0 2003 BMW 525I 2.5 L check engine light on and fault codes stored the vehicle operate normally

1. on the basis of the stored codes for secondary air system, there is little or no flow of secondary air into the engine. Typical causes of this problem are unsuccessful the secondary pumps for air and/or secondary air check valve. Secondary air pump must operate under normal circumstances, when the vehicle is beginning to test the system. Pump will usually be heard when standing in front of the right corner of the vehicle. 2 secondary air pump is located in the right front of the engine compartment. Secondary air pump relay located in the glove compartment is controlled by the engine control module and sends energy to the secondary air pump. 3. air pump can be turned off with the power and ground at the pump to check the operation is possible.

4. shut-off valve in front of the right cylinder head can be supplied with vacuum and visually checked to open the valve. 5. the Vacuum line from the valve of the solenoid should also be checked for cracks or unplugged. Vacuum line follows the right side of the cylinder head to the rear of the cylinder head on the secondary air solenoid, located under the left rear side of the intake manifold. 6 Solenoid should allow vacuum flow to the valve during the operation of the vacuum pump. Solenoid is controlled directly by the control module and the engine gets power during key on engine off. Potential causes: A.I.R. Check valve engine control module (ECM) codes-engine control module fault. Faulty secondary air pump secondary air pump relay secondary air supply hose broken vacuum line diagnostic codes: P0491 P0492,

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0 2002 BMW 325I 2.5 L Service Manual

Check engine light on and stored fault codes. The vehicle is working normally. Procedures/tests: 1. on the basis of the stored codes for secondary air system, there is little or no flow of secondary air into the engine. Typical causes of this problem are unsuccessful the secondary pumps for air and/or secondary air check valve. Secondary air pump must operate under normal circumstances, when the vehicle is beginning to test the system. Pump will usually be heard when standing in front of the right corner of the vehicle. 2 secondary air pump is located in the right front of the engine compartment.

Secondary air pump relay located in the glove compartment is controlled by the engine control module and sends energy to the secondary air pump. 3. air pump can be turned off with the power and ground at the pump to check the operation is possible. 4. shut-off valve in front of the right cylinder head can be supplied with vacuum and visually checked to open the valve. 5. the Vacuum line from the valve of the solenoid should also be checked for cracks or unplugged.

Vacuum line follows the right side of the cylinder head to the rear of the cylinder head on the secondary air solenoid, located under the left rear side of the intake manifold. 6 Solenoid should allow vacuum flow to the valve during the operation of the vacuum pump. Solenoid is controlled directly by the control module and the engine gets power during key on engine off. Potential causes: A.I.R. Check valve engine control module (ECM) codes-engine control module fault. Faulty secondary air pump secondary air pump relay secondary air supply hose broken vacuum line.

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0 2000 BMW 528i (E39) SHAFT front wheel removal and installation guide

Replacing the front wheel (hub) (base) Note! Camp cannot be dismantled. Do not wash, camps. Remove brake disc (brake line remains connected), refers to the brakes and controls; Disc brake system. Remove ABS sensor pulse. Remove the balancer connection of the stabilizer, steering and suspension. Open the nut. Installation: use the washer (1). Tapered tap and bore without grease. Replace samozap?vasi. A brace of Hexagon socket if necessary. Tightening torque refer to steering specifications. Click outside the track rod with a special tool 31 2 240.

Mark the installation position of the spring strut tube (1) into the swivel bearing (2) with paint-never marked with describing the tool. Marking is not required if the factory is still identified. R installing position of the right spring strut tube L installation position left of the spring strut tube version with factory markings over a roller bearing. Open the nut. Expand the swivel bearing with special tool 31 2 200 and pull the swivel bearing down. Installation: Click spin bearing up to stop the winch seminar and Note the marking of installation position. Replace samozap?vasi. Tightening torque, refer to suspension specifications open the screws and remove the wheel bearing. Assembly: contact person (2) of the wheel bearing and rotating camp and threaded bores (1) must be clean and free of grease. Tightening torque, refer to suspension specifications

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0 1993 BMW 325i (E36) removal and installation/replacement heater and air conditioning fan (M50, S50, M52)

Air conditioning notes removing and installing/replacing heater and air conditioning fan (M50, S50, M52) further work on the 2-door model: removing the console on the system of the windscreen-wiper. The Position of the windscreen wiper, left, vertically. Pull off the rubber part and pry, Grill. 

Zoom print medium in size for printing * remove screws of the cable channel. * Remove the screws and take off the right side of the holder. * Unscrew the left-hand screw. * Pull out the air manifold in the upward direction. Note: Air collector will be difficult to withdraw. M50, M52 Unclip lids. Unscrew the bolts. Remove the cover plate of the injection valve. Unclip the cover and remove the screws. * Remove the lid open the clips and remove the cover of the fan. * Unplug the connector. * Open the clips and lift the upper left section of the fan. Note: Air conditioning remains installed. Illustration shows air conditioning – removed.

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0 2000 BMW 528i Replacing Front Wheel Bearing

Caution! Bearing cannot be dismantled. Do not wash out bearings. Remove brake disk (brake line remains connected), refer to Brakes and Traction Control; Disc Brake System. Remove ABS impulse sensor. Remove stabilizer link from stabilizer, Steering and Suspension. Unfasten nut. Installation: Use washer (1). Tapered spigot and bore both free of grease. Replace self-locking nut. Brace on hexagon socket if necessary.

Tightening Torque, refer to Steering Specifications. Press off track rod with special tool 31 2 240. Mark the installation position of the spring strut tube (1) in the swivel bearing (2) with paint – never mark with scribing tool. Marking is not required if the factory mark is still identifiable. R installation position of right spring strut tube L installation position of left spring strut tube Version with factory marking above the swivel bearing. Unfasten nut. Expand swivel bearing with special tool 31 2 200 and pull swivel bearing downwards. Installation: Press swivel bearing upwards to stop with workshop hoist and note marking of installation position.

Replace self-locking nut. Tightening Torque, refer to Suspension Specifications Unfasten screws and remove wheel bearing. Installation: Contact face (2) of wheel bearing and swivel bearing and the threaded bores (1) must be clean and free of grease. Tightening Torque, refer to Suspension Specifications

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0 2002 BMW M3 Coupe A/T-SMG transmission clutch Repair manual

Gear indicator in the instrument flashes while driving or at work on site, on-site can be selected, but the clutch is not triggered and indicator flashes. The REASON the "Lid closed" status is not recognized by SMG control module, because one or two micro switches and Hood latch not functioning properly.

1. If one of the micro switches failed, it is possible to put out, but gear indicator in the instrument cluster will Flash. 2. If you have failed and the two micro-switches, gears can be selected, but will not engage the clutch and gear indicator in the instrument cluster will Flash. Micro switch failure may be caused by damage during Assembly, or improper adjustment. Another possible cause is improper treatment of micro-switches during a visit to a workshop. In the seminar should be taken to ensure that no tools are pushed into the lower lid latch assemblies as a switching element of micro switch can be bent or damaged. The opening should not be used for holding tools! ADJUSTMENT based on customer complaints, check function of the two Hood latch micro switches use DISplus or GT1. Replace damaged Lower/lower Hood latch Assembly, or properly Hood adjustment, if necessary. Procedure for correction and specifications can be found in the instructions to repair 41 61 014. PROCEDURE at the time of diagnosis, the switch element of the lower must not be pushed too hard (illustration shows the internal review of the Hood latch Assembly). Illustration shows a bent element switch illustration shows intact micro switch.

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0 BMW 2002 Repair Manuals

This Repair Manual is intended to ensure that the maintenance and repair work required for BMW cars is done in the correct manner. Therefore this manual should be used by inspectors and fitters as it helps to supplement the practical and theoretical knowledge they have acquired at our service training school

What's Inside:

• Auto Transmission
• Body Equipment
• Body Work
• Brakes
• Clutch
• Engine Electrical
• Electrical General
• Engine
• Equipment
• Exhaust
• Foot Pedals
• Front Axle
• Fuel Tank Lines
• Fuel System
• Gear Select
• Gear Box
• Heating and Air Conditioning
• Instrument Panel
• Intro
• Oversize Wiring Diagrams
• Radiator
• Radio
• Seats
• Rear Axle
• Seats
• Steering
• Wheels and Tires
• Wiring Diagrams
• Parts Book
  

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DOWNLOAD PART 5

File Size: 400 MB

File Type: PDF, RAR

0 BMW 1969-73 6 Cylinder Models Brake Repair Manual

Models Covered

• 2500 (1969-70)
• 2800 (1969-70)
• 2800 CS & CSA (1969-71)
• 3.0 CS & CSA (1969-71)
• Bavaria (1972-73)

DESCRIPTION

Models 2800 CS and CSA use ATE four-piston fixed caliper disc brakes on front and leading-trailing shoe drum brake on the rear. All other models use four wheel ATE disc brakes with four-piston caliper on front and two-piston caliper on the rear. All models use twin circuit, tandem piston master cylinders. Four wheel disc brake system use a pressure limiter to control hydraulic pressure applied to rear brakes. Hydraulic pressure to rear brakes is adjustable with the pressure limiter. Hand brake actuates cable to rear brake shoes. A special duo-servo drum-disc combination is used on rear wheels with disc brakes.

ADJUSTMENT

DRUM BRAKES 

2800 CS & CSA - Release handbrake, hoist vehicle and using suitable wrench (6038) loosen each brake shoe with its eccentric adjusting screw. While revolving wheel, turn left adjusting screw counterclockwise and right screw clockwise, until wheel will no longer turn. Loosen each screw ⅛ turn at a time until wheel turns freely.

DISC PADS

Front and rear disc brake assemblies are self-adjusting, therefore, no adjustment in service is required.

PARKING BRAKE

PISTON ALIGNMENT

Disc Brakes (With Integral Drum On Rear) - Release parking brake lever, raise and support vehicle and remove rear wheels. Insert brake adjusting tool through .6" hole in rotor. Turn start wheel adjuster until rotor can no longer be turned, then back off adjuster two or three teeth. Working inside driver compartment, tighten adjustment nut on hand lever until parking brake holds vehicle (before fifth ratchet stop is reached).

Models With Rear Drum Brakes - Drum brakes must be adjusted before attempting to adjust handbrake. Handbrake should be adjusted if hand operated lever can be pulled up more than five notches. Adjust with handbrake lever completely disengage, by turning adjuster on cable and next to hand brake lever. Adjustment is correct when handbrake will lock rear wheels without passing through more than four or five notches on ratchet.

HYDRAULIC SYSTEM BLEEDING

NOTE - Manufacturer recommends replacing brake fluid entire system once a year to avoid moisture build-up. Attach a pressure bleeder to master cylinder reservoir. CAUTION - Do not exceed 29 psi. Raise and support vehicle and remove wheels. Attach a bleeder hose to bleeder screw, and immerse opposite end of hose into a container partially filled with brake fluid. Open bleeder screw, allow all air has been expelled  from system. NOTE - On front wheel four piston calipers, bleed lower inboard screw before bleeding lower outboard screw.

REMOVAL AND INSTALLATION

DRUM BRAKE SHOES

Removal - Hoist vehicle, remove rear wheels and brake drums. Detach brake shoes from bottom support, then pull shoes out of wheel cylinders. Disconnect hand brake cable from rear shoes. Separate shoes by removing return springs.

Installation - Reverse removal procedure and note the following: Install long end of shoe push rod spring toward handbrake lever. Adjust brakes.

DISC PADS

Removal - Raise and support vehicle and remove wheels. Drive out retaining pins toward inside of vehicle and remove cross spring. Using a suitable extractor tool (3.9314-14002), remove disc pads from caliper assembly.

Installation - 1) NOTE -  Replacement of disc pads should be done in complete sets only. Using a cylinder brush, clean guide surface and support surface in caliper. Siphon sufficient fluid from outer cylinder reservoir to prevent overflowing, then press pistons to bottom of bores.

2) On rear two piston calipers, ensure machines position of piston face makes a 20° angle to lower caliper wall. Install disc pads, cross spring and retaining pins. After installation, depress brake pedal several times to position pads against rotor.

CALIPER ASSEMBLY

Removal - Remove master cylinder reservoir cap and plug fluid outlet lines. Raise and support vehicle and remove tire and wheel assembly. Disconnect hydraulic line(s), remove caliper mounting bolts, and separate caliper from caliper from backing plate.

Installation - Reverse removal procedure and bleed hydraulic system.
ROTOR
Removal & Installation (Front) - With caliper assembly removed, remove hub grease cap, cotter pin, and nut. Remove hub and rotor assembly. Remove Allen head bolts retaining rotor to hub and remove rotor. To install, reverse removal procedure, tighten all bolts and fittings evenly, and bleed hydraulic system if necessary. Adjust front wheel bearing. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section.
Removal & Installation (Rear) - Remove rear wheel and caliper assembly, then pull rotor out from axle shaft flange. To install, reverse removal procedure, tighten all bolts and fittings evenly, and bleed hydraulic system if necessary.
PARKING BRAKE SHOES
Removal - With rear caliper and rotor removed, disconnect lower return spring using brake spring pliers. Turn retaining springs 90 degrees using suitable tool (7014) and remove. Pull brake shoes apart at bottom and lift away upwards.
Installation - Reverse removal procedure and adjust parking brake shoes and cables.
MASTER CYLINDER
Removal - Remove master cylinder reservoir cap and plug fluid outlet lines. Remove hose fittings from master cylinder and raise above reservoir fluid level. Mark hydraulic lines for reassembly reference and disconnect from master cylinder. Remove nuts attaching cylinder to power unit, and separate master cylinder from power brake unit.

POWER UNIT PUSH ROD ADJUSTMENTS

Installation - Reverse removal procedure and note the following: Make sure rubber "O" ring seal between master cylinder and power unit is not damaged. Check clearance between power unit thrust rod and master cylinder piston with Plastigage and, if necessary, set to .020" by inserting a shim behind plunger head. Bleed hydraulic system and check for fluid leaks.
POWER BRAKE UNIT
Removal - 1) Remove air cleaner and battery, disconnect oil reservoir for power steering (if equipped) and move to one side. Block brake fluid reservoir outlets and remove hoses from master cylinder.
2) Remove lower left instrument panel housing and secure to one  side. Remove brake pedal clevis pin, and disconnect vacuum hose from intake manifold. Remove hydraulic lines from master cylinder marking positions for reassembly reference. Remove nuts retaining power unit to support and remove power unit.
Installation - Reverse removal procedure, bleed hydraulic system, and check following adjustments: Adjust length of piston rod (A) to 14.49-14.53". Adjust pedal height (B) to 9.65". Adjust exposed depth of brake light switch plunger (C) to .24-.28". See illustration.
Check Valve Replacement - Check valve is located in power unit vacuum line at intake manifold. To remove, loosen hose clamps, remove vacuum hoses, and remove valve. To install, reverse removal procedure, making sure arrow or block portion of valve faces intake manifold.
Filter Replacement - With power brake unit removed from vehicle, pull back rubber dust boot and remove retaining ring. Remove silencer and filter. To install, reverse removal procedure.
REAR BRAKE PRESSURE LIMITER
Removal & Installation - Plug fluid outlets in brake fluid reservoir. Disconnect brake hose and rear brake lines from pressure limiter. Remove mounting bolts and pressure limiter. To install, reverse removal procedure and bleed hydraulic system.

OVERHAUL

DRUM BRAKE WHEEL CYLINDER
Disassembly - With wheel brake drum removed, back off shoe adjusting cams, disconnect brake line and remove cylinder from backing plate. Disassemble wheel cylinder and pay particular attention to location and direction of parts.
Cleaning & Inspection - Clean all parts in alcohol or other suitable non oil base solvent. Discard all rubber parts and inspect all other parts for wear or damage.
Reassembly - Dip new parts in clean brake fluid or apply ATE cylinder paste. To install cylinder, reverse disassembly procedure and bleed brakes.
BRAKE CALIPER
Disassembly - With caliper removed from vehicle and disc pads remove from caliper, remove clamping rings and rubber protecting caps. Hold one piston in place using a suitable clamp, insert a piece of wood in caliper  cavity, then apply compressed air to fluid inlet and remove opposite piston. Remove sealing ring using a suitable plastic tool. Remove remaining piston(s) and seal(s) in same manner. NOTE - DO NOT separate caliper halves unless a leak is detected. To disassemble, remove expansion bolts, separate caliper halves and remove sealing rings.
Cleaning & Inspection - Clean all parts in alcohol and check for wear or damage; replace parts as necessary.
Reassembly - Reassemble caliper (if separated) using new seals and expansion bolts. Tighten expansion bolts from inside out. Coat pistons and caliper bores with ATE brake cylinder paste (or equivalent), install sealing rings, then install pistons into bores. Make sure pistons are not tilted when inserting. On two pison calipers, make sure machined surface of piston face makes a 20 degree angle to lower caliper wall. Install rubber protecting caps and clamp rings.
MASTER CYLINDER
Disassembly - Push in on primary piston and remove secondary piston stop screw. Remove snap ring from end of cylinder and remove primary and secondary piston assemblies and return spring. Disassemble piston assemblies noting number of parts used.
Cleaning & Inspection - Clean all parts in alcohol and inspect for wear or damage. NOTE - Cylinders with surface defects in bores must be replaced; do not overhaul.
Reassembly - Reassemble piston assemblies using a thin coating of ATE brake cylinder paste (or equivalent). Install piston assemblies into cylinder bore using a suitable guide sleeve (BMW 6063) to prevent damaging seals. Install secondary piston stop screw, making sure that piston is pushed fully forward before screw is installed and tightened. Install retaining ring in end of master cylinder bore.

0 BMW 1963-73 4 Cylinder Brakes Repair Manual

Models Covered

• 1600 (1966-71)
• 1600-2 (1966-71)
• 1800 (1963-66)
• 1800 Ti (1963-66)
• 2000 (1966-69)
• 2000 Ti & Tilux (1966-68)
• 2000 CS & CA (1966-67)
• 2002 (1968-73)
• 2002 Ti (1967-72)
• 2002 Tii (1972-73)

DESCRIPTION

Brakes on all models consist of ATE fixed caliper front disc brakes and leading-trailing shoe rear drum brakes. Disc calipers are either two or four piston units. All vehicles from 1970 onward, use tandem piston master cylinders. Hand brake system is operated by lever and cable, and attached to rear brake shoes.

ADJUSTMENT

FRONT DISC BRAKE PADS

Front dis brakes are self-adjusting, therefore, no adjustment in service is required.

REAR DRUM BRAKE SHOES

Raise and support rear of vehicle and release parking brake. Using an offset wrench (BMW 6038), tighten eccentric adjustment nuts while rotating wheel until wheel locks. Loosen adjusting nuts ⅛ turn or until wheel is just free to turn.

PARKING BRAKE

With rear brakes properly adjusted, pull rubber boot on parking brake lever and loosen lock nuts. Pull brake lever up to fifth ratchet stop and check for braking action at rear wheels. If adjustment is required, tighten adjusting nuts until rear wheels are locked. Tighten lock nuts and ensure wheels turn freely with parking brake lever released.

HYDRAULIC SYSTEM BLEEDING

NOTE - Manufacturer recommends replacement of brake fluid in entire system once a year to avoid moisture build-up. Attach a pressure bleeder to master cylinder reservoir. 

NOTE - DO NOT exceed 29 psi. Raise vehicle and remove front wheels. Attach a bleeder hose to bleeder screw and immerse opposite end of hose into a container of brake fluid. Open bleeder screw, allow all air to escape, then close bleeder screw. Continue operation until all air has been bled from system. NOTE - On front disc brakes, bleed lower inboard screw before bleeding lower outboard screw.

REMOVAL AND INSTALLATION

FRONT DISC BRAKE PADS

DISC PAD REMOVAL & INSTALLATION

Removal - Raise and support front of vehicle and remove wheels. Drive retaining pins out toward center of vehicle and remove cross spring. Using a suitable pulling tool (ATE 3.914-1800.2), remove brake pads. If pads are to be reinstalled, mark for reassembly reference. NOTE - Pads are not interchangeable.

Installation - NOTE - Replacement of disc pads should be done in complete sets only. Using a cylinder brush, clean guide surface and support surface in caliper. NOTE - DO NOT use oil based solvents. Siphon sufficient fluid from master cylinder reservoir to prevent overflowing, then press pistons to bottom of bores. Install disc pads, cross spring, and retaining pins. Pump brake pedal several times to position pads against rotor.

FRONT DISC BRAKE CALIPER

Removal - Raise and support front of vehicle and remove wheels. Disconnect hydraulic lines and plug openings. Remove bolts securing caliper to steering knuckle and remove caliper.

Installation - Reverse removal procedure and note the following: Left and right calipers are not interchangeable. When installed, bleeder screws must face upward. Tighten all bolts and fittings evenly and bleed hydraulic system.

FRONT DISC BRAKE ROTOR 

Removal - Remove caliper. NOTE - Do not allow caliper to hang from hydraulic line after removal; support out of way. Remove hub grease cap, cotter pin and nut, then remove hub and rotor assembly from axle. Remove Allen bolts and separate brake rotor from wheel hub. 

Installation - Install rotor onto wheel hub and tighten bolts securely. Install hub and rotor assembly onto axle, install outer wheel bearing, washer and nut. Adjust wheel bearings and install cotter pin and grease cap. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section. Install caliper and bleed hydraulic system if necessary.

REAR BRAKE DRUM

Removal - Remove tire and wheel assembly and loosen eccentric adjusting nuts. Pull drum straight out from axle to remove.

Installation - Install brake drum to axle, install tire and wheel assembly, and adjust brake shoes and parking brake (if required).

REAR BRAKE SHOES

REAR BRAKE ASSEMBLY

Removal (Exc. 1600-2 Models) - Hoist vehicle, remove rear wheels and brake drums. Detach brake shoes from bottom support, then pull shoes out of wheel cylinder. Disconnect hand brake cable from brake lever. Seperate brake shoes bye removing returning springs.

Removal 1600-2 Models - Release hand brake, hoist vehicle and remove cotter pin from axle castle nut. Remove wheel brake drum and axle flange as a unit. NOTE - If flange will not slide off axle, it will be necessary to remove wheel and drum from flange.

Installation (All Models) - Reverse removal procedure and adjust brake shoes. See Drum Brake Adjustment.

REAR BRAKE WHEEL CYLINDER

Removal - With brake drum removed, disconnect hydraulic line, and remove bleeder screw and wheel cylinder attaching bolts. Using on offset wrench (BMW 6038), turn brake shoe eccentric adjusting nuts until shoes are spread out from wheel cylinder as for as possible. Remove wheel cylinder maneuvering out of backing plate.

Installation - Reverse removal procedure and note the following: Make sure rubber "O" ring is installed on master cylinder between cylinder and power unit. Check clearance between master cylinder piston and power unit push rod. Clearance should be .020" and is adjusted by removing or installing shims behind head of power unit push rod.

POWER BRAKE UNIT

Removal - With master cylinder removed, disconnect power unit push rod from pedal assembly by removing clevis pin. Disconnect vacuum line from check valve, remove nuts attaching power unit to support, and remove power brake unit.

Installation - Reverse removal procedure, taking care to install rubber "O" ring on master cylinder between cylinder and power unit.

Check Valve Replacement - Vacuum check valve is located in vacuum line at intake manifold. To remove, loosen hose clamps, separate vacuum hoses from valve, and remove valve. To install, position check valve so that arrows or black portion of valve face intake manifold, install vacuum hoses, and install and tighten clamps.

Filter Replacement - With power brake unit removed from vehicle, remove rubber dust boot, retainer, silencer, and filter. To install, reverse removal procedure making sure slots in filter and silencer are offset 180° in relation to one another.

OVERHAUL

FRONT DISC BRAKE CALIPER
Disassembly - With caliper removed from vehicle, remove rubber protective caps, taking care not to damage pistons. Insert a piece of wood in caliper cavity, and remove pistons by applying compressed air to inlet holes of caliper. Using a plastic (or other soft material) tool, remove sealing rings from caliper bores. NOTE - Do not separate caliper halves unless a leak is detected. To disassemble caliper, remove expansion bolts and separate caliper halves. Remove sealing rings.
Cleaning and Inspection - Clean all parts in alcohol and dry with compressed air. Check cylinder bores, pistons and flange surfaces for rust, corrosion or other damage. Replace parts as necessary, do not attempt to machine caliper bores or pistons.
Reassembly - Reassemble caliper with new sealing rings and expansion bolts if halves were separated. Tighten caliper extension bolts alternately and evenly from inside out. Coat pistons and sealing rings with ATE brake cylinder paste (or equivalent) and install into caliper bores. Install protective caps.
REAR WHEEL CYLINDER 
Disassembly - Remove dust caps, then withdraw piston and seal assemblies and spring. Remove bleeder screw. Remove rubber seals from pistons.
Cleaning and Inspection - Clean all parts in alcohol. Check all parts for wear or damage; replace parts as necessary. Make sure that grooves on cylinder body are not corroded.

PRIMARY (REAR) PISTON ASSEMBLY

Reassembly - Coat all parts with ATE brake cylinder paste (or equivalent) and reverse disassembly procedure. NOTE - Manufacturer recommends replacing piston seals whenever cylinder has been disassembled.
MASTER CYLINDER
Disassembly - Push in on primary piston and remove piston stop screw on top of master cylinder. Remove retaining ring from end of cylinder and withdraw primary piston assembly. Use compressed air to remove secondary piston assembly from cylinder bore, then remove piston return spring. Disassemble piston assemblies, noting number and position of parts used.

SECONDARY (FRONT) PISTON ASSEMBLY

Cleaning and Inspection - Clean all parts in alcohol and check for wear or damage. NOTE - Cylinders with surface defects in bores must be replaced; do not overhaul.
Reassembly - Reassemble piston assemblies using a thin coating of ATE brake cylinder paste (or equivalent). Install piston assemblies into cylinder ore using a suitable guide sleeve (BMW 6063) to prevent damaging seals. Install secondary piston stop screw, making sure that piston is pushed fully forward before screw is installed and tightened. Install retaining ring in end of master cylinder bore.

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.

0 BMW 1969-74 Drive Axles Repair Manual

1969-74 BMW SPLIT HOUSING

MODELS COVERED:

• 2500 Series (1969-70)
• 2800 Series (1969-70)
• 3000 Series (1971-74)

DESCRIPTION

HALF SHAFT CONSTANT VELOSITY JOINT

Differential has hypoid type ring and pinion gear set, and may have one of two cluch 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 lettter "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.

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 joint. Remove dust boot-to-joint surfaces, and install seal cover after packing joint with suitable grease.

STANDARD TWO PINION DIFFERENTIAL ASSEMBLY 

LIMITED SLIP DIFFERENTIALS (TYPICAL)

AXLE SHAFTS AND BEARINGS

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

PULLING 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 flange, follow Differential Carrier, Disassembly and Overhaul procedure, in this 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 is stress free when installed.

OVERHAUL

DISASSEMBLY

CHECKING RING GEAR BACKLASH

Differential Assembly - Remove differential assembly as previously outlined and mount assemly in suitable holding fixture. Drain oil and mark pinion shaft and companion flange for reassemly 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 patter. 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.

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), insert 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.

CHECKING PINION GEAR PRELOAD (TYPICAL)

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

DRIVE PINION GEAR ASSEMBLY

Differential Assembly - Reverse disassemly procdure noting the following checks and adjustments.
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, etch". Compare marks on tapered ends of old and new gears. Subtract the two numbers. In relation to original new gears. Subtract the two number. 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 compnion flange and nut and tighten nut to obtain specified drive pinion bearing preload. NOTE - If preload exceeded, new collapsible spacer must be installed, and this procedure is repeated

CHECKING SIDE-TO-PINION GEAR
BACKLASH (TYPICAL)

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 wahser, 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.

MEASURING TYPE 1 CLUTCH
ASSEMBLY

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

Clutch Assembly End Play (Type 2 Limited Slip Differential) - Without using the four small diameter thrust washers, two small spring washers, or two large spring washers, assemble clutch assembly in housing. Compare depth of housing cover thrust surface and thickness of large spring washers, to distance between edge of housing and outer clutch disc. Install suitable large spring washers to obtain specified end play. NOTE - If excessive end play exists, thicker outer clutch discs may be installed.

MEASURING TYPE 2 CLUTCH
ASSEMBLY

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 is not to specifications, install thicker or thinner case cover-to-clutch assembly thrust washers.

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 contact pinion gear shaft. Install carrier in housing and tighten cover retaining bolts. Check preload by turning flange bolt using on INCH pound torque wrench. When cover bolts are torqued to specifications, 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, shim 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 Gear Backlash.

DIFFERENTIAL BEARING PRELOAD
SHIM THICKNESS MEASUREMENT

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 geaer backlash. Check ring gear tooth contact pattern. NOTE - Refer to Rear 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 patter. After setting backlash, complete differential reassembly procedure.

RING GEAR BACKLASH
SHIM LOCATION (TYPICAL)