalldifferential as an assemby.
Remove bolttools.
G6
G7
Reassemblediff erential. Insta ringgearon carr assernbly. sure I Make er contact sLrriaces free burrs. are of
Use new bolts. The bolts are tightened to yield limit and cannotbe reused. [Jse a ternate side pattern for tightening bolts. Torqueto: Standard bolt head:7H0 Nm = 50-58 ft.lbs. Flanged t head:90-110Nm :65-80 ft.lbs. bo
Group 46
fr tI
E
2
t tl
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I H
H e I
I
On prevous differentials where boih the differentialside gears and the differential gear retai ners have splines for the drive shafts,the spl nes must be algned with the help of the drive shaftswhen the bolts are tighte-
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1. Bot 2. Differenlialhousing 3 . D i s c , 1 5m m = 0 . 0 6
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gearsand discs Installshafts,
Lubricate each part beforeinstallation. Place the discs and other parts n the order shown in il ustrationin the ring gear half of the different housing. al A ign the dlscs and fit the smaller half of the differentialcarrier. Install bo ts. Torqueio: the 60-75 Nm = 44-55 ft.lbs.
34
46 Group Rearaxle
Assembling rearaxle
I n s t a l l i np i n i o n g
Gl0
2685 2a4A
2841
Installtoolson pinion
Use extremely line emery cloth to clean the p i n r os h o u l d e r n Install adjusting ng and wrench [/]ake r surethe ocking screwol the adjuslingring is n open posrtron. Finaldrive Adjusting rlng Wrench or T0 3 0 2685 2841 (5157) 1031 2840 2841 (s157)
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Measurement A
The pinion must have a set distance (A) to the flng gear center line. Due to tolerances In the manufacturing, there are deviations from the set distance. These deviationsare indicated on the pinion.The deviationis alwaysplus and in hundredthsof amillimeier.The plus sign is omitted.
mm 0.20 o.21 o.22 o.23 0.24 o.25 0.26 o.21 0.28 0.29 0.30
nches 0.0079 0.0083 0.0087 0.0091 0.0094 0.0098 0.0102 0.0106 0.01'10 0.0114 0.0118
Trm
inches
0.31 a.32 0.33 0.34 0.35 0.36 4.37 0.38 0.39 0.40
0.4122 0.4126 0.0130 0.0134 0.0138 0.0142 0.0146 0.01s0 0.0154 0.0157
Group 46
pinionlocation Checking
use: - dialindicator - indicator retainer 2284 - measuring 2393 tool Measuring 2393 lool consists two pans: of gauge a pinion andan adjuster fixture.
ZEROIN LOCATION
G14
Alignmeasuring tools
Locate indicator retainer thatthe dialindi the so cator touches adjuster tip the fixture.
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22A4
It_.,
gauge. catortip touches pinion the gauge Thepinion should reflect figureindicathe ted on rhe pinion.for example: lhe pinronis rf gauge marked the 0.33, pinion shouldlie0.33 mm below adjuster the fixture. Adjustby turningthe wrenchof the ninionuntil Q thedialindicator shows correct reading. lJse locking the screw lockthe wrench. to Remove measuring toolsandpinion. Gl6
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rearaxle Assembling
M e a s u r e h i mt h i c k n e s s s
Usemicrometer. NOTE: It is very difflcui to obtainabsolutely correct Following deviations permitare shimthickness. - 0.02 mm = 0.0008" + 0.05 mm = 0.002"
0
Installrearpinionbearingon pinion
G18
Use tools: 2395 Type1030 for 2842 forType 1031 NOTE: First timea rearpinionbearing removed, is there is a spacer washer under the rearpinionbearing innerring.LtrrustNOTbe reinstal ed.
G19
Installpinionbearingrings
0 0
f Positionshirn just determined o r r e a r p i n i o n oeanng. l11stal outerringsfor pinionrearand front bearings. LJse toolsl 2686 forType 1030 2845 forType 1031
G2A
P o s i t o np n i o n .I n s t a l t h r e e h i r n s . 7 5m m = s 0 lrontpinion 0.03"thlck and bearing. Insta ioo lS45(alt.5156) lwrench 2404 andpress o n p i n i o nr o n t n d . r e s i n p i n i o n f P s e NOTE: press p nionforward f usinga nut runner, the so races with impact that it doesnot hit the bearing
Installpinion
46 GrauP
37
Assenblingrearaxle
Installpinionnut
Remove tool 1845.Lei wrench2404 remainin place. Install pinionnut.Torque 250Nm : 185ft.lbs. to
G22
Ol
Shimthickness, frontpinionbearing
piniongauge,dial indicator Install reta,ner and d i a li n d i c a t oP.u l ld o w n h ep i n i o n h i l e u r n i n g r t w t back and forth at the sametime.Zero the dial In0tcalor. Press pinionup whi e turningbackandforth. the Read diallndicator. the G23
Adiustshim packthickness
Tapthepinion rerrove to it. Newbearngs: - remove shims accordingto dial indtcator reading PLUS 0,09 mm = 0.0035". Previously bearing: used rernoveshims accordingto dial indicator readng PLUS 0.07 mm = 0.0028"
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G24
Installpinion
Positionpinion. lnstal shim pack determi11ed for lro.r pr'1,on oed irg. Installlronrp nion beari'1g. Installwrench 2404and presstoo 1845(att.5156) on piniolrfront end. Pressrn pinion. NOTE: lf usinga nut runner,pressthe pinlon forwardso that i does not hit the bearingraceswith impact iorce.
46 Group
38 I
I n s t a lp i n i o n u t l n
Remove10011845. Let wrench 2404 renaln in place Instal washerand nut.Torquenut tol 250 Nm = 185ft.lbs.
''I
Checkpinionbearingpreload
G26
r-/
2284 p C h e c k i n i o no c a t i o n l
G27
Use dial indicator,telairet 2284 and measuring tool2393 Zero-setthe dia indicalor againsi the adluster
IIXIUTE,
S h i f t h e d i a li n d i c a t o r t h e p i n i o n a u g e n d g to a check pinionbearng. the Pinlon ocatlonmust not deviate from correct p o s io n m o r e h a n : t t -0.02mm-00008" + 0.05 mm - 0.002"
46 Group
Installingdifferenlial
H1
Installadiusting rings
Oiladjusting rings 2595Install differential. on Black-oxldized adjusting on ringgearside. ring H2 Oilbearing in seats rearaxle. Position differentia adjusiing ringsassembly and In rear axle.
H3
Ad,ustbacklash
Adjust adjustlng the rings apartuntilihe differentialis heldfirmlyb!t notpreloaded. Position dial rndicator. the tip approx.3 the Set mm = 1/8"from endof a ringgeartooth. the Holdthe pinionand move ringgearbackand the forth. Note the backlash. Allowedbacklashis 0.12-0.18 = 0.005-0.007', shouldbe set mm but as near0.15 :0.006"aspossible. mm Adjust by turning both adjustingrings in the same direction.
Attercorrectbacklash obtained is
Locktheadjusting ringsin position. Remove ditterential adjusting and ringsassemoty. H5
Determine shimthickness
NOTE: Always remember sideon whichbearings the and shims to be installed. are plate nreasuring Position ceniering the fixture on (3) 2600. Position bearing in the measuring a fixplate,springand nut (flat side up). ture. Install Rotateplate and bearingassembly back and forth several times so that the rollersassume position. correct Posilion adjusting ring (1)on measuring fixture. Instalretainer 2284 (2). anddialindicator Position dlal indicator against adjusthe tip the iing ring (1)andset to zero. Thenchange lip the location the bearlng. to Notethe dia indicaior reaorng.
GtouP46
Measure shimlhickness
shouldbe lJsemicrometer. Totalshimthickness noted value PLUS 0.07 mm = 0.0028".
H8
H9
Installbearing, ringgearside
Installlock plate (A) for ring gear bolts,determined shimpackandbearing. Use drifl4l l2 to press the bearing. on Use drift 2599on the bearingopposite side to prevent dama9es.
H10
Installditferentialassembly
Use retainers 2601 to positionexpanding tool 2394 rearaxlehousing. on Expand tool untilit fits in Then tightenthe securely holes in housing. screw additional 3.5turns. an 3 Position differential wiih bearingouter rings in rear axleho0sing, Bemove expanding 2394. tool
Group 46 ReatAxle
41
Installbealingcaps
Check markings. Torque bolts to 50-70 Nm : 35-50ft. bs.
Hl2
Check backlash Allowed is backlash 0.12{.18mm = 0.00H.007" but sho!ld be as near0,15 mm = 0.006" possas lble. Remove wrench 2402,
H13
I n s t a lo i l s l i n g e r l Installnewoil seal
Packspringof new oil sealwith grease. Otherwise the coil may jump out of positiono u n n g installation. Grease sealinglips. 1.Oilseal 2. Spring grease wilh tJse drift2806 install oil seal. to the
o(
Installpinionflange
(or5156). Usepresstool 1845
Hl5
Installnut
Torques: (3/4"UNF)24G.j00 Nut 88626 Nm - 17s-220 ft.lbs. Nut946831 (3/4"UNF)200-250 Nm : 145-185 ft.lbs. Nut947855 (N,,120 200-250 x 1.5) Nm : 145 1B5 ft.lbs. Gtoup46
Ht6
42
I
....5009 '1801
a I n s t a lg a s k e t n dc o v e l l
H18
Installdriveshaftseals
Usedr it 5009and handle1801. NOTE: Fil spacebet\,!een sealinglips with grease. Also iil space between roller reta ner and bearinginner ring with grease. H19
H20
Fillwithcorrectlubricanl
Capacity: 1030: lilers: 1.35 qts. 1.3 US : 1 0 3 11 . 6 i t e r s 1 . 7 Sq t s . : l U F i n a d r i v e i l S A E 9 0 , A P IG L - s ( M l L L 2 1 0 5 8 o orc).
46 GrouP
43
lnstallingrearaxle
Installing rearaxle
1
Prepare installation
Position axlein fixture rear 2714. Position fixture andrear axleunder vehicle.
12
Attachtrailingarms
Install boltsfinger the tight. Alsoinstall brackets thesiabilizer rear the for bar attachments.
14
46 Group Rearaxle
lnstallingrcat axle
Atlachreactionrods
Donottighlen.
16
17
parkingbrakecables Connect
Group46 Reataxle
lnstallingrearaxle l9
Installparkingbrakeshoes
r1oo tl
Installbrakediscs
Install screws retaining brake discs
111
Installbrakecalipers
112
brakelines Connect
and the Attachbrackets clampssecuring brake lrnes. Hookon retaining springs parking of brake cables the upper to clamps.
114
Installcollision guards
115
I n s t a ltlh e s l a b i l i z eb a r r
117
RearEndTorque.
Lower rockthecarbeiore and tighlening. Torque Use Specs Chart.
:,/
Nm
Reaction rod: A Bodyanachment..... B Rearaxle sttachmnt Trsd< rod (Ponh6rd.odl: Rearaxleattachment D Bodyattachment..... Roar spdng: Upperattachment Lowrattachment,... Shod<ab6orb6r:
ft. lbs. 62
85 85 85
14
G Upperattachment
H
Loweranachmnt.... 115
Trailingarm: I Bodyattachment..... F Bearattachment(: E ring lower Sttachment) Strbilizor: (= J Front Sttachmenr shock ab6orbr) K R e a a t t a c h m e . . t, , . . . . . . . . . . . . . . . . . . r n Who6ls: Nuts, .. tightned cris!-cross ... . .. ... . .. ,,..
't9
85
lalional