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.

0 Chevrolet LUV 1972-74 Axles Repair Manual

1972-74 Chevrolet LUV

DESCRIPTION

Axle housing is banjo type with removable differential carrier and semi-floating axle shafts. Ring and pinion gears are hypoid type in which centerline of pinion is set below centerline of ring gear. Differential case is one piece, two pinion design. The axle shafts are retained in housing by cone type roller bearing retainers at axle housing outer ends.

AXLE RATIO AND IDENTIFICATION

All LUV models are equipped with one type of 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 Shafts and Bearings

Removal - Raise vehicle and remove wheel and tire assembly. Remove brake drum, brake shoes and disconnect parking brake inner cable. Disconnect brake line from wheel cylinder and cover end to prevent loss of fluid and entry of dirt. From inboard side of brake backing plate, remove four nuts from the bearing holder through bolts. Pull axle shaft from housing.

Bearing Replacement - 1) Flatten locking tab of lock washer, then mount axel shaft in a vise, clamping vise jaws around lock nut. Using suitabl tool (J-24246) positioned on lub bolts, turn axle shaft loose from lock nut. Mount axle assembly in a press and remove lock nut, lock washer, bearing and holder, and brake backing plate. Remove oil seal from outboard side of bearing holder, then drive off bearing outer race with a drift.

2) To reassemble, install bearing outer race and grease seal into bearing holder using suitable drivers. Apply wheel bearing grease to bearing holder, rear axle tube, and bearing inner race. Insert the four through bolts into backing plate, making sure oil seal side of bearing holder is against backing plate. Place backing plate assembly over axle shaft, position bearing over axle shaft and press into bearing holder. Install new lock washer with dished side away from bearing, and thread lock nut onto shaft. Place lock nut between vise jaws, and using tool used during disassembly, tighten lock nut securely. Bend over portion of lock washer opposite locating tab to prevent lock nut from turning.

AXLE SHAFT SHIM SELECTION

Installation - 1) If both axle shafts were removed ,isert a .079 (2 mm) shim between bearing holder and axle tube flange of first axle shaft to be installed. Insert shaft into axle tube and install and tighten bearing holder-to-flange bolts. For the second axle shaft (or if only on shaft was removed), insert shaft without shims into axle tube until it comes in contact with thrust block in differential. Measure clearance between bearing holder and axle tube flange (see illustration).

2) Proper size shim for this location may be determined by adding .004" (.1 mm) to measurement just obtained. Select a shim or combination of shims, withdraw axle shaft, and install shims between bearing holder and flange face. Reinstall axle shaft and tighte four though bolts. Connect brake line to wheel cylinder, then install brake shoed, parking brake cable, and brake drum. Install wheel and tire assembly, adjust broken and bleed system.

DIFFERENTIAL CARRIER

Removal and Installation - Raise rear of vehicle, remove wheels and brake drums, and disconnect brake lines at rear wheel cylinders. Disconnect parking brace cable brackets at rear spring locations, remove four through bolts from each end flange, and partially with draw axle shafts from axle tubes. Disconnect propeller shaft from pinion flange and place out of way. Remove nuts attaching carrier to axl housing and remove carrier assembly To install, reverse removal procedure, making sure to refill axle with lubricant.

OVERHAUL

Disassembly

REMOVING PINION SHAFT LOCK PIN

1) Mark side bearing caps for reassembly reference, remove nuts and bearing caps, then remove differential case assembly. NOTE - Keep right and left side bearing races with respective bearings. Remove differential side bearings from case using a suitable puller and adapter (J-22888 and J-81072). Record thickness of each side bearing and each shim pack, then place with appropriate bearing race.

2) Remove ring gear bolts and separate ring gear from case. Drive out pinion shaft lock pin using a long drift. NOTE - It may be necessary to remove caulking in lock pin using a 5mm drill. Remove pinion shaft using a drift, then withdraw thrust block, pinion gears, side gears, and thrust washers.

3) Remove pinion nut and pinion flange. Drive the pinion gear from carrier using a soft hammer or drift. Withdraw front pinion bearing and oil seal. Using a drift, remove pinion bearing races from carrier. Mount pinion gear in a press and remove rear pinion bearing and depth shim from pinion gear.

REASSEMBLY AND ADJUSTMENT

Drive Pinion Depth - 1) Install front and rear pinion bearing races into carrier bores, lubricate pinion bearings, and position in respective races. Install a suitable gauging plate (J-23597-7) and preload stud and pilot (J-23597-9) through pinion bearings and tighten nut snugly. Rotate bearings to insure proper seating, then tighten lock nut until 20 in. lbs. (25 cmkg) of torque are required to rotate new bearings, or 8-10 In. Lbs. (9.2-11.5 cmkg) are required to rotate used bearings.

TOOL SETUP FOR MEASURING PINION
DEPTH

2) Place mounting discs (J-23597-8) onto arbot tool (J-23597-1) and place assembly in position in side bearing bores. Install bearing caps. Mount dial indicator on arbor post, preload dial 1/2 revolution, then tighten indicator in this position. Position indicator plunder on gauge plate, slowly swing across until highest reading of gauge plate. Swing plunger off gauge plate and note indicator reading. Reading is the correct thickness of rear pinion bearing depth shim for a nominal to .101". An indicator reading of .000" or .001" requires shims of .100" and .101" respectively.

3) Examine head of drive pinion; pinion depth code is stamped by chemical ink and is the lower of three numbers. A "+" (plus) number indicates need for greater mounting distance (decrease shim thickness), while a "-" (minus) number indicates need for smaller mounting distance (increased shim thickness). See following chart to determine proper shim variation to compensate for plus or minus markings. NOTE - If no pinion depth code is present, pinion is "nominal" and no correction to dial indicator reading is required.

Pinion code                                        Correction Required

+10............................................ Subtract .005" (.13 mm)

+8.............................................. Subtract .004" (.10 mm)

+6.............................................. Subtract .003" (.08 mm)

+4.............................................. Subtract .002" (.03 mm)

+2.............................................. Subtract .001" (.03 mm)

0................................................ No Correction Required

-2............................................... Add .001" (.03 mm)

-4............................................... Add .002" (.05 mm)

-6............................................... Add .003" (.08 mm)

-8............................................... Add .004" (.10 mm)

-10............................................. Add .005" (.13 mm)

4) Place selected shim on drive pinion and press rear bearing on pinion. NOTE - Do not press on roller cage; press only on bearing inner race. Remove gauging tools from carrier.

Pinion Bearing Preload (W/ Solid Bearing Spacer) -  1) Place drive pinion and bearing spacer into carrier, then position original pinion shim and front pinion bearing over pinion gear. Install pinion flange and nut, tightening nut snugly. NOTE - Do not install oil seal at this time. Rotate bearing to insure proper seating, then tighten pinion nut to 190 ft lbs. (26.3 mkg). Wind a small amount of string (approximately 4-6 windings) around pinion flange. Using a pull scale, note pull scale reading required to rotate flange.

2) Reading should be approximately 13-17 lbs. (5.9 - 7.7 kg) for new bearings, or 8-10 lbs (3.6-4.5 kg) for reused bearings. If necessary to adjust preload, remove nut and pinion flange and remove or install shims behind front bearing. Shim are available in thicknesses of .003" (.08 mm), .005" (.13 mm), and .010" (.25 mm). NOTE -To increase preload, decrease shim thickness; to decrease preload, increase shim thickness. When correct preload is obtained, remove pinion nut and flange, install oil seal, then reinstall flange using a new pinion nut.

Pinion Bearing Preload (W/Collapsible Bearing Spacer) - 1) Place drive pinion and collapsible spacer into carrier, then install front pinion bearing and oil seal. Mount pinion flange on drive pinion, apply lubricant to pinion threads, install pinion nut and tighten to 85 ft. lbs. (11.3 mkg). Rotate pinion to insure bearings are seated, then wind a small amount of string (approximately 4-6 windings) around pinion flange. Using a pull scale, note reading required to rotate flange.

2) Continue tightening nut in small increments until pull required to rotate flange in 17 lbs. (7.7 kg) for new bearings or 7-9 lbs (3.2-4.1 kg) for reused bearings. CAUTION - Preload builds quickly. Nut should be tightened only in small increments and pull scale used after each small amount of tightening. If preload is exceeded, a new collapsible bearing spacer must be intalled.

Case Assembly - Install side gears and thrust washers in case. Position thrust washers 180 degrees apart, then roll gears into position making sure they are in alignment to allow installation of pinion shaft. Place thrust block between pinion gears and drive pinion shaft into position, making sure roll pin hole aligns with hole in case. Measure backlash between side gears and pinion gears; if greater than .003" (.08 mm), install selective thrust washers to bring backlash within specifications. Washers are available in thicknesses of .037" (.94 mm), .041" (1.04 mm), and .045" (1.14 mm). NOTE - Increasing washer thickness decreases backlash; decreasing washer thickness increases backlash. Install lock pin into pinion shaft and caulk end to prevent loosening. Install ring gear into position on case, apply Lactite to bolt threads, and install and tighten ring gear to case bolts in a diagonal sequence.

Backlash & Side Bearing Preload - 1) If original side bearings, differential case, ring and pinion, and differential case, ring and pinion, and differential carrier are being reused, the original shims may be reinstalled in their respective positions. If only new side bearings are being installed, measure new bearings with a micrometer and compare thickness with original bearings. If new bearing is thicker, SUBTRACT difference from shim pack. If new bearing is thinner, ADD difference to shim pack.

CHECKING  RING GEAR RUNOUT

2) If new bearings and/or differential case, ring and pinion, or differential carrier are being installed, new shims must be selected as follows: Install side bearings onto differential case, but do not install shims at this time. Mount case into carrier bores. Move ring gear tightly against carrier on ring gear side (away from pinion), and hold in this position. Using a feeler gauge, measure clearance between bearing and differential carrier on side opposite ring gear. Record clearance.

3) A predetermined dimension (.018" on 1972 models, .002" on 1973 and later model(s) is needed to establish proper preload. Therefore, ADD this dimension to clearance obtained in this step 2) for proper preload. This will give necessary combined total thickness of both shim packs. Divide the total dimension into two packs equals the difference between original shim packs.

4) Remove case from carrier, remove side bearings and install shim packs, then reinstall bearings. Install differential case into carrier, tapping carefully into place. Install side bearing caps in original positions, install and tighten attaching bolts. Measure run-out of ring gear (see illustration). If run-out exceeds .002" (.05 mm), correct by cleaning or replacement of parts.

CHECKING RING AND PINION
BACKLASH

5) Mount a dial indicator against ring gear teeth and measure backlash in three locations. Backlash should be .005-.007 (.13-.18 mm): if not, shims behind side bearings must be adjusted. NOTE - To maintain preload when backlash is adjusted, the total thickness of both shim packs must not be altered. Therefore, if it is necessary to increase one shim pack, the opposite shim pack must be decreased by the same amount. To increase backlash, right side bearing shim must be increased, and left side decreased. To decrease backlash, rigth side shim must be decreased, and left side increased. NOTE - Backlash changes approximately .002" (.05 mm) for each .003 (.08 mm) shim change. After adjustment, make gear tooth pattern check to insure correct assembly.

0 Courier 1975-77 Drive Axles Repair Guide

DESCRIPTION

This axle assembly incorporates a removable carrier differential, having a hypoid type ring and pinion gear set, with the pinion being retained in the carrier by a companion flange and nut. Semi-floating axles are secured in the housing by the axle shaft bearing retainers.

IDENTIFICATION

Only one type of axle assembly is used. Axle ratio for manual transmission models is 4.11-1 and for automatic transmission models is 4.65-1. This can be determined by dividing the number of teeth on ring gear by the number on the pinion gear.

REMOVAL AND INSTALLATION

Axle Shafts and Bearing

Removal - After removing complete brake assembly, including nuts securing backing plate and bearing housing-to-axle housing, slide axle shaft out of housing. Remove inner oil seal from axle shaft, spread locking tabs on lock washer, then using a suitable spanner (T72J-4252) remove lock nut and washer. Using a suitable puller (T72J-1225), remove bearing with housing from shaft. Remove bearing cup and outer seal from bearing housing.

Installation - Using suitable tool (T72J-1177), install new outer seal in bearing housing. Press or drive new bearing cup into retainer using suitable tool (T72J-4252-B). Install brake backing plate and bearing housing on axle shaft, then position bearing on axle shaft. NOTE - Insure bearing taper points in the right direction. Slide a suitable tool (T72J-4252-A) over shaft, place axle shaft on end in press, and press bearing into place. Install lock washer and nut, using a spanner to tighten nut. Install axle shaft and loosely assemble two bolts through bearing housing and axle housing flange. Mount a dial indicator to backing plate so axle end play can be measured. NOTE - If both axles have been removed, check end play of each shaft as it is installed. If end play is not to specifications, adjustment is made by using appropriate shims between axle housing flange and bearing housing. After correct end play is obtained, install and tighten as necessary, all remaining components.

FIG. 1 EXPANDED VIEW OF COURIER DIFFERENTIAL ASSEMBLY

DIFFERENTIAL CARRIER

FIG. 2 EXPLODED VIEW OF AXLE ASSEMBLY

Removal - Raise and support vehicle. Drain lubricant from differential, replace drain plug, then remove axle shafts as previously outlined. Mark drive shaft and companion flange at differential for reference at time of reassembly, then remove drive shaft. Remove carrier-to-housing retaining nuts, then remove ccarrier from housing.

Installation - Reverse removal procesure using a suitable sealer between the carrier and axle housing, and insure drive shaft-to-companion flange reference marks are aligned.

OVERHAUL

FIG. 3 CHECKING RING GEAR
BACKFACE RUNOUT

1) Remove differential carrier as previously outlined, then mount carrier assembly in a suitable holding fixture with ring gear facing upward. Mount a dial indicator to carrier housing and check ring gear runout for reference at time of reassembly. Also make a gear tooth contact pattern check. Refer to Rear Axle Gear Tooth Patterns in this section.

2) Punch mark differential bearing caps and adjusters for reference at time of reassembly. Remove adjuster lock plates. Loosen bearing cup nuts and back off adjusters using a suitable spanner (T72J-4076). NOTE - Adjuster on left has left hand thread. Remove nuts, bearing caps, and adjuster, keeping each bearing cap with its own adjuster.

3) Lift out differential assembly keeping each bearing outer race with its own bearing. To remove differential bearings, use a suitable puller (T70P-4221). Remove bolts and locks retaining gear to case, then remove ring gear. Drive out differential pinion shaft lock pin and remove pinion shaft and thrust block. Rotate pinion gears 90 degrees and remove them. Lift out differential side gears along with their trust washers.

4) Hold pinion gear companion flange and remove nut, then the flange. Remove drive pinion and rear bearing. NOTE - If required, use soft headed mallet to tap pinion gear from case, and guide pinion out to avoid damage to gear teeth. Remove collapsible spacer, oil seal and front bearing. Remove pinion bearing races from carrier using a drift in the slots provided. Remove bearing from pinion gear using a suitable tool (T72J-4630) and remove shim from pinion gear.

REASSEMBLY AND ADJUSTMENT

Case Assembly 1) If original ring and pinion gear set is being installed, use original shim between bearing and pinion head. If a new gear set is being installed, determine the size of shim to use in the following manner: Drive pinions may be stamped either "+1,2,3" or "-1,2,3", or they may be unmarked. Compare marks on tapered ends of old and new gears. Subtract the two number. Subtract the two number. A plus remainder means to install a thinner shim than the original. A minus remainder means to install a thicker shim than the original. If the  number is the same on both gears or if both gears are unmarked, use the original shim. NOTE - Shims are available in thicknesses from .120" to .135" (3.048 mm to 3.429 mm) in increments of .001" (.025 mm).

FIG. 6 INSTALLING DRIVE
PINION BEARING RACES

2) Using suitable driver (T72J-4616) install pinion gear bearing races. Install selected shim on pinion gear then install bearing on pinion using suitable tool (T70P-4625) and a press, Install pinion gear and bearing in carrier followed by the collapsible spacer, front bearing, oil seal and companion flange. Install, but do not tighten, companion flange nut.

3) Using an inch pound torque wrench on companion flange nut, rotate pinion gear and note drag o foil seal. Remove inch pound torque wrench and start tightening nut. As nut is tightened, keep checking rotating torque with inch pound torque wrench. When nut is tightened to 145 foot pounds (20.0 mkg) minimum and rotating torque is 11.3-15.6 INCH (20.0 mkg) pounds (13-18 ckg) plus the oil seal drag, preload is correct. NOTE - If preload is exceeded, install new colllapsible spacer and repeat procedure. Do not back-off nut to obtain preload.

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

FIG. 7 CHECKING PINION-TO-GEAR
BACKLASH

Side-to-Pinion Gear Backlash - After installing side and pinion gears, insert pinion shaft, without thrust block, into its proper position. Chec side-to-pinion gear backlash. If backlash exceeds .008" (.20 mm), refer to table and install appropriate side gear thrust washers to obtain the correct backlash. Remove pinion shaft, then reinstall it with the thrust block.

                      Side Gear Thrust Washers 

I.D. Mark                                  Thickness

6..............................................  .063" (1.6 mm)

7..............................................  .067" (1.7 mm)

8..............................................  .071" (1.8 mm)

Ring-to-Drive Pinion Gear Backlash - After differential is completely assembled and installed in carrier, snug bearing cap nuts. Turn adjusters, using spanner, until bearings are properly seated and end play is eliminated with a slight amount of ring-to-drive pinion gear backlash. Slightly tighten one bearing cap nut on each side. Mount dial indicator to carrier flange with indicator plunger set at a right angle to rign gear teeth. Check ring-to-drive pinion gear backlash of four or five points around ring gear. Turn both adjusters equally to obtain specified. Proceed by setting differential bearing preload.

FIG. 8 CHECKING DIFFERENTIAL BEARING PRELOAD