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Rearaxle Repairsand Maintenance

Rearaxle 1976-

Contents Page 1 2

Specifications Specialtools Sparepartsillustrations Rearaxleassembly Differential

6 7 B

Limitedslip differential

Descriptions Flearaxle

Diflerential Limitedslipdifferential

10 'tl

Serviceprocedutes

Op.No.

On vehiclerepairs - C h e c k i nl gi m i t e sd l i pd i f f e r e n t i .a. l. . . . - C h e c k i n ge n df l o a o t f a x f es f r " f U t e " r i n g. . . . . . . . . . pi'1ron Beplacrng seal R e p l a c i nagx l es h a f bl e a r i nagn ds e a .| . . . . . . . . . . . . .

12 B1_83

c1-c7

14

D1-D21

Removingrearaxle

21

O i s a s s e m b l irnega ra x l e. . . . . . . . . . . . . . . . . . . . . . . . . - D i f f e r e n t i a l w i t hl oi m u ti t e sdl i p. . . . . . . . . . . . . . . . . . D i f f e r e n tw i ai lt hl i m i t e sdl i p. . . . . . . . . . . - . . . . . . . . . . . - C l e a n i n ign, s p e c t i o n -.. -.. .

F1-F13 F14-Fj7 F18_:F22 F2g

25 28 29

Assemblingdillerenlial - Differential withoutl i m i t e d s l i p . -. . . . . . . . . . . . . . - . . - Differential with limi t e d s | i p. . . . . . . . . . . . . . . . . . . . . . . - Installing pinion . .

G8 G9 G10-G27

34

Installingdifferential Inslallingrearaxle

H1-H20 11 I17

40

TP 30039/2 3000.06.81 Printedin USA

Specilications

Specifications Rearaxle qear ax e. type Track . .

Metric Semi-floating 1 3 5 0m m

USmeasurements 53.1s',

Finaldrive

Tvpe

Hypoid

Reduction ratio Type1030 Type1031 Wa p. ringgea' Backlash............

: 1, 4 . 1 0 : 1 3.73:1 3 ,. 9 1 3.54:1,3.73:1 mm max.0.08 0 . 1 3 - 0 . 1m 8m

0.0032' 0.005-0.007'

Pre-loadingon pinionbearings n e wb e a f l n g s . . . . . . . . . used bearings P.e-loadingon oifferenLial bearngs

25M50 Ncm 6 0 1 1 0N c m 0.13-0.20 rnm

21-39in.lbs. F10 in.lbs. 0.00H.008"

Lubricant OLa iry.standarddi'fere'rial . . I m.reds ip oiffprentral Viscosrlyrormal opa'arirg co'1ditiors. . when temperatureis steadiy below l 5 " F - 1 0 " Cu s e

A P tG L - 5( M i rL - 2 1 0 5 - B ) withadditive APIGL-5(l\lilL-2105-B) for limitedslipdifferential SAE90 SAEBO

Capacity:Type 1030 Type1031

1.3lrters 1.6liters

'1.35 USqts 1 . 7U Sq t s

Tighleningtorques Caps

Nm 50 70

ft.lbs. 35-50

Ring gear:standardbolt heads flangedbolt heads.

70-80 90 110

50-58 65-80

Wheelruls..

1 0 01 4 0

70-100

F l a n g en u t s .8 8 6 2 6( 3 / 4 "U N F ) . . . 946831(3/4"UNF) . . 947855(M20| l5)

240-300 200-250 2A0 250

175-220 145-180 145-180

Gtoup46

Specialtools

Specialtools 1801 Slandardhandle 1845 Presstool3/4'-16UNF installing driveflange 2261 Pullel rounddriveflange 2284 Dialgaugeholder adjusting finaldrive 2337 Tool removlng carrrer 2392 Puller rearpinionbearing 2393 Measuring tool pinion(ill.at 2284) adjusting 2394 Expandingtool removing/installing limitedslip differential 2395 Drift installing rearpinionbearing 2404 Wrench installing frontpinionbearing (ill.at 1845) 2483 Puller differential carrierbearings 2524 Workstand 2522 Fixture 2595 Adlustingrings differential 2598 Dritt removingtearpinionbearingouter r i n g( i l l a . t1 8 0 1 ) 2599 Drilt r e m o v i n g ' r opnitn i o nb e a n go u l e r ringand installing differential carrierbearings 2600 Measuring fixture for adjusting rings2595,2685,2687, 2689and 2840 260'1Relainer torexpanding tool2394(ill.at 2394) 2685 Adlustingring ptnton 2686 Presstool pinionbearingouterrings instalJing 2709 Extractor driveshaft

Group46 Rearaxle

2714 Fixlure removing/installing rearaxle 2779 Socket propeller removing shaft 2806 Drift insialling sealon drivef ange 2809 Holder plateanddialgauge 2838 Presstool rernoving/installing driveshaltbearing andsnapflng 2840 Adlustingring pinionheight(ill.at 2685) 2841 Wrench for adjustingrings2840,2685and 2689(ill.at 2685) 2842 Sleeve installing rearpinionbearingouter ring(ill.at 2395) 2843 Otill removing rearpinionbearingouter r i n g( i l l .a t 1 8 0 1 ) 2844 Puller rearpinionbearing(ill.at 2392) 2845 Presstool installng pinronbedri']qourer'rngs (ir.at 2686) 2846 Socket propeller removing shaft(ill.at 2779) 2917 Extractor brakepads 4112 Drilt instalingdifferential carrierbearings 5009 Drift installing driveshaftinnerseal 5010 Ring installng bearingandsnapringon driveshaft(ill.at 2838) 5069 Puller Pinionseal 5149 Wrench instaliing/removing drivef lange 5156 Presstool instalingdriveflange(ill.at 1845) 5157 Wrench for adjusting ring(ill.at 2685) 5214 Ring (fortool 521515216) 5 2 1 5P u l t e r p i n i o nb e a r i n (1030 g axle) 5216 Puller pinionbearing(103'1 axle)

0) O)

Speclal ioo/s

1801Siandardhandle 2598 Drift removingrearPinionbearing outerrrng 2843 Drilt removingrearPinionbearing outerring

1845Piesstool3/4'-16UNF installing driveflange 2404 wrench inslalling frontpin on beanng 5156 Presstool installlng driveilange

2261Puller round drivef ange

t

\ 2284 Dialgaugeholder finaldrive adjusting 2393Measuringtool pinion adjusting

5215 Puller(1030)new rearpinionbearing 5216 Puller(1031)new rearpinionbearing 5214 Ring

2337 Tool removtng carner

2395 2842

2394 Expanding tool removing/installing limited slipdifferential 2601 Holder forexpanding tool2394

2395 Drift installing rearpinion lreanng 2842Sleeve installing rearpinionbearing outerring

2483

2483Puller differential carrierbearings

Graup46 Rearaxle

3

Specla/tools

2520Worksland 2522Fixture

Adlustingrings differential

2685 Adiustingring prnron 2840 Adlustingring p i n i o nh e i g h t 2600Measuring tixture 2841Wrench for adjustingrings2595,2685, g rings2840,2685 for adjustin 2687, 26A9and 2840 and2689 5157Wrench for adjustingring

Drift removing frontpinionbearing outerringandinstalling difierential carrierbearings

2686 Presstool pinionbearingouter installing flngs 2845 Presslool pinionbearingouter lnstalling rings

g" 2709 Exlractor driveshaft

4

Grouq46 Reataxle

2/14 Fixlure rearaxle removlng/installing

2779 Socket

propellershaft removing 2846 Socket removing shaft Propeller

Specia/tools

2806 Drift installingsealon driveflange

2838 Presstool removlng/installing driveshaft bearingandsnapring 5 0 1 0R i n g installing bearingandsnapring on driveshaft

2809 Holder plateand d al gauge

o 112 )

lr,rl Extractor 0raKepaos

5069Puller pinionseal

Drift installing differentialcarrier oearngs

5009 Drift installing driveshafiinner seal

5149Wrench installng/removing driveflange Gtoup46

SparePartslllustration ALTI

ALT 2

ii ') @l or&-,

s

i

I

Rearaxleassembly

Gtoup46 Reataxle

SparePartslllustration

Differential (Finaldrive)

o o I

o c

,-:1

[-..,\6

\@

Gtoup46

SparcPaftslllustrction

I

I q

{z-vtD '/ ,' \t ,

..*,

\

r\

x

I

o o

DescrtPtton

Description, rearaxle

2. Tralingarm 5. Stabilizer

o

The rearaxle is connectedto the body by 1wo trailingarnrs(2).Longitudinalforces aretransfer redby tworeactionrods{3)andtransversal torces by a track rod (Panhardrod) (4).Trailng arms, reactionrodsand trackrod areattachedto body andrearaxleby replaceable rubberbushings. (not llost vehicles wagons), are equippedwith a rearstabilizer (5)fittedbetween thetrailingarms.

0

Dfiveshafliournaling

TheoLiterendsoi ihe driveshaftsarejournaled In raoe-oller beaflngs,Bea-_g crearancers n o l a d t u s l a b lae_ d i s d e t e r m1 e d b y o e a r i n g design,see Fig. lett. Oil sealsare providedon the outsideof the driveshaft bearings.

Graup46

Description, ditferential

Description

differential gears

shrmsa , d j u s tb a c k l a s h

I 20

nnggearteeth,

s h i m s ,a d j u s ti i x i a l o c a i l o n lhe rlnqgear

nnggear

3 0 iu oeannq

,',

only) {produclion

shims,adlustpin on \

/

beafng pre oad

Thefinaldriveis of the hypoidtype,whichmeans that the drivepinionliesbelowthe centeroTrne rrng gear-lt consistsof pinion,ring gear and gear.Gearbacklashand diiferenta differential carrierbearir1g lensionareadjustedby shimsinsidethedifterential carrierbearings. Differential carrierand ring gear assemblyare journaledin the finaldrivehousingby iwo taper rollerbearings. The ring gearis attachedto the differeniial carrierby bolts.Thedifferentialgears in the diiferentialcarrierconsistof two oevel Group46

p nions on a trunnionand two side gears in whichdr ve shaitsarecarriedby internalsplines. gearsarejournaledso thai they The differential can rotateand permitthe driveshaftsto rotateat d fierentspeedswhenlhe car is beingdnvenin curvesThereis a thrustwasherundereachof thediffereniiagears. Thepinon bearings arelaperro er bearings. The axial locaton oi the p nion relativeto the ring gear s adjusledby shimsunderthe outerraceof the rearp n on bearings.

Descrtptlon

Limitedslip differential brake",'antispin") {"Differential Exceptlor thedifferential assembly, the design isthesameasforstandarddifferential.

4

#

,/!

lai

\? 1 2 3 4

D i f f e r e n t i ac a f i i e r ,s m a e r s e c t i o n D i s c si n t e r n a l t e e t h D i f f e r e n i i asl i d eg e a rr e i a l n e r D i f f e r e n l l apl i n l o nq e a r

5 6 7 8

tr

Spider D i f f e r e na t l carrier largerseclion D i l f e r e n i i asl i d eg e a r D l s c s ,e x t e r n a, t e e t h

Twoshaltsmakeup ihe spiderfor the differential plniongears.On the sidewhereit is againstthe ditferential carrier,each shaft has a V-shaped bevel.Thedifferential carrieris correspondingly designed. WhenpowerfroTnthe enginestartsto drivethevehicle, theshafts(A)g ideup the bevellod re.es. in rhe differerrialcarrer. lhis compresses the frictionplatesbehindthe differential sidegearsso that the ditferential assemblybrak e s T h eb e v eal n g r eo r l h ed ' r e ' e r r i acl a r , r ei.s designed andchosenin sucha waythatthedifferental gearsare not entirelylocked,but max. 75% of enginetorquecan be transmittedto a driveshaft.

Group46

11

.t On-vehiclercpairs - Limitedslipdilfercntial-

Onvehiclerepairs Checkinglimitedslip differential

Fabricale tool As shownin illustrationout of 3/16" steelstock. Specialtool 2709can be used after modifications. necessary

A2

Jack up the vehicle At one of the rearwheels.Blockthe other.Place gearleverin neutral.Release parkingbrake.Removethewheel.

A3

Placetool ovel wheelstuds

Checktorque Thefrictiontorqueof the limitedslip differeniial shouldbe: minimum55 Nm = 40ft.lbs maximum 1 5 0N m = 1 1 0 f t . l b s Notethe torquereadingwhenthe wheelrotares (rotationalfriction).lf torque readingis below minimum,replacediscs.

GtouP46

0

a

?i::nl:::::::; ",.u_

Checkingendfloaton axleshaftbearing

Theendfloatfor the axleshaftscannotbe adjusreo. However, it may be necessaryto determine whethertheendf loatiswithinacceptable limits. B1

Jack up vehicleand removewheel. Removebrakepads. Usepuller29lTif necessarv.

B2

Installmeasuringequipmenl, a. Usetool 2809to clampan iron plateagainst ih6 hr.l6

^.lin6r'