FINAL DRIVE CONTENTS Operation Operation No. Page No. Description = 51-3 Drive flange — Renew 5118.36 51-6 Drive pinion shaft oil seal -~ Renew 51.2001 51-8 Final drive unit — Overhaul 51.2619 si Final drive unit: — Renew 91.2613, 5110 Hypotd casing rear cover gasket — Renew 51.2008, 51-68 Output shaft assembly (one side) — Renew 51.10.20 si? Output shaft bearings — Renew 91.10.22 si? Output shaft oil seal — Renew 51.2004 51-9 Pinion bearings — Renew 51.1819 sit Torque wrench settings 51-3FINAL DRIVE 351-048 (CROSS-SECTION OF THE LIMITED SUP REAR AXLEFINAL DRIVE ‘TORQUE WRENCH SETTINGS Tightening Tore tar Spanner Description ‘Size Na oti bee ‘Caliper mounting Bracket 10 unit Tear | AmUNCesions | e13093 | a3095« | cowos Diteranval bearing cans tinar | jmuncsetbots | 95.4097 | a7iwa9s | 631072 Drive pinion nut Thin a TinuNFau | 24410256 | 249212634 | 180%0 190 rive gear to itferental ange finar | qinuNrsewons | roz0118 | 107801218 | 771088 Powr-Lok citferential case finar | jinunceetbots | 583%067 | 595069 | 431050 Fear cover attachment ginat | AwUNceetoons | 2051027 | 2.110276 181020 ing geas attachment winat | Ain UNFRippbot | 13610151 | 138101546 | 100%0111 ‘SERVICE TOOLS Tool No. Description 186 1205 Flange Holder 18G 134 MS 550, 550, L550) Adeotor Handle SL550-1 Outer Pinion Cup Remover 47 (MS 47, SL 14) Hand Press fousae Diferental Side Bearing Remover suiean Diferennal Sige Bearng Remover Burton {sg Cock Gauge Too! laa Pinon Height Setting Gouge SL550-9 Pinion Inner Bearing Cup Replaces SUSso-8/1 Pinion Outer Bearing Cup Replacer fag Pinion Head Bearing Remover SL 47-1/2 Pinion Head Bearing Replacer 186 1428 fear Oil Seal Replacer SLisa, Spanner 186 681 Caw sea Torque Orwver isi 47-31 Output Shaft Outer Gearing Remover [sv.47.372 ‘Output Shah Outer Bearing Replacer O14 Oummy Shaft {ems marces mus are sot as sets DESCRIPTION Tre standard _vansmssion unit is a | the cross-shafts to move up'the ramps and, | four rubber and metal sandwich mountings Salsbury €HU final drve, sneorporating Pow-LOk atlerental when speciied: this 1s entiied by the letters PL’ on a tab under a cover bolt A Powr-Lok aiferenil ciers from a conventional bevel gear unit by he acaivon of plate clutches loaded by input torque to oppose rotations of the output shafts relate to the dilferental cage. Clutch plates are splined to the cage, and ther mauing discs to the output bevels: tl loading between plates and dis increases wih input torque due party to the Separaung forces of bevels and algo to the Devel pinion cross:shalte being carried on ramos stead of being positwely located in the cage Increase in output torque ca by pressing plates and aiscs together. 10 Tack the difrental. this gives the effect of 2 aifeconvaliess asle at maamum torque without nereasing the disadvantages ofthis {ype of axe in lowetorque conditions. Some lowtocque stitiness, 10 reduce one-wnee! ‘50M on ices prowded by forming the outer plates as Belleile washers 10 produce compression between plates and ciecs: fone whee ¢ held and the propeller shat disconnected, 2 torcue of between 5.6 and 9.6 kallm (40 t0 70 IU) is equred io tun the other whee! ‘The final deve unt is rigidly attached t0 a fabricated sheet steel crss-beem winch is Mlenbly mounted 10 the body structure by [Novses coming fram the vcinty of the final eve unit usually ongnate rom ingorrect ‘meshing of drwe gear and pinion, oF rom Deanngs on diflerenual oF pinion shafts developing play. Operation procedures for ‘me cortecvon of these nosse sources are fully covered in operavon 51.25.19, but 3 novse occurring at low speeds only, under braking, could be caused by oss of predoad sm the Output shaft beanngs, Bearing Inspection involves the removal and renewal of a oil Seal belove resetting preload, and 's covered in operation 5120.04, while if inspection indicates that bearing renewal i ‘adweable ths i= detaled in operaton 511022 51-3FINAL DRIVE TO CHECK THE TOOTH CONTACT PATTERN SSatinly paint eight or ten of the drive goat twth with a si mixture of marking rade oF engineats bive, Move the paint gear woth ia mesh ‘mth the pinion unt a good impression ofthe total contact is obtained. The result should conform with the ideal tooth contact patorn (Fig 1) 2 —a c F192 Hho cont pater A. a Ny 8 c es Fig. 4 Toe contact pattern 51-4 Saar e me \ Fig. Idesl tooth contact pattern, Fig, 3 Low tootn contact pattern Fig, § Heol contact pater [A The HEEL isthe larger outer end ofthe tooth 6B The TOE ie the small or inner end of the tooth The DRIVE side ofthe drive gear tooth is convex 1 The COAST sid ofthe drive gear tooth is concaveFINAL DRIVE FAULT DIAGNOSIS. "TOOTH PATTERN REMEDY ‘The ideal tooth bearing impression onthe dive and coast sides ‘of the 98a" teeth 15 evenly aistibuted over the working Gepth of the tooth orotile and is located nearer to the toe femal! end) than the heal llaige end) This type of contact permite the tooth bearing to spread towards the heel under ‘operating conditions when allowance must be made for dellection In High Tooth Contact it will be observed that the tooth ‘contact 1s heavy on the drive gear face o° addendum. To fectiy ths conden, move the pinion deeper inio mesh, that's, educe the pinion cone setting distance, by adding shims between the pinion inner bearing cup and the housing and ftung a new collapsible spacer. Move the dive pinion deeper into mesh ie reduce the pinion cone settng, Tm Low Tooth Contact wall be observed that the tooth contact is heaw on the dre gear flank or dedendum. Ths 's the oppaste condition from that shown in High Tooth Contact and is therefore corrected by moving the pinion out of mesh. that is, inereaso the ‘pinion cone setting distance by remowng shims from between the pinion inner bearing cup and housing and fing @ new collapsible ‘Move the rive pinion out of mesh 1 increase the pinion cone setting “Toe Contact occurs when the bearing is concentrated at the small end ofthe tooth Move the drive gear out of mesh, shat is, increase backlash by twansterring shims from the drive gear side of the iferential tothe opposite side Heel Contact is indicated by the concentration of the bearing atthe large end of the tooth ‘Move the drive gear closer into mesh, that is, caduce backlash, by adding shims to the drive gear side of the diflerential anc removing an equst thickness of shims from the opposite side NOTE: It i most important to remember when making this adjustment to correct @ heel contact that sufficient backlash {or satisfactory operation must be maintained. If there is Insufficient backlash the gears wil atleast be noisy and have 8 greatly reduced Ife, whilst scoring of the tooth profile and breakage may result. Therofore, always maintain ‘minimum backlash requirement of 0,10 mm. (0.004 in). 51-5FINAL DRIVE DRIVE PINION SHAFT OIL SEAL Renew 51.20.01 Service tools: Torque sorewekiver 186 681. Ol seat repiacer 186 1428. Detach the four bolts (7, Fig, 6 securing ropelier shat o final drve flange: support propeller shaft rear end and clean flange ‘and nose of final drive Fig. 6 Accurately measure torque requited 10 win flange through backlash, using torque serewdiver 186681 (2, Fig. 6) wth a suitable adaptor ana socket, NOTE: Set screweriver intaly t0 0,057 kat/m (Sibtin) and increase seting progressively until torque figure is reached ‘at which lange commences to move. Flange MUST be tured fully anticlockwise through backlash between each check. ‘Mark nut and pinion shat o that in reiting rut may be returned to its original position fon shaft (3, Fig. 6 Unsere nut and remove washer and place both washer and nut aside for efiting Draw flange (4, Fig. 6) aff pinion shaft using Prse oll seal (5. Fig. 6) out of final drve casing Refitting (using original bearings) Thoroughly clean splines on pinion shaft and flange. Clean cil seal recess and coat internally with Weiseal liquid sealant. Using tal No. 1861426 tap new ol seal squarely into position with sealing lp facing to rear 0.97) 51-6 Fig.7 ‘Smear sealing lip with grease Apply grease ighty 10 outer two thirds of Diion shaft slines Lightly tap flange back on pinion shat, using wooden mallet Refit washer and nut and tighten nut until it exactly aches position previously marked, Re-check turing torque. Torque required to ‘urn pinion shatt through backlash should exceed by 0,7 to 1.4 kgm (6 10 10 tin) the torque recorded eater. If, however torque required to tuen pinion shalt exceeds 0152 kati (45 Ibn, final drive overhaul ‘poration 51.28.19 MUST be carried out Lift propeller shatt into position, replace bots. fend tighten nuts to correct torque ‘Check oil evel in final drive unit and top up it necessary Remove car from ramp and road tes W final dive is noisy, an overhaul must be carried out FINAL DRIVE REAR COVER GASKET Renew 51.20.08 Remove the foureen } in AF bolts and setscrews (1. Fig. 8) securing the bottom lieplate to the cross-beam and inner fulcrum brackets Drain the i frm the nal drive. Remove the ten jn AF eotscrewe (1, Fig. 9) and remove the rear cover (2, Fig. 9) noting the postion ofthe identification tabs. Clean of any gaskot 0” sealant ttm the ro cover and the hypoid housing, Smear the rear cover flange with Welseal jointing compound and piace the gaskot on the casing Rett the rear caver and secure withthe ten setscrews, prio ofiting coat the threads of the bolts wth Loctite, Reh wth new oF NOTE: The vehicle must be on level ground before checking the oll level. Replace the bottom te-pate and tighton the bolts and setseraws tothe correct torque.FINAL DRIVE Fo.8 Fig. OUTPUT SHAFT ASSEMBLY (One Side) Renew 51.10.20 To remove an output shaft is necessary 10 detach the inboatd end of the drive shat, the forward attachment of the radius rod, land to remove the Brake caliper and disc (1 Fg, 10), ‘These operations are detailed in Section 70, the Brake System Fig. 10 Cut locking wire and remove five set bolts (2, Fig. 101 securing caliper mounting flange to tinal deve Withdraw complete Dutput shalt assembly and discard 'O' ring Fig 10) Belore fiting, ensure that four bolts (4, Fg. 10) are in position. and that new ‘0! ring (3, Fig) 10} is Inted Lightly oi soines and outside of bearing with final deve ol insert assembly. ft bolts with spring washers, ughten to 6.410 9.66 kat (6040 69 lov, ightening the bolt nearest to the inpu flange ts, ond wire lock bolt heads together so that wie tension i tending to Lighten bots Replace brake caliper and csc as described in Brake System section. check camber dangle of rear wheels, and adjust necessary, refer to Section 64 for the correct procedure OUTPUT SHAFT BEARINGS Renew 51.1022 Service tools: 47 Press, Torque screwdriver 186 681, Adaptor. Spannor SL 15A or 15, Output shaft bearing removerreplacer SL47-3/1, SL 47-372 Remove output shatt sssombly incorpor ‘ating bearing 9 be removed Clean assembly and clamp caliper mounting bracket between suitably protected jaws of Turn down tabs of lock washer and remove fut (1, Fig, 11) kom shaft using spanner SL 16a (Bg 12) Remove and discard lock washerFINAL DRIVE Windraw ouput shatt (1. Fig. 13) ftom Caliper mounting Dracket (2, Fig. 13) Collect inner bearing (3, Fg. 13) and cone. Discard collapsed space’ (4, Fig. 13) NOTE: If outer bearing remains on shaft and pushes oil eal out of caliper mounting bracket on withdrawal remove it from shaft using tool SL 47-9/1, 47 (1, Fig. 14). Fig 14 Prise ol seal fram caliper mounting bracket. Collect outer bearing and cone. Discard ail Using @ suitable drit, gent tap bearing cups (6, Fig. 13) outof housing Remove ealiper mounting bracket from vice ‘and caretuly clean internal ssra24a Fig. 13 NOTE: When bearings are to be renewed, Iways replace complete bearings. Nover it ew cone and roller assemblies into used cups. Belore siting, bearings should be lightly ‘greased, but itis most important that at least 4 ce of hypoid ol added tothe cavity between the bearings during assembly. and thatthe oil seals lubricated by packing the annular space between its sealing edges with grease, This prevents premature seal or Dearing wear bolore ai flow begins from the adie conve, Rotitting Press cups of replacement Bearings into housing, using sue press and adaptors to ensure that cups are pressed full home in housing Place roller and cone assembly of outer ‘bearing (already greased) in position Press replacement oll seal into postion (1 Fig, 151 ensuring that spring-loaded sealing 2499 i adjacent to bearing. Load seal wth (grease between sealing adges. 19-087 Fig. 15 Clamp caliper mounting bracket between protected jaws of vice. (Check that four special bolts for brake disc ate 19 position in output shaft flange ano fnter shalt trough seal ang outer bearing Fit new collapsible spacer and ill he space berween bearings with Hypoid EP 90 ol! belore replacing rollers ond cone of inner bearing and fiting new lock washer on shat. Place nut on shat, grease face next to washer and ighten finger-ight only Using spanner SL15A and @ tommy-bar at disc atfachment ots 12 oppose torque, tighten nut on shaft just sufficiently to ‘almost eliminate play trom bearings. Torque Fequired to turn shat should be 0.14 to (0.28 kal/m {100 20 btn)FINAL DRIVE Further ughten nut, very slightly (not more than 2 thity-second of @ turn — about 5 rm (in) at perimeter of nut) and recheck torque required to turn shah Continue to Lighten nut in very small increments turning shaft seat bearings and measuring torque fer each nerement, unt corect figure reached (CAUTION: Hf torque required to tur shaft exceeds by more than 0,28 kgtlm (20 lbt/in) torque recorded in fret check, it necessary to dismantlo assembly. discard collapsed spacer and rebuild with new collapsible spacer. it is not Permissible to slacken back nut after collapsing spacer as bearing cones sre then no longer rigidly clamped. Turn down tab washers in two places to lock rut and removo assembly from vice. Rett output shaft assembly to fina dive uni, see operation 51 10.20, OUTPUT SHAFT OIL SEAL Renew 51.20.08 Service tools: 47 Press, torque screwdriver 18G 681, Adaptor, Spanner SL 15A or 15 Output ‘shatt bearing remover/rplacer 8L47-9/1, $L47-9/2, Femove output shalt assembly. Clean assembiy and clamp caliper mounting bracket between suitably protected jan of Turn down tabs of lack washer (1. Fig. 16) land remove nut from shall using spanner SLISA(1, Fig. 17) Fig. 17 Remove and aiscard lock washer. Withdraw output shaft from caliper mounting bracket Collect inner bearing and ‘cone and mark for correct reascembly Discard collapsed spacer igo oil seal from caliper mounting bracket ‘and dicard Collect outer bearing and cone. Femove caliper mounting bracket trom vice and thoroughly clean internally TW outer bearing remains on shaft and pushes oil seal out of caliper mounting bracket on withdeawal, remove om shaft Using toot SLA7-3/1. 47 (1, Fig, 18) NOTE: Carefully inspect taper roller besring components before refitting. if any fault is found in either bearing, replace both complete bearings. Rafer to operation 51.10.22, for full deta. Never ft new ‘cone and roller assemblies into used cups. Before ftting, bearings should be tightly ‘greased, but i's most important that at least 4 ce of hypord oil's added to the cay between the bearings during assembly. anc that the oit seal (2, Fig, 16) i lubricated by feacking the annular space between its Sealing edges with grease. This prevents premature seal or bearing wear before oil flow begins trom the ase centre Rofitting (using original bearings) Place roller and cone assembly of outer bearing (already greased n postion Press replacement oil seal into position, ensuring that spring-loaded sealing edge 1s adjacent to bearing, Load seal with grease between sealing edges Clamp caliper mounting bracket (3, Fig. 16) between protected jaws of vce (Check that four special bolts (4, Fig 18) for brake dise are in postion in output shaft flange and enter shaft through seal and fit the outer bearing using tools SLA7-3/1 SLA7-3/2 1, Fig, 19), Fa. 19 ‘Smear dil on portion of shaft n contact with eal Ft new collapsibie spacer (6, Fig. 16) and ‘il the space between bearings with Hypoid EP 90 oi before replacing rllers and cone ‘of nner bearing and fitting new lack washer on shaft Place nut (6, Fig. 16) on shaft, grease face rex to washer and tighten fageetignt only Using iacque screwdriver 186681 ond adaptor check torque required to turn shaft in ealiper mounting bracket against rasistance ofthe ol seal Record the torque,FINAL DRIVE NOTE: Set screwariver intially to 0.05 kglfm (4 bin). Setting should then be progressively increased until torque figure is established at the point when shft Using spanner SL1BA and a tommybar at diseattachment bolts to oppose torque, Tighten nut on shaft just suticiently to almost eliminste pay rom bearings. Repeat torque check Torque required to turn shaft should be unchanged, iit has increased. slacken nut ver slight and e-check, Further tighten nut, very slighty (not more than a thity-second of a turn — about 8 mm (i in) perimeter of aut — and re check torque required to turn shaft this torque exceeds by 0,08 10 0,10 kaflm (4 t0 {lovin} the torque recorded earlier, comet bearing preload has bean achieved, othormse continue 10 tighten nut in very small increments, turing shaft 10 seat beatings and measuring torque after each increment, unt eorect figures eached fexceods by more than 0,10 kgtim (8 Ibn) torque recorded initially, it is diamantio ‘ssombly, issible. to slacken back nut after collapsing spacer as bearing cones are ‘hen no longer rigidly clamped Turh down tab washer in tw places to lock rut and remove assembly from vice Refit output shah assembly to final dre Unit, refer to operation 51 10.20 for full corals FINAL DRIVE UNIT Renew 51.25.13 ‘Service tool: Dummy shaft JD 14, The final drive unit cannot be remeved from the vehicle unless iis detached as part of the rear suspension unit, removal of this item 1g detailed in the rear suspension Drain the oil from the unit to prevent any leakage from the breather, and invert the whole assembly onto workbench 51-10 Remove the fourteen jin AF bolts, nuts and setscrews (1, Fig. 20) securing the bottom tueplate to cross-beam and inner fulccum brackets Fig. 21 Fig. 22 Remove the Hf in AF nuts and washers (1 Fig 21) securing the dampers to the wishbone and drift out the retaining pins (1 Fig. 221 recover the spacers and tie-down brackets. Slackon the clips (2, Fig. 21) securing the inner universal joint shrouds and side the shrouds outwards Remove the four fin AF self ocking nus ( Fig 23) eitier side securing the ave shaft inner universal joint to the brake disc and output lange Remove the fin AF nut (2, Fig. 21) rom the inner wishbone fulcrum shaft and drift out the shaft (1, F.g, 24) collocting the spacers, seals. ond ‘bearings trom the wishoone wots 2, Fi. 23) Remove the drive shalt, ub and wishbone assembly from the rear suspension assembly emove the camber shims from the dive shaft flange studs atthe brake disc on both sides Aemove the spacer tubes tram between the luge of the fulcrum brackets and turn the suspension assembly over on the bench Disconnect the brake feed pipes from the calipers, ceal the ends ofthe pipes and the Ports in the calipers. Release the brake return springs from the operating levers (Cut tne tocking wite and remove the four Bn AF bats (1, Fig. 26) securing the final dive to the cross-beam and lit the cross-beam off the unit (Fg 26FINAL DRIVE Fig. 26 Invert the unit and remove the locking wites land the Hj in AF setserens securing the fulerum brackets to the final drive unit Fig 271 Fig. 27 Remove the brackets, noting the position and number of shims at each attachment point Cut the wites trom the fin AF caliper mounting baits, remove the bolts and calipers 11. Fig. 28). Remove the brake ‘ises, noung the number of shims between the discs ang the flanges Replace the shims and disc on one output shaft flange and secure with two nuts, Replace the caliper. ughten the mounting Bolts and check the cemening and the run ‘out of the dise The centering tolerance it 40.25 mm (0.010 in) ts can be rectiied by trancterring shims trom ane side of the {56 10 another The disc run out should not exceed 0 15 mm 0 006 in) Tighten the caliper bolls to @ torque of 678-760 kgtim 664-745 Nm (é0 56 lt) Repeat the above operations on the ‘opposite side Remove the us from Both Place the cioss-beam over the final dive falgn and repiace the bolts and tighten to ‘he cortect torque and wire lack 10.4 kal, 101.68 Nm (75!) Slacken the orake feed pipes at the centre union, unsea| the brake pipes and the ports in the caliper. align and it the pipes and sightan the Replace the handbrake lever return springs and invert the assembly on the bench Position the tulerum brackets against the final drive ueut-and locate each bracket loosely wih two setscrews. Replace the shims between the ulctum brackets and the final ve ut Tighten the setscraws and wire lock Ret the camber shime 1 the drive shaft studs on ‘one sie, Fil the dave shat on to the studs fand loosely ft the nuts and then tighten fully. Replace the spacer tube between the lug of the fulerum bracket Clean. inspect and giease the lower wishbone bearings. theust washer etc. Fit ew seals and offer up the wishoone fulcrum bracket lugs and locate with dummy shafts Tool No JO14 (1. Fg 28) Fig. 28 Take great care not to displace any Ceamponent during this operation. Dit the {dummy shafts rom the fulerum bracket with the fulerum shalt Restrain the cummy shat to prevent spacers or thrust washers rapping out of position Tighten the fulerum shatt nuts to @ torque ot Inner 610-678 Nm, 623-691 tre (25-50 tet Outer 131-145 Nm, 134-148 kgilm (97-107 Ib Fepositon the dre shalt shroud and seeure it with the cl. Line up the damper lugs withthe wishbone bosses and replace the damper shat, ncluding the spacer anc tie dawn bracket ang tighten the nuts to 2 torque of 43.4-4B.8 Nm, 443-497 kglfm (52-36 tft Replace the wishbone, ahve shaft and damper shalt on the opposite side. Replace the bottom te-plate and tighten the bolts ‘and sorsorons, Replace the rear suspension unit Check the ‘eer wheel camber Bleed the brakes and fill the final dive wth of as NOTE: Use Shell Super Spirax 80 or BP Gear Oil 1453 if new gears have been Fitted: othorwiso use a recommended refi cor top up oil a specified in Section 09. FINAL DRIVE UNIT Overhaul 51.25.19 Service tools: 186 1205, 47, SL47-1/1 18G 134, SL S50/1, SL 14-9/1, SL14-9/2, SL660-1, SL3, 4HA, SL'550-9, SLB5O-8- 4,8L47-1/1, SL47-1/2, 186 1428, Dismantling Ensure that al ubricant is drained from the Lunt and support the unt im vies Fig.30 BitFINAL DRIVE femove the ten J in AF rear cover secuting bots 1, Fig, 30), the cover and the gaske Remove the locking ware and five § in AF bots securing the caliper mounting beacket fon one side and withdraw the output shaft assembly Repeat for the shat onthe other side Remove the nwo 2m AF bolts (1, Fig. 31) securing the diferential bearing cap it out the cap rom tho ferential using. repeat tor tne other side Using two suitably padded levers, prise out the difrental uni Using t00! 186 1205 (1, Fig 32) t9 hold the tive flange, remove the pinion nut ang washer and withdraw the flange (2, Fig 32), Fig. 32 Using a sutable press extract the pinion from the housing, Using tool 186 134 remove the ol sal. ol ‘thrower and outer Bearing cone. Examine the inner and outer bearing cups ‘or wear, if replacement ie required extract the outer cup using tools 186 134 and SSLBSOV1 for inner bearing removal, careluly tan the bearing cone out witha brass punch In the cut-outs provided in the diferentat casing and carefully collect the shims. Femave the pinion head bearing using tools 4711, Fig 33), SL47-1/1 (2, Fig, 33) 51-12 Fig. 33 Remove the differential side bearinge using tool Nos. 47 11, Fig. 34), SL14-2/2 (2. Fg. 34) and SL 14-3/1 (3, Fig, 34), and collect she shims. Fig. 34 Fig. 35 Powr-Lok only In the absence of any alignment marks ( Fig. 35), serve a line across both halves of ‘tromtal casing to facitate reassembly. Femave the ten Hin AF crown wheal bolts (1, Fig. 36) and remove the crown wheel (2, Fg. 36) Remove the eight fin AF bolts (1, Fig. 37h securing oth haves of the differential casing (2. Fig. 37) Remove diferential side cng (3, Fig. 372 Femove pinion side gear and pinion cross shatts complete wath gear Fg. 37) Separate cross-hatts (5, Fg. 27) Remove remaining side gear (6, Fig. 37) andnng (7.Fig. 37) Exact the remaining clutch diss (8, Fig 37) and plates (9, Fig. 371FINAL DRIVE “The same serial number must be marked on the pinion end and the outer periphery of the Grown wneel (1, Fig 38), eg. 7028. these requirements are not met the un ‘must be exchanged Fig. 38 Powr-Lok only Prior to reassembly coat ll plates and discs vith Pow foo Rett two Ballevile clutch plates (2. Fig. 38) 0 that convex sides are against diferenial casing Felt clutch plates (4, Fig. 39) and discs (3, Fig. 38) a8 shown into each halt of the casing Ficside ing (5. Fig. 39) Position one side gear into ring recess (6 Fig 39) Fit cross shafts. Fett pinion mating crossshatts complete ‘with pinion gears ensuring that ramos on the shafts coincide with the mating ramps in the diterenal case (7, Fig 39) Assemble remaining side goat (6, Fg. 39) and ring 7, Fig 39) Offer up righthand half of differential case (8. Fig. 39) 10 lange hatin accordance with Identiication marks and postion clutch ‘nction plate tongues sa that they align wath ‘groaws in atterernal case Assemble ighthand half to lange hat of lferenal case usng eight bolts coated with Loctite 275 but donot tighten at ths stage Fig. 39 Tighten eight bots t0 9 torque of 6.05 to 6.9 kim (431050 It) whe drive shafts rein positon (1, Fig. 40,1, Fig. 41), With one deve Shaft locked, the torque to turn the other (2, Fg. 41) shouldbe between a0 Ibftand70 bt 29, hold one shaft in vce soft jaws whist ‘uming the other Fig. 40 NOTE: Ensure that prior to assembly the crown wheel mounting face is free from ‘damage or burs, particulary on the edge: ‘should any burs be left on the carier they ‘must be removed with an oll stone plot to fitment of the erown wh Fit the wheel 10 the ‘lamatricaly using the ten bolts and tab washers, orque up The bolls to 10.78 10 12.4 kati (77 to 88 bi) Thickness of shims requred im the installation of the diferencal side bearings ie determined as follows Fit the difeential side bearings (1, Fig 42) using tools 18613412. Fig 42). and SL550-1 (3, Fig 42) wtnout the shims Como the aiferential ease, making sure that Fig. 39 Fig. 41 the beanngs and housing are perfocty clean Place the ddiferential assembly with the bearing in ther housing nto the aiflerertial {ease without the pinion in postion 81-13FINAL DRIVE Install 2 dial indicator gouge setting the burton against the back face of he crown vwnee! (1, Fg 431 Inserting two levers between housing and the bearing cups, move the diterenval assembly to one side ofthe carer Set he dal indicator to zero Move the assembly to the other side and record indicator reading, giving 01a) clearance between bearings, as now assembled, and adutment faces ofthe gear Fig. 44 i— 2 Fig. 45 Remove diferental assembly from the gear Reinstall he pinion outer bearing cup using tools 186 134 (1, Fig. 44 & 45} and SL 5509 2, Fg. 44.845) Frtthe nner bearing cup. Fig. 48) and shims using tos 186 134 and Si. 5508 (2. Fig. 45) 51-14 Fig. 46 Press the inner bearing cone onto the pinion using tools 47 (1, Fig. 47), SLA7-14 (2 Fg 47) and SL 47-1/2 (3, Fig. 47). Fig. 47 NOTE: The hypoid drive pinion must be ‘corecty adjusted before attempting further ‘assembly, the greatest care being taken to ‘ensure accuracy. ‘Te correct pinion setting is marked on the ground end of the pinion. The matched ‘assemaly sonal number 1s also marked on the periphery ofthe crown wheel, and care should be taken 10 keep similarly marked gears and pinions in their matched sote as fe8ch par 1s. lapped. together before ‘despatch fram the factory. The letter on the left 15 @ production code letter and has no signiicanco relative to assembly o servicing fof any axle. The letter and figure on the ght ler to the tolerance on offset or pinion {ro simension, which is stamped on the cover facing ofthe gear carier housing. The number atthe battom gives the cone setting distance ofthe pinion and may be Ze10 (0) Pus i+lor Minus (1. (Fig. 48) Fig. 48 When cortecty adjusted a pinion marked Zero wil be at the zero. cone setting ‘distance dimension which is 66,67 mm (2.6251) (ve. from the centre line ef the gear to the face on the amall end of the Pinion A pinion marked Plus two +2) should be adjusted to the nominal (or Zero) cone setting plus 0.0508 mm (0.002 in) and a pinion marked Minus two (~2 tothe fone setting distance minus 0,0508 mm (0.002 19) Thus for 3 pinion marked Minus two I=2) the cistance fram the conte of the ‘ive goar t0 the face of the pinion should bbe 65,619mm 12 86,67 0.0508 mm (2.6230 1e 2625-0002 in) and for a pinion marked Plus thrae (+3) the cone Sotting sistance should be 66,746 mm [2.628 i. Place pimon, together ven inner bearing cone. ito gear carter ‘A. Pinion crop 38,1 mm {1.8in B Zoo cone sexting 66,67 mm 12.625 in) © Mounting distance 108,62 mm la312i) D Cente line to bearing housing 39,57 mm (5.496in} to 39,83 mm {5.505 nl Fig. 49FINAL DRIVE Turn carter over and support pion wth a suiable block of wood for convenience belove attempting further assemdWy Fit pinion outer besting cone, companion flange. washer and nut only, omitting the collapsible spacer, oll wower and ol seal and tighten mut to remove all backlash Check pinion setting distance by means of (gauge tool SL (1, Fig 50} Fig. 50 ‘Agjustbracke caring dalindcstor using HA setting block For diferentals with a write painted cele on the fear cover use tool no, $132.(2, Fig, 50)and set il ace to ze. Check pinion setting by taking a dial indieator reading on the diferent! bearing bore with the assembiy frmiy seated on the ‘ground face of the pinion (3. Fi. 50). The fareect reading wil be the minimum ‘obtained; mat, when the indicator spindle se at the bottom of the bore Slight movement of the assembly wil enable the ‘correct reading 1o be easily ascertained. Tho dial indicator shows the deviation of the pinion setting trom the zero cone seting fand itis important to note the direction of any such deviation aswell a5 the magnitude If pinion seting is incorrect tis necessary to iemantle the pinion assembly and remove the pinion ier bearing cup Add or remove shims as requted ftom the pack locating tne bearing cup and re-stal the shin pack and beanng cup. Adjusting shims are fvallable in thicknesses of 0.076 mm, 0.127 mm. and 0.254mm (0.003, (0.005 in and O010in), Repeat setting operations until satisfactory result is obtained Extract pinion shatt from gear cai fa fenough to enabie the outer Beering cone 0 be removed Kom the pinion Fi the collapsible spacer 10 the pinion ensuring that soats firmly on the ‘machined shoulder on the pinion shaft Inert pinion into gear earner Refit the outer bearing cone, ol thrower and Using too! 186 14281, Fig 51) ft the ol sea Loctite the spins ofthe pinion shaft and fit the flange. Fit 9 new washer, convex face ‘outermost. Ft but DO NOT tighten the flange retaning rut Begin tightening the flange nut, stopping at frequent intervals to check the torque required ‘0 urn the pinion, using the sting and spring balance, uti the requted torque obtained. Fig. 81 The flange nut may have to be ightened to ‘ag much a¢ 18 kgm (130 117, Torque requited to turn pinion beacings and olseal Od bearings 25 tin) New bearings — 0,38 ta 0.48 kot (2010 40 bin} Note the actual igure requited to turn the pisvon 0.20 10 0,28 kati 120 10 It the above values are exceeded @ new collapsible spacer must be fitted ON NO faccount must the nu be slackened off and Fetightened as the collapsed spacer wall not then suficently clamp the bearing cones. Place differential assembly complete with side bearings but less shims. the housing Ensure that beanngs and housing are perfect clean Using the shim pack prowously selected wary the shir thicknesses between each Deering cup and he carer face ta achieve @ backiash of 0.15 to 0.25 mm (0.008 10 (0.010 im! measured atthe outer edge ofthe ing gear (Fig, 52 ‘Aad an adesional 0,07 en (0.003 in) shim {to each pack ang careully nate Irom whieh side of the diferental case the pack was Remove the bearing Cups end cones from the diferent case using SL 14-3/2 and SL 143i Ft appropsiate stim pack o the diflerentia! case anc rit the bearing cone Ensure that the matching shim pack and cone ate fitted to the same side of the tfrental housing that they were removed from, Fig. 62 Lower ferential assembly into position Hahty tapping the bearings Home with = hide hammer NOTE: Ensure that gear teeth are led into ‘mesh with those of the pinion. Cerslass handling at this stage may result in bruising the gear teeth. Removal ofthe consequent damage can only be partally uccessfl anc will result in inferior performance. When refiting side bearing caps, ensure that positon of the numerals marked on ‘gear carver housing face and side bearing cap comeide 1, Fig 53. Tighten cap bolts to 2 torque of 8.82 to 10,08 kin (63 t0 72 tat 12, Fig. 3). Fig. 63 Mount @ dial indicator on gear carrier housing wit the button against back face of gear 1, Fig. 54) 51-15FINAL DRIVE Turn pinion by hand and check run out 09 back face of gear. Fun out should not exceed 0.13mm (0.005 inl i run out excessive, sirip the assembly and rectiy by cleaning the surfaces locating the drive ‘gear Any burrs on these surfaces must be Femoved Remount dal incicator on gear carrier housing wath button tangentially agah of crive gear teeth, Fig 55) Fig. 55 Move ative goar by hand ro check backlash hich shouts be 0.18 to 0.2 mm (0.006 to 2.010 nt backlash isnot to specication, ttanstor ihe necessary shims irom one side of the ciferential case to the other to obtain the desited setting Check backlash in at least four posivons of drive gear, ensuring that backlash is. always greater than 10.15 mm (0.008 in) Fig. 56 51-16 Creck that tne torque to turn the input flange 1s 1.4 to 2.8 katim, (10 t0 20 ‘thal additonal to the toique measured prewously 10 turn the inion gage 5115) Smear cover tlange only wath Welsea! joining compound. place gasket on lina we casing, place cover over gasket and insert two Bolts to retain, coating threads sth Loctite Replace femaining eight bots, coating threads with Loctite and replace the tabs Tighten screws by diagonal selection to cortect torque 2.110 2.8 kgm (15 t0 20 rout Rett both output shalt assemblies ( Fig. 96) and torcue the bolts to 8.4 to 9.66 folim (60 to 69 ot), replace the cram plug and rehit the drive unit to the cross member 1. Fg. 57) Secure with bolts (1, Fig. 68) torque and lockwre (2, Fig 58), ensuring that when locked, he wire is tightening the bolts Alter retiting the unit the vehicle fil withDRIVE SHAFTS AND PROPELLER SHAFT CONTENTS: Operation Operation No. Page No. Description = 47-2 Drive shaft — Overhaul 47.10.08 a7~2 Drive shaft — Remove and refit 47.1001 472 Propeller shaft — Overhaul 47.18.10 473 Propeller shaft — Remove and refit 47.1801 47—3 Torque wrench settings = 47-2 atDRIVE SHAFTS AND PROPELLER SHAFT TORQUE WRENCH SETTINGS TIGHTENING TORQUE rTM DESCRIPTION Nm kfm tor ft Contre bearing mounting plate to body FINUNE bots 1910244 19410 248 140018 Genre bearing to mounting pate FNUNE bots 1910284 19410248 141018 rive shatt to ceve unit (Cevetoe) YenUNE rut 65410745 6781076 2055 Drive shaft to hub carer FinUNE nut 13610 163, 13810 166 10010120 Propeler shaft ferge bolts —Automatcgeator | TinUNF botsandnus | 98710434 37410442 762 — Manual gearbox TOmmbotsandnas | 5D 5.12 a Fea propel shaft to centre U L368 375 7 SERVICE TOOLS DRIVE SHAFT DRIVE SHAFT Too! No. Description toro Hone | Remove and refit 47.10.01,| Overhaul 47.10.08 ‘Service tool: Hub remover JD 1D. DRIVE SHAFTS AND PROPELLER | To remove 0 dive shalt itis necessary to | Dismantling SHAFT detach the hub and to swing one | Remove deve shaft suspension unit aside 10 clear tne inner | Remove ‘reese ripples (1. Fig, 2), place Description The crive shats replace the half shats of conventional rear aslo, and in addition serve {88 upper Wansverse members to locate the rear wheels: their inner universal joints are fttached to the final drive unit by ols ‘which algo carry the brake discs, but the brakes are not disturbed in cv shat removal. The outer joints are integral with the hub deving snalts, and the hubs must therefore be separated from the drwve shat betove they can be emaved pe, atthe font end of which isa reverse spine iting couple to the gearbox and at the rear a flange bolted ta the input dive flange ofthe final ive unit hen fiting @ propelir shat itis essential, to ensure that the unwersal joints operate freely, any suiless, even in & single joint, wil niiata propeller shaft bration 47-2 sure that car is securely supported on stands before removing the wheel. Release ips 1. Fig. 1! and before removing nut rom deve shaft in hub, side inner shroud along shatt shaft im vice and remove two opposed ccrcips (2, Fig 2). NOTE: Tap bearings slighty inwards to assist removal ofercline Fiat Remove grease nipple from hub carrier. and using tool JO 1D 2. Fig 1. withoraw hub from shalt. Allow the Mub carter to pwot about wishbone pin, Before detaching inner joint, “ralease lower end of reo Spring/damper unit (3, ig 1) and swing aside to clear joint. Collect and retain ary | shatt ‘camber setting shims fited Between inner Joint and brake ase Refitting Replacemert drive shafts are supplied | Inspection vuthout shrouds, oi Gea! track ot spacer remove these items and traneter them to the new shalt, Seal shroud joints with undersea! Ensure that chamfer on eit sea! | for ‘wack clears radius on shah, and. apply Loctite to spline before reiting hub Tighten fall nuts and bolts to the correct torque. Check and sf necessary adjust hub bearing lena fioat and ensure that camber angles of the wheels are correct. Wash ali pars in peo! ‘Check splines yoke for wear of splines Examine beating races and spider journals scoring oF aistortion NOTE: Spicer or bearings should not be renewed separately, premature failure ofthe replacement tess essential that bearing races are alight deve it myoke tunnvon, Tap one bearing inwards to displace opposite bearing (3. Fig. 2) Trap displaced bearing in view and remove shaft and joint from bearing Replace shalt bearing by tapping joint sper across and enact second bearing Remove two grease seals (4, Fig. 2) Detach spider, veth end section trom cenve section of shaft Place end section of shaftin vice and repest above operations, Remove spider rom end section o shaft Repeat above operations on apposite end of ‘isplace second of shat, oad markings, ‘a8 thie wil causeDRIVE SHAFTS AND PROPELLER SHAFT Resssembling Remove bearing assombies from one replacement spider; i necessary, retain roles in housings with ptroloum ely. Leave grease ‘shied in positon, Fit spider to one end section of shat. Fit two bearings and crcips in end section trunnions. Use softrounddiftagainst bearing housings Insert spider in trunnions of centre section of shat Ft two bearings and crclips in centre section trunnions Fi.gresse nipple to spidor Repeat above operations on opposite end of ‘ve shaft Grease pnts with hand grease gun Refit dive shaft PROPELLER SHAFT Remove and refit 47.16.01 ‘Service tools: Engine support tool MS 534 ‘or extension jack To provide access, remove the exhaust heat shield where fited ‘Mark the relationship between the propeller shaft and final drive flanges, and remove the bolts securing the anges. Remove the bolts securing the centre bearing ‘suppor plate, tothe centre bowing and body. Remove the support plate. Collect twa spacers wath the front bls Using servce tool MS 634 or, alternatively place an extension jack unde the gearbox, put Under the oi pan, take the weight off the rear engine mounting Separate the exhaust systematthe downpipe and intermediate pipe fants On cars equipped witha catayst sacken the rut and move the exhaust support sty o one side, Remove the exhaust strengthening plate from the transmisson case; colect two spacersand ‘one washer. Raise the roar of the enginalgearbox unit to reduce the lading onthe mounting spring Rereve the bots secunng the engine mounting to the tunnel closing plat, and detach the mounting pate. Collect sping, two ‘spacers, two special washers and burp stop rubber [Mark the rlatonship between the propeller ‘shaft front flange and gearbox flange. Remove the bots, tuming the shaft 0 give access to each nut. Separate the flanges and withdraw the complete propeller shaftrearwards through the ‘ranemission tunnel, NOTE: Before rfitng the shaft, ensure that all the universal joints operate freely: 2 tight pti cause viraton, Insen the propeller shaft through thereof the tunnel and line up th font flanges as marked. Fitthe bots trough the flanges, ft and tahten the nuts. Refer to torque wrench setings, Replace the rear engine mounting and Strengthening plate and detach the engine suppor tool orjack Replace the rear flange to final dive flange as marked, fitfourbots, ft and ighten the nuts ‘the corecttoraue, COfferup the centre bearing suppor plata tothe centre bearing and body structure. Insert bots ‘2nd spacers but do not fly tighten. Move the Centre bearing as far as possible tothe right hand side ofthe tunnel anc ghten the bos. NOTE: If propoler shalt vbraton is ‘experienced. move the cent bearing tothe left in smal steps unti the vibration = eliminated. It & most imporant that the spacers which control the vertical location of the bearing are replaced as. crgnally installed Replace the exhoust stay (catalyst equipped ats) and remake exhaust flange join using regu PROPELLER SHAFT Overhaul 47.18.10 including: Propeller shaft — rear — remove and refit 47.15.03 Sliding joint and gaiter — remove and refit 47.15.08 Centre bearing — remove and refit 47.1833 NOTE: The propel shaft is suppiod as a balanced unit and tis not possible to replace the front or rear shafts separately. Only the siding joint gar, contre bearing, ona anges. ‘and spiders of the unwersal joints can be renewed Fig. Dismantiing Remove the propel shaft assembly rom the venice and place on a workbench, Clean the assembly and mark the relationship between the centre yoke and the rer shaft. Rear propeller shaft “To remove the rear propeller shat, insert a suiable distance piece (eg. 2 scrap nut between the head of the bok (1, Fg. 3) securing the centre oint yoke to the rear shaft ‘and the spider ofthe centre universal joint Using an open-ended spanner, unscrew the bot (1, Fg. 3 from the ear shaft; to separate ‘theshats, breaktheLoctte adhesion betwen the spines and withdraw the rear shat from the centre yoke. Contre bearing Using 2 suitable puller, remove the conte bearing frm the reer propeller shaft. Engage thelegs ofthe pullerin the inner einforen ging of the rubber mounting Universal joints To overhaul the propeler shaft unversajoints, remove the snapings from the graowes (2, Fa3) NOTE: if dificuty is encountered, tap the bearing cup ©. Fg. 3) inwards to relieve the pressureon the snap-ng, Hold the flange yoke and tap the yoke with a softfaced hammer. The bearing eup should ‘gradually ererge and canbe finaly removes, Altematvely, secure the propeller shaft n a ioe, Usinga suitable soft metal dt, dftdown (ona beating cup to displace the opposte cup, Remove the propel shaft from thevice, hold thecisploced cupin the vice and separate from the propeller shaft by puling and twisting Repeat the above operations forthe opposite bearing cup. andthe remeining bearing cups at each endof the shat, 547-004 a3DRIVE SHAFTS AND PROPELLER SHAFT Sliding joint and gaitor To remove the gaiter from the sing joint or the front propel shat, ean the gaiter and the area of the shaft achacent ot Ensue that the arraws are visible on the sleeve yoke and shaft (Fig. 4) Cut the metal and rubber rings (2, Fg. 4) securing the gtr tothe yoke and shaft withdraw the gaiter 5, Fig. 5) along t shat Fad Partialy withdraw the sleeve yoke (8, Fig. 5) ‘rom the splined shaft and examine the spines for wear. If there i$ more than 0,1 mm (0.008 inhozcumferentalmoverment measured ‘on the outside damater ofthe spine, then the ‘complete propeller shaft assembly must be renewed Withdraw the sleeve yoke U, Fig 5} for the spines shaft and remove the gate (5, Fig. 5). Inspection CCarfuly inspect the intemal and extemal spines of the siding jint. Ensure tht the welch washer in the female spline is sooure and leakproof. ‘Wash lithe other components ofthe propelor ‘haftassemblyinpetvlexaminebeerngraces ‘and sper journals for signs ofloseness, load markings, scoring oF distortion. Spiders or bearings should not be renewed separatly, 3s this wil cause premature failure of ‘the replacement Itis essontal thatthe bearing cups 3, Fg. 5! are ight drive fit inthe yoke Wunnions. Resssembling Universal joints Using new universal joint assombbes if necessary, insert tho journal css into the flange, tng ito engage m the yoke bores. Ensure tatalthe need ors aren positon fi each bearing cup one-third fl of grease of the recommenced type Fone the beerng cups (9, Fig. Sinthe yoke bore, and using 2 stable soR metal dit, ap the bearing cup uly home. Fit a new snapsing (2, Fig. 5) ensuring itis correctly located inthe groove Assemble the other spiders and bearing cups, and fit new snaprings, to retain the bearing cups, Sliding joint and gaiter Lubrcte the interns! and extemal splines ‘generously with Blanded Spline Grease (rt INR (A) Supplied by iene Ltd), align the arrows and engage the male and female spines. Ensure that a dimension of less than 185 mm (73 in) canbe obtained between th yore joint centretine and the weld centrosine on the propeler sate \Withoraw the shaft and check for compete overage ofthe spines by the brant. To prevent damage to the ruober rings and dgaiter weap thin metal or plastic fim over the ‘male spines, Pass the two rubber sings over the spines, flowed by the smaller end ofthe ‘ater, pace the ngs over the gat. Femave the protective fm from the spines Postion the metaringclipon the gaiter,reakon the sptnes and ease the gaiter over the siding joint. Check tet the arows align (1, Fig. land fithe sleeve yoke tothe shaft. Secure tho gate cip, a4 Rear propeller shaft Coat the splnes ofthe rar propor shaft with Loctite grade AVV and fit to the conte joint ‘yoke, sign the marks previously made. Frtand tignion tho bolt, Fig. 6) secureusing a new tab washer.