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0 Datsun 1968-76 Drive Axles Repair Manual

1968-74 DATSUN INTEGRAL HOUSING (I.R.S)

MODELS COVERED

• 510 (1968-72)
• 610 Sedan and Hardtop (1973-74)
• 240Z (1970-73)
• 260Z (1974)

DESCRIPTION

The axle assembly is the hypoid gear type with integral carrier housing. The pinion bearing preload adjustment is made with a spacer and washer between the front and rear bearing cones. The differential side bearing preload and the pinion depth adjustment are made by shims. Driving power is transmitted to the rear axle by ball spline type driveshaft with universal joints at both ends.

AXLE RATIO AND IDENTIFICATION

All Datsun models with Independent Rear Suspension (I.R.S.), use one basic type rear axle assembly. Any differences in Removal and Installation or Overhaul procedures will be noted where they occur. To determine axle ratio, divide number of ring gear teeth by number of pinion teeth.

REMOVAL AND INSTALLATION

Axle Shaft and Bearings

Removal - Raise and support vehicle and remove wheel and brake drum. Disconnect driveshaft from axle outer flange. Remove wheel bearing lock nut while holding axle shaft outer flange stationary. Using suitable axle stand (ST07640000) and slide hammer, remove axle shaft. Remove wheel bearing spacer, companion flange and bearing washer, then remove inner wheel bearing and oil seal. Remove grease catcher, then press or pull outer wheel bearing from axle shaft. NOTE - Do not reuse old outer wheel bearing.

REAR AXLE ASSEMBLY (MODEL 610 SHOWN)

Installation - To install, reverse removal procedure and note the following: Clean and inspect all parts for wear or damage and replace as necessary. Grease wheel bearings and housing before installation. When installing bearings ensure outer bearing is installed with seal towards wheel and that inner bearing is installed with seal facing differential. A mark "A", "B" or "C" is stamped on axle housing. Ensure that bearing spacer with same mark is installed. Tighten all bolts and nuts and adjust wheel bearings.

Wheel Bearing Adjustment - After tightening wheel bearing lock nut to specification, check that axle shaft end play is .006" (.15 mm) or less. Check that turning torque of axle shaft is less than 1.8 lbs (.8 kg) at hub bolt. If either adjustment is not to specification, disassemble axle shaft assembly and replace bearing spacer.

DRIVE SHAFTS

Removal and Installation - Raise and support rear of vehicle on safety stands. Disconnect drive shaft from axle shaft companion flange. Remove differential side yoke attaching bolt and lift out side yoke and drive shaft as an assembly. To install, reverse removal procedure and note the following: Exercese care when installing assembly to prevent damage to side yoke and oil seal. Tighten all bolts to specifications.

PINION FLANGE AND OIL SEAL

Removal - Drain gear oil from differential, then raise and support rear of vehicle. Disconnect propeller shaft from pinion flange, then if necessary remove muffler and disconnect parking brake cable. On 240Z and 260Z models remove rear stabilizer from vehicle. On all models, remove pinion nut, while holding pinion flange stationary. Using a suitable puller remove pinion flange. Remove oil seal using suitable puller (ST33290001).

Installation - To install, reverse remove procedure and note the following: Apply suitable grease between seal lips before installation. Tighten pinion nut to specifications and ensure pinion bearing preload is correctly adjusted. Fill differential to proper level gear oil.

AXLE ASSEMBLY

Removal - Raise and support rear of vehicle. On all models except 240Z and 260Z disconnect parking brake cable from turnbuckle. On 240Z and 260Z models, remove main muffler. On all models, disconnect propeller shaft from axle assembly. On 240Z and 260Z models, loosen front side transverse link inner bolts. On all models, remove axle drive shafts. Support axle assembly on a jack, then remove nuts on both ends of axle assembly rear mounting member. Remove axle assembly front mount attaching bolts, lower assembly on jack and remove from vehicle. NOTE -On all models except 240Z and 260Z, support suspension member tor prevent damage to insulators.

Installation - To install, reverse removal procedure and note the following: Install same size mounting spacer between axle assembly and front mount. Tighten all nuts and bolts to specifications and fill assembly to correct level with gear oil.

DRIVE SHAFT OVERHAUL

DISASSEMBLY

DRIVE SHAFT ASSEMBLY

NOTE - Drive shaft should be disassembled only to lubricate ball spline.

Remove universal joint from differential end of drive shaft. Remove snap ring from sleeve yoke plug and remove plug. Compress drive shaft and remove snap ring from stopper, then remove stopper. Disconnect boot and separate drive shaft carefully as not to loose balls and spacers.

DRIVE SHAFT ASSEMBLY

INSPECTION

Check rubber boot and oil seeds for damage and replace as necessary. Inspect drive shaft for straightness, crack, damage and distortion and replace drive shaft if necessary. Check all other drive shaft assembly if any faulty part is found. Check drive shaft play as shown in illustration and replace complete assembly if play exceeds .004" (1 mm). NOTE - Measurement should be taken with drive shaft fully compressed.
REASSEMBLY

FIG. 4 REMOVING SIDE RETAINER
(610 MODEL)

To reassemble, reverse disassembly procedure and note the follwing: Align yokes and ensure steel balls and spacers are installed in correct order. Adjust axial play of universal joint to within .0008" (.02 mm) by selecting proper size snap ring. NOTE - Snap rings are available in four sizes: .0587" (1.49 mm); .0598" (1.52 mm); ..0610" (1.55 mm); .0622" (1.58 mm). Apply grease to ball grooves and oil grooves.
AXLE ASSEMBLY AND OVERHAUL
1) Mount axle assembly on suitable holding fixture. Remove rear mounting member and axle assembly cover plate. Using suitable puller, remove side reatainers and shims (610), or side flange, bearing cap screws, caps and shims (280Z) NOTE - Mark retainers or bearing caps and shims for reassembly. Left and right sides are not interchangeable. If side bearings on the 610 model are to be replaced, remove bearing outer race from side retainer using a suitable puller.

FIG. 5 REMOVING PINION
GEAR BEARING INNER
RACE

2) Hold pinion flange stationary and remove pinion nut, then using suitable puller, remove pinion flange. Press drive pinion from carrier and remove rear bearing inner race, bearing spacer and adjusting washers. Remove oil seal. Remove pilot bearing together with pilot bearing spacer and front bearing inner race. Press rear bearing inner race from drive pinion. Using a drift, remove front and rear bearing outer races.
3) To disassemble differential case, use suitable puller and remove side bearings. NOTE - Keep left and right side bearings separate, they are not interchangeable. Remove ring gear by unfolding lock strap and loosening bolts. Punch off pinion shaft lock pin from ring gear side, then remove pinion shaft, pinion gears, side gears and thrust washers. NOTE - Mark gears and thrust washers for instaallation in their original position. Thoroughly clean and inspect all parts for wear or damage and repair or replace as necessary.

REASSEMBLY AND ADJUSTMENT

FIG. 7 MEASURING SIDE BEARING WIDTH

FIG. 6 MEASURING SIDE GEAR
CLEARANCE

Differential Case Assembly - 1) Assemble pinion gears, side gears and thrust washers in original position in differential case. Fit pinion shaft to differential case so that it aligns with lock pin holes. Adjust side gear-to-pinion gear backlash or adjust clearance between rear face of side gear and thrust washer. Install pinion shaft lock pin and lock in place with punch.
2) Apply gear oil to gear tooth surface and thrust surfaces and ensure gears rotate smoothly. Install ring gears on differential case and install bolts and new lock washers. NOTE -Tighten ring gear bolts diagonally while tapping around bolt heads with a hammer.

MEASURING DRIVE SHAFT PLAY

3) When replacing side bearings, measure bearing width with a .787" (20 mm) gauge and 5.5 lb (2.5 kg) weight block. Bearing width should be slightly smaller than gauge. Press fit side bearing inner race on differential case and side bearing outer race into side retainers. Install new oil seal on side retainer and apply grease to cavity between seal lips.

Drive Pinion Preload - 1) NOTE - Perform adjustment without pinion shaft oil seal installed. Press fit and rear bearing outer races into gear carrier. Insert suitable dummy shaft spacer (ST31851000), pinion height adjusting spacer and rear bearing inner race into suitable dummy shaft (ST31212000).

2) Fit drive pinion bearing spacer, washer, front bearing inner race, suitable dummy shaft collar (ST31214000) and pinion flange on dummy shaft and tighten drive pinion nut to specified torque.

ADJUSTING DRIVE PINION PRELOAD

3) Measure pinion bearing preload using suitable preload gauge (ST31275000) and select washer and spacer that will provide specified preload. NOTE - Preload of old bearing is the same as that of a new bearing. Pinion bearing adjusting washers are available in thicknesses of .0906-.1024" (2.3-2.6 mm). Pinion bearing adjusting spacers are available in lengths at 2.2126-2.22520" (56.2-57.2 mm) on 610 models and 2.0551-2.0945" (52.2-53.2 mm) on all other models.

DRIVE PINION HEIGHT - 1) Install suitable height gauge (ST3121000) on gear carrier with dummy shaft mounted. Measure clearance between tip end of height gauge and end surface of dummy shaft. Thickness of drive pinion height adjusting washer can be obtained by the following formula.

MEASURING DRIVE PINION HEIGHT

T=W + N - (H - D' - S) x.01 - .2

NOTE - Formula values are give in Millimeters

T = Thickness of adjusting washer needed.

W = Thickness of washer temporarily installed.

N = Clearance between gauge and dummy shaft.

D' = Figure marked on dummy shaft

S = Figure marked on height gauge

NOTE - If values signifying H, D, and S are not given, regard them as zero.

2) Fit correct pinion adjusting washer in drive pinion and press fit rear bearing inner race. Lubricate pinion front and rear bearings, then install drive pinion in carrier along with drive pinion bearing spacer and washer, front bearing race, front bearing pilot spacer, pilot bearing and oil seal. Install pinion flange and tighten pinion nut to specifications

Side Bearing Preload - 1) Required thickness of left and right side retainer shims can be obtained by the following formulas

SIDE BEARING PRELOAD FORMULA VALUES

T1 = (A + C + G1 - D) X .01 + .76 - E

T2 = (B + D+ G2) X .01 + .76 - F

NOTE  - Formula values are given in millimeters

T1 = Required thickness of left side retainer shim.

T2 = Required thickness of right side retainer shim.

A & B = Figure marked on gear carrier.

C & D = Figure marked on differential case. 

E & F = Difference in width of left or right bearing.

G1 and G2 = Figure marked on left or right retainers.

NOTE - If values signifying A,B,C,D,G1 and G2 are not given, regard them as zero.

2) Install differential case assembly in gear carrier in reverse order of disassembly. Fit correct shims and "O" ring seal in both side retainers and install retainers in carrier with arrow pointing as shown in illustration.

SIDE BEARING PRELOAD IDENTIFICATION MARKS

INSTALLING SIDE RETAINER

3) Using dial indicator, remove ring gear-to-drive pinion backlash and adjust if necessary. Check side bearing preload, and adjust if necessary by adding or removing side retainer shims. NOTE - If side bearing preload is readjusted, ring gear-to-drive pinion backlash must be checked and adjusted. If necessary

Final Inspection and Assembly - After all adjustments are to specifications, make tooth contact pattern test and make any necessary correction. See Gear Tooth Contact Pattern of beginning of this section. Install rear cover and tighten nuts to specifications. Refill axle assembly to correct level with gear oil.

MEASURING RING GEAR BACKLASH

0 Arrow/Colt 1976-77 Drive Axles Repair Manual

DESCRIPTION

Rear axle is of the banjo type, utilizing the removable carrier style differential. Light weight construction joins split tubular housings for each side with center covers welded to axle housing. Final drive is of the hypoid style. Axle shafts are semi-floating type supported with bearings at their respective ends in axle housing. Bearings are fitted to axles with pressure type bearing retainers. Pinion bearing preload side bearing preload, and pinion depth adjustment are made with shims while differential side gears are adjusted with spacers

REMOVAL AND INSTALLATION

Axle Shafts and Bearings

FIG. 1 MEASURING AXLE SHAFT DEFLECTION

Removal - 1) Raise and suitable support rear axle housing so rear wheels clear ground. Remove rear wheel and brake back plate nuts, then disconnect wheel cylinder brake line. Fix suitable puller set (CT-1003 & C-637) to lug studs and work side hammer until axle shaft is free to be withdrawn. Set brake back plate with parking brake attached out-of-way. Using suitable tool (C-637 with hook) remove axle shaft oil seal.

2) To remove axle bearing proceed as follows: Grind down bearing retainer at one point until retainer thickness is .04-.06" (1.0-1.5 mm), then chisel ground portion and remove retainer. Using suitable bearing puller or press (CT-1120) remove bearing from axle.

3) Using a dial indicator, inspect axle shaft deflection in three spots (see illustration). Replace axle shaft if specifications are exceeded.
4) Rear axle bearing should be replaced when bearing noise is detected, when bearing axial free play exceeds .014-.016" (.36-.41 mm) or if bearing radial free play exceeds .001-.002" (.03-.04 mm) at approximately 11 lbs. (5.0 kg) measuring force.
5) Inspect wheel hub bolts for tightness and bearing outer retainer for deformation ,replace defective parts as nessary.

Installation - 1) Fit outer bearing retainer flat side against shaft splined end, then install bearing and inner bearing retainer. Seat bearing retainer with smaller chamfered side directed to the bearing. NOTE -Ensure bearing is completely seated.

FIG. 2 EXPLODED VIEW OF AXLE SHAFT ASSEMBLY

2) Lightly coat lips of oil seal and using suitable oil seal installer (DT-1007B & CT-1008) fit axle shaft oil seal in rear axle housing.
3) Using packings and shims in proper sequence, set clearance between bearing and outer bearing retainer to .00-.01" (.0-.25 mm).
4) Carefully insert axle shaft assembly into axle housing using care not to damage seal. Slightly turn shaft until splines line up with differential side gears. Align packing oil holes with outer bearing retainer and tighten bearing retainer to axle housing flange. Connect brake line to wheel cylinder and bleed air from system.

DIFFERENTIAL CARRIER

FIG. 3 REMOVING DIFFERENTIAL
GEAR HOUSING

Removal - Drain oil from rear axle differential housing, then disconnect propeller shaft. Pull out both rear axle shafts approximately 2 1/3". Remove differential gear housing mounting nuts and withdraw the differential gear carrier. It may be necessary to top outside of housing to break gear carrier loose.
Installation - Lightly coat each bearing and gear with oil. Apply sealing compound on packing and axle housing seat, then assemble gear carrier to housing with nuts and tighten. Fill differential gear housing with .96 quart of suitable multi-purpose gear oil (API GL-5).

OVERHAUL

Disassembly

FIG. 4 REMOVING DIFFERENTIAL
SIDE BEARINGS

Differential Gear Assembly - 1) Remove bearing carrier cap and lever gear case assembly from housing. Using suitable bearing puller tool (C-293-P & C293-39) pull differential side bearing. Keep right and left bearings and shims in sequence for reassembly
2) Remove ring gear lock plate tabs and loosen bolts in diagonal sequence, then remove ring gear. Drive out pinion shaft lock pin from ring gear back side using a punch, pull out pinion shaft and pinion. Pinion side gears and spacers are now accessible. Note placement of side gear and spacers and ensure they are reassembled in same position.

Drive Pinion Disassembly - 1) Hold end yoke with suitable tool (C-3281) and remove lock nut, then remove end yoke. Using a wheel puller, force out drive pinion with adjusting shim, rear inner bearing race, spacer and preload adjusting shim.

FIG. 6 REMOVING DRIVE
PINION FRONT BEARING
OUTER RACE

2) With suitable bearing puller (C-293-P & C-293-39) remove rear bearing inner race and at same time, pull of dive pinion adjusting shim. Using suitable drift, remove front drive pinion bearing outer race and oil seal. Repeat some procedure to remove bearing outer race.

INSPECTION
Check differential gears for correct tooth contact and replace gears if wear is excessive. Inspect bearing faces for roughness or score marks and replace, if necessary, bearing assembly. Ensure splines of side gears and rear axle shafts fit correctly. Check clearance between pinion gears and pinion shaft, if wear is excessive, replace components.
NOTE - To check gear tooth contact using pain impression method, refer to beginning of this section.

FIG. 7 EXPLODED VIEW OF COLT SEPARATE HOUSING REAR AXLE ASSEMBLY

REASSEMBLY AND AJDUSTMENT

FIG. 8 CHECKING DIFFERENTIAL PINION
AND SIDE GEAR BACKLASH

Case Assembly - 1) Install thrust washers (spacers) behind side gears in their original position and assemble pinion and side gears in differential. Insert both pinion gears with pinion washers attached, so they mesh with side gears. It may be necessary to slightly rotate pinions to achieve desired meshing. Insert drive pinion shaft.
2) Check pinion and side gear backlash as shown in illustration. If backlash is beyond 0-.003" (0-.08mm) adjust by selecting a side gear thrust washer (spacer) of correct size. If backlash is to be adjusted, ensure right and left sides are equally shimmed.
3) Thoroughly clean all dirt from ring gear mounting surface of differential case. Install bolts and lock washers. Tighten bolts alternately in a diagonal sequence and bend over lock tabs. Ensure lock washers are in contact with case rib after final torque is performed.
Drive Pinion - Using a suitable drift and hammer or a press, seat front and rear bearing outer races into gear carrier ensuring that outer races do not cock. Ensure bearing races are completely seated before proceeding. Install shim between drive pinion and rear bearing. Using suitable bearing installer (CT-1075) press bearing onto drive pinion shaft. If drive pinion and bearings are scheduled to be reused, shims should be replaced with new ones of same thickness. In instances where the gear set is to be replaced, install new shims that are the same thickness as the used shims on drive pinion NOTE - When determining the desired thickness of shim pack, amount of compression the desired thickness of shim pack, amount of compression (sinkage) of shim pack and wear of the beating (where old bearing is reused) must be taken into consideration.
Drive Pinion Depth - Install drive pinion spacer, front bearing, washer, end yoke and washer in order of removal. Fit pinion shaft retaining nut and slowly tighten nut, continously checking, until pinion bearing preload is 6-9 INCH lbs (7-10 cmkg) with oil seal not installed. Place suitable cylinder gauge on inside bearing pedestals of gear carrier housing. Place a block gauge on top end of drive pinion and slip a feeler gauge between the two gauges should be .0118" (.300 mm). This is the standard height and any deviation from this height will be marked on the head of the pinion shaft and side of ring gear. To calculate the correct pinion height, add or subtract the variation value from the standard height.
NOTE - Stamped values are in hundredth millimeters. Add or subtract the correct amount of shims an necessary.

Pinion Bearing Preload - The adjustment must be performed after the setting of the drive pinion depth. Remove end yoke and insert the bearing preload adjusting shim between pinion spacer and bearing, then tighten end yoke to 9-11 INCH lbs. (10-13 cmkg). In addition to the preload adjusting shims there are spacers available to provide proper adjustment. After finishing adjustment of drive pinion bearing preload remove the end yoke and apply a thin coat of grease to outer surface of oil seal, then drive seal into position in gear carrier. After greasing oil seal lip, insert end yoke and tighten nut.

Side Bearing Preload - Fit each side into differential case leaving shims out; use suitable tool (CT-1102) for this procedure. Ensure side bearings are completely seated before proceeding. Install differential case assembly on gear carrier, then calculate the clearance between side bearing outer race and gear carrier as shown in illustration. After obtaining clearance add .002" (.05 mm) preload figure to each side. Insert shims equally on both sides. Align gear carrier end bearing cap index marks, then tighten cap retaining bolts.

FIG. 9 MEASURING CLEARANCE
BETWEEN SIDE BEARING AND
GEAR CARRIER

Ring Gear Deflection - Attach a dial indicator to back side of ring gear and measure deflection. If ring gear has excessive deflection, correct position of the assembly in relation to differential case and again perform measurement. Replace ring gear or differential case as necessary.

Drive Pinion Depth - Measure backlash of drive pinion is at least four different spots on ring gear with drive pinion securely fixed in final position. Set up a dial indicator on ring gear teeth edges. If measured backlash is greater than .005-.007" (.13-.18 mm), shift shims from ring gear side to the back of the ring gear to obtain pro[er backlash. If the measure value is less than standard value, reverse the moving of shims as stated above. Side bearing shims are available in various thicknesses.
NOTE - Check gear tooth contact patter using point impression method described at beginning of this section.

Final Inspection and Assembly - Lightly coat each gear and bearing before and during reassembly with gear oil. After installing each component, ensure all rotating parts are free to move smoothly. Install differential gear assembly to axle housing after applying sealing agent and tighten gear carrier mounting nuts in diagonal sequence.

0 Capri II 1976-77 Drive Axles 2 Repair Manual

CAPRI II

DESCRIPTION

An integral type housing, hypoid design, with centerline of pinion set below centerline of ring gear. Semi-floating zxle shafts are retained in housing by ball bearings and a bearing retainer at axle housing by ball bearings and a bearing retainer at axle housing outer ends. All adjustments are performed using selective fit shims and gaskets.

REMOVAL AND INSTALLATION

Axle Shafts and Bearings

1) Remove brake drum retainers and remove brake drum. Remove bolts securing bearing retainer plate to axle housing. These bolts are accessible through holes in axle shaft flange. Pull axle shaft and bearing assembly out of axle housing.

2) Loosen inner retainer ring by nicking it deeply with a cold chisel in several places. It will then slide of easily. Press bearing and seal assembly from axle shaft using arbor press and suitable tool to hold and support bearing.

3) To install, inspect housing and axle shaft and lightly coat wheel bearing base with axle lubricant. Place bearing retainer plate on axle shaft and press new bearing wheel bearing on shaft using suitable tool. NOTE - Do not attempt to press on both bearing and inner retainer at the same time.

4) Using suitable bearing installation tool, press bearing inner retainer ring on shaft until retainer seats firmly against bearing. Insert axle housing and engage splines. Tap shaft into position. Install bolts securing bearing retainer plate and install brake drum and retainers.

REAR AXLE ASSEMBLY

1) Raise vehicle and remove wheels. Mark propeller shaft for proper alignment and disconnect from drive pinion flange. Release pakring brake, then remove locknut and adjusting nut from handbrake cable and disconnect cable from relay lever. Disconnect brake line from brake hose.

2) Raise and support center of rear axle and disconnect shock absorbers from axle. Remove rear axle support. Remove two stabilizer bar retaining clamps from rear axle housing. Remove rear spring "U" bolt nuts and detach bolts and plates. Lift axle assembly and remove from vehicle.

3) To install, lift rear axle assembly into position on springs, being sure that it is correctly located over spring pilot bolts. Align and loosely fit propeller shaft to drive pinion flange. Fit "U" bolts over axle, slide on lower plates, install new locknuts and tighten.

4) Using a suitable tool, hold rear stabilizer bar onto mounting pads on axle housing and install retaining clamps. Insert retaining clamp bolts, check for binding, and tighten. Raise center of rear axle and install shock absorbers. Remove axle support.

5) Reconnect brake line to brake hose and handbrake cable to relay lever on rear axle housing. Adjust nut until relay lever is just clear of stop, tighten locknut. Tighten driveshaft-to-pinion flange bolts and bleed rear brake system. Fill rear axle housing with lubricant, mount rear wheel and lower vehicle.

DIFFERENTIAL CASE

Disassembly - 1) Raise vehicle and remove wheels and axle shaft assemblies. Mark propeller shaft for correct realignment and disconnect from pinion flange. Remove ten cover attaching bolts, cover and gasket and pinion drain rear axle oil. Discard gasket and thoroughly clean cover.

2) Remove differential housing caps and mark caps for correct repositioning. Lift differential out of axle housing using two pry bars. Remove tapered roller bearing from each side of differential assembly using a suitable puller. Remove adjusting shims from differential housing. Remove ring gear attaching bolts and ring gear from differential assembly.

3) Using a suitable drift, remove lock pin securing differential pinion shaft in case and remove pinion gears, side gears and adjusting shims. Using an INCH pound torque wrench on drive pinion retaining nut, note torque required to turn drive pinion gear. Remove torque wrench, hold pinion flange and remove drive pinion retaining nut. Remove pinion flange using a suitable puller, then remove pinion from axle housing. Remove collapsible spacer from drive pinion. Remove large bearing from drive pinion using press and suitable fixtures. Remove outer pinion bearing and seal from axle housing using a suitable drive. Remove bearing races from axle housing using a drift.

FIG. 1  CHECKING DRIVE
PINION DEPTH

Reassembly - 1) Install pinion bearing races into axle housing. Set pinion depth as follows. Position cross bar of pinion depth gauge tool (T70P-4133) and side bearings in rear axle housing. Install bearing caps (number ot number) and tighten attaching bolts. Loosen bolts and retighten fingertight. Preload side bearing by expanding depth gauge crossbar by holding bar and rotating nut. Seat side bearings and check that side bearings are still preloaded. Do not cover expand cross bar. Tighten bearing attaching bolts.

2) Install dummy pinion (part of special tool) into axle housing with pinion bearings but no shims. Lightly lubricate bearings and tighten tool until correct pinion bearing pre-load is obtained. Rotate dummy pinion several times to insure seating of bearings. It is essential that the torque reading be recorded and followed by further adjustment of drive pinion. This torque must also be checked after installation of drive pinion with collapsible spacer.

FIG. 2 EXPLODED VIEW OF CAPRI II DRIVE AXLE ASSEMBLY

3) Mound dial indicator as mounting bracket and set to zero on dummy pinion. Slowly rotate dial indicator over cross bar of tool and read total deflection of pointer. This reading gives the exact thickness of the shims to be used. When pinion is marked "-1" or "-2" this amount must be added to indicator reading. When gear is marked "+1" or "+2" this amount must be subtracted from reading to obtain correct shim thickness. Using a micrometer, select a shim of the determined thickness.

FIG. 3 MEASURING SIDE
GEAR CLEARANCE

4) Position shim(s) on pinion and press on large tapered roller bearing using a press and suitable fixture. Position differential side gears, with one shim each, in differential case. The grooved side of shim must be towards side gear. Position differential pinions and thrust washers between differential side gears. Push the differential pinion shaft into position in case, taking care to align locking pin holes. Measure play of each side gear using a feeler gauge. If side gear play is not to specifications, install new shims. Secure differential pinion shaft with locking pin.

5) Position ring gear on differential case and locate with bolts. Pull ring gear evenly into position with bolts. Remove old bolts and install new bolts and tighten. To determine total play of differential case in axle housing. Press tapered roller bearing onto differential case in axle housing: Press tapered roller bearing onto differential case without shims after first inspecting bearing for damage. Install pressure blocks (part of tool T70P-4136) into axle housing on each side of differential case and install differential case and bearings in axle housing. Install bearing caps (number to number) and tighten attaching bolts. Now, loosen bolts and tighten finger tight.

6) Tighten pressure spindle (tool T70P-4136) to a torque of 43 INCH lbs. Rotate differential several times and recheck torque. Mount dial indicator on rear axle housing so that feeler contacts inner side of ring gear flange and zero indicator. Place pressure spindle into other side of housing and tighten to 43 INCH lbs. Read and note amount of indicator deflection and record as play of differential case in rear axle housing. Loosen pressure spindle, tilt dial indicator to side and remove differential, pressure spindle and pressure blocks.

FIG. 4 DIFFERENTIAL SET-UP, PRESSURE
BLOCK AND SPINDLE INSTALLATION

7) Install inner bearing on drive pinion gear along with collapsable spacer. Install drive pinion gear, outer pinion bearing, new oil seal and flange into housing. Install new pinion flange nut and hold pinion flange using a suitable holding fixture.

8) Slowly tighten nut. Keep checking pinion gear rotating torque (using INCH pound torque wrench) until rotating torque is equal to that noted during disassembly. Tighten an additional 2-4 INCH pounds torque for friction of new oil seal. Pinion nut torque should be to specification when pinion rotating torque is correct. If pinion nut torque is below specification and rotating torque is correct, install new collapsable spacer and repeat procedure.

FIG. 5 MEASURING RING
GEAR BACKLASH

9) To determine differential case bearing shim thickness: Place pressure blocks back into axle housing and place differential case with bearing races into axle housing. Install bearing caps, tighten screw, then loosen and tighten finger tight. Using pressure spindle, press differential housing with a torque of 43 INCH lbs. away from drive pinion. Rotate pinion several times. Position feeler of dial indicator gauge at right angle to one tooth of ring gear. Measure tooth flank backlash at 4 points, each time turning gear two bolt heads further. Deviations of tooth flank backlash must not exceed .002" (.05 mm). Insert pressure spindle into other side of axle housing screw in slowly until there is the specified value of tooth flank backlash.

10) Position dial indicator so that feeler contacts ring gear flange and zero indicator. Insert spind into other side of axle housing and torque to 43 INCH lbs. Read and record indicated deflection on indicator as ring gear back side shim thickness. Remove pressure spindle, differential case and pressure blocks from axle housing.

11) To calculate shim thickness, first take the value of differential case total play obtained in step 6) and add to this value a value for ring and pinion backlash which will give an even number. For example, if total play is .0529" (1.344 mm), add for preload the value .0021" (.056 mm) (preload value selected from specified range) to obtain .055" (1.40 mm). Next, take the value for ring gear back side shim thickness, measured in step 10), and subtract .005" (.13 mm) from this value. For example, if ring gear back side shim thickness is .0025" (.64 mm), subtract .005" (.13 mm) to obtain .020" (.51 mm). Now subtract value just obtained (.020" or .51mm) from total play value obtained above (.055" or 1.40 mm) to obtain ring gear face side shim pack, in this example .035" (.89 mm).

12) Remove differential case bearings and position required shims on differential case. Using suitable tools, press tapered roller bearing onto differential case after checking bearing for damage. Insert differential case in axle housing and position bearing caps as previously marked. Coat bolt threads with sealing compound and insert bolts.

13) Position dial indicator feeler in a vertical position on one ring gear tooth and check that pinion to ring gear backlash is to specifications. If not, differential must be removed and shims adjusted. If backlash is to great, remove shims from ring gear back side and vise versa. Do NOT increase or decrease number of shims, but only interchange between one side and the other.

14) Finally check gear tooth contact pattern and adjust as necessary to obtain correct pattern. Position housing cover and new gasket on axle housing and install and tighten bolts. Attach parking brake operating lever to rear axle housing and connect return spring to bracket on housing. Install rear brake assemblies on axle housing and connect parking brake cable to brake assemblies

0 BMW 1975-76 Drive Axles Split Housing Repair Guide

-Models Covered:

 - 3.0 Series

 - 530 i Series

DESCRIPTION

Differential has hypoid type ring and pinion gear set, and may have one of two clutch pack type limited slip units. Left side of housing is the housing cover and must be removed to expose carrier assembly. Cover incorporates a ball bearing and oil seal for left axle flange, and a bearing cone for the left differential carrier bearing. Right carrier bearing and seal are incorporated in housing. The pinion gear is supported by roller bearings and preload is maintained by a collapsible spacer

AXLE RATIO AND IDENTIFICATION

Ring and pinion gear set with Klingelnberg tooth design, can be identified by the letter "K" stamped on the head of the pinion gear; Gleason teeth are noted by an "H or F" stamping. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth. The number of teeth on ring and pinion, and the code for limited slip differential (S40), is stamped on right side of differential housing.

FIG. 2 EXPLODED VIEW OF HALF SHAFT
CONSTANT VELOCITY JOINT

REMOVAL AND INSTALLATION

DRIVE SHAFTS AND UNIVERSAL JOINTS

Remove drive shaft after removing retaining bolts from axle and half shaft flanges. Remove cover from joint housing and snap ring from end of drive shaft. Remove clamps from boot then press drive shaft from joint. Remove dust boot. To install reverse removal procedure using sealer on boot-to-joint surfaces, and install seal cover after packing joint with suitable grease.

FIG.  1 EXPLODED VIEW OF TYPE 1 AND TYPE 2 LIMITED SLIP DIFFERENTIALS

AXLE SHAFTS AND BEARINGS

FIG. 4 PULLING AXLE DRIVE FLANGE

Raise and support vehicle. Remove wheel, drive shaft, axle flange retaining nut, and using a puller, if required, remove axle flange. Using soft headed mallet, drive axle shaft out of housing. Drive out bearings and seals, then remove spacer sleeve and shim. To install, reverse removal procedure noting the following: Install outer bearing then determine distance between outer races of inner and outer bearings. Measure spacer and shim, then install spacer and a suitable shim that will obtain the specified wheel bearing end play. Pack bearings and new seals with suitable grease, then complete installation procedure.

AXLE FLANGE, SEAL AND BEARING

FIG. 5 REMOVING AXLE DRIVE
FLANGE BEARING

Remove drive shaft. Hold axle flange using suitable tool (7012) and remove flange retaining bolt. Using suitable puller (7011-2) remove axle flange. Pry out oil seal and if required, remove ball bearing on cover side, using suitable puller. To install, reverse removal procedure after packing bearing and/or filling between sealing lips of seal with grease. Install seal flush with housing or cover bore.

NOTE - Differential carrier can be removed from housing with differential assembly installed in vehicle. After removing axle flanges, follow Differential Carrier, Disassembly and Overhaul procedure, int his story.

DIFFERENTIAL ASSEMBLY

Remove propeller shaft and drive shafts, tie drive shafts up out of way. Support differential and remove bolts securing it to front brackets and rear support. Remove differential assembly. To install, reverse removal procedure, insuring rear support stress free when installed.

OVERHAUL

Disassembly

FIG. 6 CHECKING RING GEAR BACKLASH

Differential Assembly - Remove differential assembly as previously oulined and mount assembly in suitable holding fixture. Drain oil and mark pinion shaft and companion flange far reassembly reference. Remove inspection hole cover, mount dial indicator in one cover bolt hole and check ring gear  backface runout and ring-to-pinion gear backlash. Check gear tooth contact pattern. NOTE - Refer to Rear Axle Gear Tooth Patterns in this section. Remove axle flanges and side cover, then remove differential carrier assembly. Proceed as follows for standard or limited slip differential carrier disassembly.

Standard Differential Carrier (Two Pinion Type) - Remove carrier bearings using suitable puller (Rolex LM 503349). Separate ring gear from carrier. Drive out pinion shaft lock pin, remove pinion gears shaft and pinion gears, then remove side gears with shims and thrust washers.

Standard Differential Carrier (Four Pinion Type) - Remove carrier bearings using suitable puller (Rolex LM 503349). Separate carrier halfs and lift out pinion gears with shafts, then remove side gears with shims and thrust washers. Remove ring gear from carrier.

Limited Slip Differential Carrier - Remove carrier bearings using suitable puller (Rolex LM 503349). Remove bolts securing case-to-ring gear flange (Type 1), or cover-to-case (Type 2), invert case and lift case off clutch and gear assembly. Separate ring gear from flange. Remove clutch components. Lift off hub, remove side gear and one set of pinion gears. Repeat procedure for other half of case.

FIG. 7 CHECKING PINION GEAR
PRELOAD

Drive Pinion Gear - 1) Remove differential carrier as previously described, then check pinion bearing preload using an inch pound torque wrench. Remove pinion flange nut lock ring and using a suitable tool (7012) hold flange and remove nut.

2) Press pinion gear out, through flange and housing, then remove oil seal and front roller bearing. Using suitable puller set (6053), remove pinion bearing outer cones from housing.

REASSEMBLY AND ADJUSTMENT

Differential Assembly - Reverse disassembly procdure noting the following checks and adjustments.

FIG. 8 SECTIONAL VIEW OF DRIVE
PINION GEAR AND BEARING
ASSEMBLY

Drive Pinion Bearing Preload - 1) If original ring and pinion gear set is being installed, and gear tooth pattern and pinion bearing preload was satisfactory at time of disassembly, install drive pinion gear using original shim and a new collapsable spacer. If a new gear set is being installed, determine correct size of shim to use in the following manner: Drive pinion gears may be stamped either "+1,2,3, etc" or "-1,2,3 etc". Compare marks on tapered ends of old and new gears. Subtract the two numbers. In relation to original shim, a plus remainder means a thinner shim is required; a minus remainder means a thicker shim is required.

2) Remove then reinstall pinion gear, using new shim(s), collapsable spacer, and seal as required. Install companion flange and nut and tighten nut to obtain specified drive pinion bearing preload. NOTE - If preload is exceeded, new collapsible spacer must be installed, and this procedure repeated.

FIG. 9 CHECKING SIDE-TO-PINION

Side-to-Pinion Gear Backlash (Standard Differentials) - Install two pinion gears with shaft and one side gear. Mount dial indicator to carrier so plunger contacts side gear. Force side gear hard against pinion gears, zero indicator, then force side gear hard against case. With proper shim and thrust washer, backlash should be as specified, and preload of all three gears should not exceed specified value. Repeat procedure on opposite side (with second set of pinion on four pinion type), then retain side gears pressed outward against carrier so axle flange retaining bolts can later be installed.

Clutch Assembly End Play (Type 1 Limited Slip Differential) - Assembly cluch assembly without ring gear or case. Apply 220 psi (15.5 kg/sq. cm) to one end of assembly. Measure from inner surface of flange to top surface of spacer ring. Measure depth of case. If clutch assembly-to-housing end play is not to specification, adjust by using thicker or thinner inner clutch disc.

                                                                                                    FIG. 10 
                                                                 MEASURING TYPE 1 CLUTCH 
                                                         ASSEMBLY INSTALLED HEIGHT WITH PRESSURE APPLIED 

FIG. 11 MEASURING TYPE 2 CLUTCH
ASSEMBLY I

Checking Pinion Gear Torque (Limited Slip Differentials) - With differential carrier assembled, install axle flanges in carrier. Clamp one flange in vise and using and INCH pound torque wrench (Type 1), or foot pound torque wrench (Type 2), turn other flange. If rotating torque of side and pinion gears i not to specification, install thicker or thinner case cover-to-clutch assembly thrust washers.

FIG. 13 MAKING MEASUREMENT FOR
ESTABLISHING SHIM PACK
FOR DIFFERENTIAL BEARING PRELOAD

Differential Bearing Preload - Install one shim behind carrier bearing outer cone in side cover. Install bearing cone using suitable tool (6053). Install drive flange bolt, without flange, so it contacts pinion gear shaft. Install carrier in housing and tighten cover retaining bolts. Check preload by turning flange bolt using an INCH pound torque wrench. When cover bolts are torqued to specification, measure gap between cover and housing using a feeler gauge. If preload is lower than specified, shims must be thicker than gap; if preload is higher than specified, shims thickness behind cone must be less than gap between cover and housing. Install required shims under bearing cone in cover. Heat ring gear to 176-212 Degrees Fahrenheit, install ring gear on carrier using locking compound on bolts, and install carrier in housing. Check Ring-to-Drive Pinion Gear Backlash.

FIG. 13 MAKING MEASUREMENT FOR ESTABLISHING
SHIM PACK FOR DIFFERENTIAL BEARING PRELOAD

Ring-to-Drive Pinion Gear Backlash - With differential bearing preload set, remove inspection hole cover, mount dial indicator in one cover bolt hole, and check ring-to-pinion gear backlash. Check ring gear tooth contact pattern. NOTE - Refer to Axle Gear Tooth Patterns in this section. While maintaining established shim thickness, move shims behind carrier bearing outer cones, from one side to the other as necessary, to obtain proper contact pattern. After setting backlash, complete differential reassembly  procedure.

FIG. 14 SECTIONAL VIEW SHOWING RING GEAR BACKLASH SHIM LOCATIONS

0 BMW 1975-76 Drive Axles Repair Guide

BMW INTEGRAL CARRIER 2002 SERIES

DESCRIPTION

Differential has hypoid ring and drive pinion gear set and may have a clutch pack type limited slip unit. Differential housing has removable rear cover. Differential carrier is retained in the sides of the housing by retaining plates, and is supported by roller bearings. Drive pinion gear is supported by roller bearings, and in addition, a long neck housing has ball bearing supporting the drive pinion at the companion flange. Drive pinion preload is maintained by a collapsible spacer in the short neck housing, and by a spacer and shims in the long neck housing.

AXLE RATIO AND IDENTIFICATION

The ring and pinion gear set with Klingelnberg tooth design, can be identified by the letter "K" stamped on the head of the drive pinion gear; Gleason teeth are noted by on "H" or "F" stamping. To determine axle ratio, divide number of ring gear teeth by number of drive pinion gear teeth. The number of teeth on ring and drive pinion gears is stamped on forward left side of differential housing.

REMOVAL AND INSTALLATION

Drive Shafts and Universal Joints

Remove drive shaft after removing retaining bolts form axle and half shaft flanges. For universal joint or dust boot replacement, use the appropriate procedure below.

Constant Velocity Joint - Remove cover from joint housing, then remove snap ring from end of drive shaft. Remove clamps from boot then press drive shaft from joint. Remove dust boot. To install, reverse removal procedure using sealer on boot-to-joint surfaces and install seal cover after pakcing joint with suitable grease.

Sliding U-Joint - Drain oil form joint, note position of hose clamps, then remove clamps. Pull of housing  and roller caps and coat needle bearings with grease. Remove dust boot from spacer ring and then remove boot and ring. To install, reverse removal procedure, locating hose clamps in original position.

Cross and Roller U-Joint - NOTE - If yoke is bent or twisted, complete drive shaft must be replaced. Remove bearing cup snap rings, then press out bearing cups using suitable arbor press or vise and supporting tools. Remove cross assembly from yoke. To install, hold cross between ears of drive shaft and partially install two bearing cups. Align cross with cups, then using arbor press or vise, press cups into yoke until snap rings can be inserted.

AXLE SHAFT AND BEARINGS

FIG. 2 SECTIONAL VIEW OF AXLE SHAFT
ASSEMBLY

Raise and support vehicle. Remove wheel, loosen castellated nut, securing flange to axle shaft, then using a suitable puller, remove flange. Remove dive shaft, then using a soft headed mallet, drive axle shaft inward and out of housing. Drive out bearings and seals, then remove spacer sleeve and shim . To install, reverse removal procedure noting the following: Install inner bearing, then determine distance between outer races of inner and outer bearings. Measure spacer and shim, then install spacer and a suitable shim that will obtain a wheel bearing play of .002-.004" (.05-10 mm). Pack bearings and hub with suitable grease, then using new seals, complete installation procedure.

DRIVE PINION COMPANION FLANGE OIL SEAL

NOTE - On short neck differential housing, complete disassembly of differential is required for seal replacement. Refer to Drive Pinion Gear Removal and Installation procedures for seal replacement.

Long Neck Differential Housing - Remove propeller shaft, nut retaining companion flange on drive pinion gear, companion flange and oil seal. To install, reverse removal procedure insuring seal installed depth is .24" (6 mm) from front of seal to front edge of housing.

FIG. 3 REMOVING AXLE DRIVE FLANGE

AXLE FLANGE AND OIL SEAL

Removal - Remove drive shaft. Hold axle flange using suitable tools (604 wrench; 6040 Spacer) then remove flange retaining bolt. Using a suitable puller (20/10) and support bracket (7011-1) remove axle flange. Remove oil seal.

Installation - Fill between sealing lips of seal with grease, then install seal in retaining plate to a depth of .16" (4 mm). Thoroughly clean flange and carrier splines and if any backlash between splines exists apply small amount of locking compound to flange splines. Install flange and retaining bolt.

DIFFERENTIAL ASSEMBLY

Remove propeller shaft and drive shafts, tie drive shafts up out of way. Support differential and remove four frame-to-housing attaching bolts, two differential cover-to-bracket nuts, and two bracket-to-frame bolts. Remove differential assembly. To install, reverse removal procedure, insuring rear bracket is stress free when installed.

FIG. 4 CHECKING RING GEAR
BACKLASH

OVERHAUL

Disassembly

Differential Housing - Remove differential assembly as prevously outlined, and mount assembly in suitable holding fixture. Drain oil and mark drive pinion shaft and companion flange fro reassembly reference. Remove rear cover plate. Remove both axle flanges, as previously described, keeping right and left side ports separated. Mount a dial indicator to housing, and check ring gear runout for reference at time of reassembly. Make a gear tooth pattern check. NOTE - Refer to Rear Axle Gear Tooth Patterns in this section. Mark and remove carrier bearing retainer plates and shims. Turn housing rear opening upward, move carrier to right side, tilt and remove carrier from housing. Proceed as follows for standard or limited slip differential carrier disassembly.

FIG. 5 VIEW OF ASSEMBLED LIMITED
SLIP UNIT WITH CASE REMOVED

Standard Differential Carrier - Remove carrier bearings using suitable puller (Rollex LM503349). Remove bolts securing ring gear to carrier, then remove ring gear. Drive out pinon shaft lock pin, remove pinion gears shaft and pinion gears. Remove side gears with shims and thrust washers.

Limited Slip Differential Carrier - Remove carrier bearings using suitable puller, (HM 89449). Remove bolts securing case cover to ring gear flange, insert case and lift case of clutch and gear assembly. Separate ring gear from flange. Remove clutch components lift off hub, remove side gear and one set of pinion gears. REpeat procedure for other half of case.

FIG. 8 SECTIONAL VIEW OF LONG
NECK HOUSING PINION SHAFT
FRONT BEARING ASSEMBLY

Drive Pinion Gear - 1) Remove differential carrier as previously outlined, then using an inch pound torque wrench, check preload on drive pinion gear. Hold companion flange and remove retaiining nut. Press drive pinion from flange and housing, then remove bearings. NOTE - On long neck housing, firt remove flange nut, flange, cover and shim. Using a suitable tool (6046) remove drive pinion lock nut, then press gear out.

2) Remove drive pinion shaft oil seal then using suitable tools (5109 and 5120) press drive pinion outer bearing cones from housing. NOTE - On short neck housing, remove rear bearing cone first. On long neck housing, remove forward bearing come first.

REASSEMBLY AND ADJUSTMENT

Differential Assembly - Reverse disassembly procedure noting the following checks and adjustments.

Drive Pinion Bearing Preload - 1) If original ring and pinion gear set is being installed, install drive pinion gear using original shim and new collapsible spacer. If a new gear set is being installed determine correct size of shim to use in the following manner: Drive pinion gears may be stamped either "+1,2,3 etc", or "-1,2,3. etc". Compare marks on tapered ends of old and new gears. Subtract the two numbers. In relation to original shim, a plus remainder means a thinner shim is required; a minus remainder means a thicker shim is required.

FIG. 8 SECTIONAL VIEW OF LONG
NECK HOUSING PINION SHAFT FRONT
BEARING ASSEMBLY

2) Remove then reinstall drive pinion, bearings and cones, as required, so new shim(s), collapsable spacer, and seal can be installed. NOTE - On long neck housing, preload must be etablished with pinion lock nut before installing front housing cover.

3) Install companion flange and nut (short neck housing), or pinion lock nut (long neck housing) and tighen nut to obtain specified preload NOTE - If preload is exceeded, new collpsable spacer must be installed, and procedure repeated.

FIG. 11 CHECKING SIDE GEAR-TO-PINION
GEAR BACKLASH ON STANDARD DIFFERENTIAL

Side-to-Pinion Gear Backlash (Standard Differential) - With pinion gears and one side gear installed, mount dial indicator to carrier. Force side gear against case, zero indicator then force side gear against pinion gears. With proper shim and thrust washer, backlash should be as specified and preload of all three gears should not exceed 14 ft. lbs. (1.9 mkg). Repeat procedure on opposite side gear, then retain both side gears pressed outward against carrier, so axle drive flange retaining can be later be installed.

FIG. 12 MEASURING LIMITED SLIP CLUTCH
ASSEMBLY INSTALLED HEIGHT WITH
PRESSURE APPLIED

Clutch Assembly Endplay (Limited Slip Differential) - Assemble differential clutch and gear assembly, without ring gear or case. Apply 220 psi (15.5 kg/sq cm) to one end of assembly. Measure from inner surface of flange to top surface of spacer ring. Measure depth of case. If clutch assembly-to-housing end play is not to specification, adjust by using thicker or thinner inner clutch discs.

Checking Pinion Gear Torque (Limited Slip Differential) - With differential carrier is assembled, install axle flanges in carrier. Clamp one flange in vice and using an inch pound of torque wrench, turn other flange. If rotating torque of side and pinion gears is not to specifications, install thicker or thinner case cover to clutch assembly thrust washer.

FIG. 13 CHECKING PINION GEAR TORQUE
ON LIMITED SLIP DIFFERENTIAL

Differential Bearing Preload - With differential carrier installed in housing without ring gear, and with carrier bearing retainer plates installed without shims, thread a bolt in against differential pinion gear shaft. Equally tighten retainer plate bolts until specified bearing preload is obtained. Using feeler gauge, check clearance between retainer plate and housing to determine required shim thickness. Take required shims and install them equally under both retainer plates.

Ring-to-Drive Pinion Gear Backlash - After establishing differential bearing preload, check ring-to-pinion gear tooth contact pattern. While maintaining established shim thickness, move shims from one retainer plate to the other, as necessary, to obtain proper contact pattern. After setting backlash, complete differential reassembly procedure.