REAR AXLE - jholst.net
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1. 8 INSTALLATION OF DRIVE PINION SHAFT BEARING CONES AND CUPS Place bearing cups in position in carrier refer to Tool set C 758 D 3 Fig 21 and proceed as follows With bearing cups squarely in posi tion in carrier assemble Tool C 758 D 3 by placing pinion rear bearing over main screw of tool Fig 22 and insert tool into carrier from gear side Place the pinion front bearing over main screw followed by adaptor SP 535 washer SP 534 and nut SP 533 Fig 23 Press bearing cups into place by tightening tool nut as shown in Figure 24 Allow tool to rotate slightly in order not to damage bearings or cups during this operation CAUTION Do not install pinion oil seal during preload and pinion setting operations otherwise there will be added drag on pinion giving a false bearing preload on torque wrench Pinion Bearing Pre load Adjustment The importance of correct pinion bearing pre load cannot be over emphasized The selection of adjusting washers to give the desired pre load should be carefully made When pinion SP 1730 SLEEVE 52x379 A Fig 22 Bearing Installed on Main Body of Tool C 758 D 3 CHRYSLER SERVICE MANUAL COMPRESSION SLEEVE TOOL CENTRALIZING WASHER TOOL FRONT BEARING NUT TOOL 5712 Fig 23 Compression Sleeve and Centralizing Washer Positioned in Carrier bearings are installed without pre loading the cones are not drawn far enough into their cups to bring t2. REAR AXLE 11 Pre loading the pinion and differential bear ing is important because it holds the drive pin ion and differential in place and prevents back and forth movement which would create incor rect gear and pinion tooth contact NOTE If the differential assembly was satis factory from the standpoint of noise before be ing disassembled the drive pinion may be as sembled with the original adjusting washers PINION LOCATING WASHER OR SHIM ASSEMBLY OF SP 526 CARRIER ASSEMBLY ASSEMBLY A OF SP 526 gm FIRST SET UP TIGHTEN GAUGE TO 40 50 FOOT POUNDS AND DETERMINE PINION LOCATING WASHER ONLY PRE DETERMINED PINION LOCATING ONE WASHER SECOND SET UP USE PRE DETERMINED PINION WASHER AND PINION SPACER TO DETERMINE PINION BEARING PRELOAD SPACE PINION BEARING PRELOAD SPACER CARRIER ASSEMBLY Fig 25 Used on New Yorker Imperial Tool C 758 D 3 Installed in Housing 12 REAR AXLE and shims If replacement parts are installed or differential adjustment is necessary the prop er thickness washer must be installed between the pinion and rear bearing The drive gear and pinion are manufactured and lapped in pairs The position in which the best tooth contact is obtained is etched on end of pinion shaft To obtain proper pinion setting in relation to drive gear the correct thickness thrust wash er must be selected before drive pinion is in stalled in ca
3. bearing and bearing cup Fig 38 the bearing cup is driven into the axle housing with Tool C 413 until the face of installing tool bottoms tightly against the shims Remove tool and in stall the dust shield lockwashers and nuts Tighten 30 35 foot pounds torque Working from the opposite end of the axle housing install the other axle shaft with bear ing until inner end of axle shaft contacts the axle shaft thrust block Lightly tap end of axle shaft with a fibre mallet to insure shaft is con tacting the thrust block this will force the REAR AXLE 17 x 56x235A Fig 38 Installing Axle Drive Shaft Bearing Cup with Tool C 413 opposite shaft away from the thrust block to its full travel Install the bearing cups carefully Fig 38 until no axle shaft end play exists without pre loading the bearing Rotate axle shaft during installation of the cup to properly seat bearing NOTE The bearing cup will protrude beyond the face of the axle flange Hold the tool firmly against the bearing cup and install a feeler gauge between the axle housing flange and the face of the tool This measurement will be approximately 040 inch To obtain 013 to 018 inch axle shaft end play add a minimum of 013 to whatever the feeler gauge reading indicates NOTE It is recommended that the end play be held to the high limit rather than the low The end play will decrease during operation due to heat expansion CAUTION When
4. Gear Runout REAR AXLE 15 Fig 33 Adjusting Differential Bearings Screw in adjuster on tooth side until indi cator shows 006 to 008 inch backlash Lock adjusting nuts in place and tighten both top bolts 110 foot pounds torque Secure the dial indicator to the carrier flange so pointer of indicator is squarely contacting one of the drive gear teeth thrust side Fig 34 After the first reading is taken move the dial indicator away from the gear tooth and rotate and check drive gear at 90 degree in tervals for specified backlash between drive gear and pinion If adjustment is followed the bearing supports will be spread differential bearings pre loaded and backlash between drive gear and pinion established CAUTION Whenever adjustment of differential assembly is changed to obtain correct tooth contact re Fig 34 Checking Back Lash between Drive Gear and Pinion 16 REAR AXLE Fig 35 Heavy Face Contact adjust differential bearing pre load and back lash between drive gear and pinion If all adjustment have been correctly made the gears will be properly meshed and quiet operation will result 13 GEAR ADJUSTING FOR CORRECT TOOTH CONTACT Check tooth contact by means of gear marking compound applied to drive gear teeth as shown in Figure 34 Apply load against back face of drive gear with a round bar as drive pinion is rotated This leaves a bare area the size shape and location o
5. pinion away from the center of the drive gear by using a thinner washer behind pinion Re adjust backlash CHRYSLER SERVICE MANUAL 14 INSTALLATION OF DIFFERENTIAL CARRIER Check carrier flange and flange face for nicks and burrs Mount differential and carrier to axle housing using a new gasket Tighten as sembly mounting nuts 35 foot pounds torque 15 AXLE DRIVE SHAFT REPLACEMENT AND END PLAY ADJUSTMENT Loosen the brake shoe cams and remove the rear hub and drum assemblies with puller Tool C 845 Fig 3 NOTE Do not attempt to remove the brake drums by hammering on end of an axle drive shaft as damage to the bearings and thrust block will result Disconnect the brake line at each cylinder and remove the brake support plates and dust shields as assemblies NOTE Remove axle shaft keys and install Tool C 745 for LC1 and LC 2 and C 757 for LC 3 and LY 1 to protect the axle outer seal Fig 4 Remove shims Remove axle drive shafts and bearing cups Fig 5 Remove inner oil seals Fig 7 NOTE It is advisable to replace inner and outer oil seals when replacing an axle drive shaft Clean all parts thoroughly Inspect bearings and cups for brinnelling and axle shaft for signs of fatigue or worn bearing and seal sur faces Install shims totaling 040 inch at one end of the axle housing Shims are available in 05 010 0125 015 and 030 inch thickness Lu bricate the bearing and install the axle shaft
6. pounds If bearing pre load is more than 35 inch pounds a thicker shim should be used under front bearings Shims are available in thickness of 010 012 014 016 018 020 022 024 and 026 inch If bearing pre load is less than 25 inch pounds a thinner shim should be used NOTE Correct pre load readings can only be obtained with pinion shaft tool in a vertical position CHRYSLER SERVICE MANUAL GAUGE BLOCK TOOL ems Fig 27 Installing Gauge Block on Main Body Assemble gauge block SP 528 Fig 27 to main screw Place SP 561 bearing arbor in carrier bearing supports as shown in Figure 28 NOTE Remove any burrs or upsets in bearing supports before installing bearing arbor as ar bor must be securely seated in bottom of bear ing bores Center arbor in differential bearing pedestals of carrier Insert a piece of 002 inch shim stock between arbor and each cap and tighten caps to 10 foot pounds torque Select a pinion wash er of sufficient thickness so that it will just pass between gauge block end of setting tool and machined surface of arbor as shown in Figure 29 For example if a 090 inch washer can be inserted but a 092 washer cannot be forced between the two surfaces by hand the 090 Fig 28 Installing Arbor REAR AXLE 13 inch washer should be used even though it might feel loose Check end of drive pinion as it should indicate amount that should be added or subtracted fr
7. remove the carrier cap shim stock and arbor from carrier housing Disassemble tool from carrier Install pinion setting washer over pinion stem with chamfered side against the pinion Make certain the contacting surfaces of rear bearing cone are perfectly clean Install cone on stem and press bearing on stem with Tool DD 955 Fig 30 Install the selected shim pack Lubricate pinion front and rear bearing cones with heavy oil Apply a light coat of sealer in carrier bore at seal area and install new seal driving seal with Tool C 3656 until driver bottoms on pin ion front bearing Fig 31 Seal installed Install companion flange on pinion stem with Tool C 496 Holding companion flange with Tool C 784 tighten nut to 240 foot pounds torque 11 PINION BEARING PRE LOAD AND PINION SETTING LC 3 LY 1 Check the bearing cups and carrier for grit and dirt Assemble washer SP 2921 followed by correct pinion locating washer and spacer SP 2920 along with rear bearing on main shaft of Tool C 758 D 3 Insert tool bearing and washer assembly in carrier along with original shims previously removed from drive pinion Install front bearing compression sleeve SP 535 centralizing washer SP 534 and main nut SP 533 Hold compression sleeve nut with hold ing Tool C 784 or C 3281 and torque nut to 240 foot pounds PRESS REAR BEARING CONE DRIVE PINION 352x382 Fig 30 Installing Pinion Bearing Cone on Pinion Shaft CHRYSLE
8. same shaft and on opposite sides of the V so that the total shaft to case clearance can be checked Do this for both shafts Clearance should not exceed 020 inch If clearance exceeds 020 inch with exist ing clutch plates install new plates and recheck If clearance is still excessive check shafts and case for wear CHRYSLER SERVICE MANUAL FEELER GAUGE ae UE i PINION SHAFT Fig 60 Checking Clearance between Pinion Mate Shafts and V in Case 26 INSTALLATION Install drive gear and differential assembly in the same manner as outlined under the con ventional differential assembly LUBRICATION Fill Sure Grip Differential with 314 pints of special differential lubricant MOPAR 1879414 Check level of unit after filling SERVICE DIAGNOSIS 27 REAR WHEEL NOISE Wheel loose on axle shaft c P Worn drum or axle shaft keyways Wheel hub bolts loose Brinnelled or scored wheel bearings eo Insufficient lubrication e nh D Improper shimming at axle bearing g Bent or spring axle shaft 28 REAR AXLE NOISE a Lubricant level too low b End play in drive pinion bearings Also see paragraph 3 Gear noise on coast c Excessive gear lash between ring gear and pinion Also see paragraph 3 Gear noise on pull d Loose drive pinion companion flange nut e Scuffed gear tooth contact surfaces 29 REAR AXLE GEAR NOISE a Gear noise on pull a heavy pitch noise
9. shafts should be inspected and replaced if there is evidence of damage The axle shaft should REAR AXLE 5 be free of nicks and burrs before assembly NOTE Gaskets and other seals should be re placed whenever they are removed as an insur ance against leakage Bearings thrust washers and differential pinion shaft should be thor oughly lubricated before final assembly SERVICE PROCEDURES 2 REMOVAL OF DIFFERENTIAL CARRIER ASSEMBLY All models Raise car off floor and block the brake pedal PULLER TOOL 56x233A Fig 3 Removing Hub and Drum Assemblies SEAL PROTECTING SLEEVE TOOL dy OIL SEAL Fig 4 Removing or Installing Protective Sleeve so pedal cannot be depressed Drain lubricant from housing Back off brake shoes with Tool C 845 Remove rear wheels hub and drum as semblies as shown in Figure 3 Disconnect the brake line at wheel cylinders Remove rear axle drive shaft keys install special sleeve Tool C 757 in axle outer oil seal Fig 4 and remove the brake backing plate Remove the shims from each end of axle housing Each set should be kept separate so that at reassembly the PULLER REAR AXLE SHAFT 46x140 Fig 5 Removing Axle Shaft and Bearing Fig 6 Removing Bearing from Axle Shaft 6 REAR AXLE central location of the axle shafts and thrust block will be maintained Remove axle shafts and bearings from housing using puller Tool C 499 Fig 5 If
10. CHRYSLER SERVICE MANUAL REAR AXLE 1 Section II REAR AXLE CONTENTS Page Removal of Differential Carrier Assembly o ooooooomoo mmm 5 Removing Drive Gear and Case Assembly 0 02 eee eee eee eee 6 Drive Pinion and Bearing Disassembly 0 0 0 cece eee eee eee 8 Pinion Bearing Pre Load and Pinion Setung 11 Gear Adjustment for Correct Tooth Contact 16 Differential Carrier Installation o oooooocrorrrrrroooo 17 Axle Shaft End Play Adjustment ro eee 17 Axle Drive Shaft Bearing 6 605443 20h A gedd 18 Rear Axle Housing Alignment 0000s nannan earen ee 18 Sure Grip Differential ro 19 Service DIAGDOSIS e aia 24 DATA AND SPECIFICATIONS Rear Axle LC 1 LC 2 LC 3 LY 1 Semi Floating Semi Floating Hypoid Hypoid 8 75 8 75 2 2 Tapered Roller Tapered Roller Shim Pack Shim Pack Differential Bearings anunnnnaan rruan 2 2 d KEE Tapered Roller Tapered Roller Adj stment es dr os Threaded Adjuster Threaded Adjuster 2 REAR AXLE CHRYSLER SERVICE MANUAL REAR AXLE DATA AND SPECIFICATIONS Continued Rear Axle LC 1 LC 2 LC 3 LY 1 Drive Gear Pidi0N Matched Sets Matched Sets Drive Gear Run Out 005 Maximum 005 Maximum Drive Gear and Pinion Backlash 006 to 008 006 to 008 Differential Side Gear Clearance 0 to 008 Axle PUO des tob e deg dedicas Standard Torque Elbe odess
11. E DRIVE PINION IN DIFFERENTIAL CASE CLUTCH PLATES IIA ELL A nana 7 Gg S st S Fe ES x AXLE SHAFT LA N N LLL NA m N EEN uui a DIFFERENTIAL SIDE GEAR yet DIFFERENTIAL PINION AA TITTLE LL EL Ai A 58x261 Fig 48 Power Flow Axle Shafts Turning at Same Speed friction of the differential gears make the pinion shafts resist turning so that the driv ing force causes the pinion shaft ramps to slide against the differential case ramps push ing the pinion shafts apart slightly As the pinion shafts move outward two of the pin ions on one of the pinion shafts bears against one of the pinion thrust members and the two pinions on the other pinion shaft bear against the other thrust member Each thrust member is splined to one of the axle shafts and drives REAR AXLE 2 um AXLE DRIVE GEAR j AXLE DRIVE PINION SS SS Z DIFFERENTIAL CASE AAA Y T SN PLATES a PZZ SH Ee DIFFERENTIAL PINION ODM MMMM i he AXLE SHAFT AXLE SHAFT Y DIFFERENTIAL SIDE GEAR i Uy AL SOS T IM EMEN SS 58x262 Fig 49 Power Flow Axle Shafts Turning at Differential Speeds two friction plates of the clutch The other two friction plates of each clutch are attached to the differential case so that when they
12. R SERVICE MANUAL A Jl rr Mas ES Fig 31 Pinion Seal Installed With an inch pound torque wrench rotate wrench in a clockwise direction several revolu tions to seat bearings The correct torque read ing should be from 25 to 35 inch pounds If bearing preload is more than 35 inch pounds a thicker shim should be used under front bear ing cone Shims are available in thicknesses of 012 016 018 020 022 024 and 026 inch If bearing preload is less than 25 inch pounds a thinner shim should be used NOTE Correct pre load can only be obtained with tool in a vertical position Remove tool with shim pack bearing cone pinion locating washer and spacer from car rier Assembly of Pinion in Carrier With stem end of pinion facing up install se lected washer on pinion stem Chamfered side of washer facing the drive pinion head Posi tion rear bearing cone on pinion stem Make sure contacting surfaces of washer pinion head and rear bearing cone are perfectly clean and free of dirt or foreign particles Install rear bearing cone onto pinion stem with Tool DD 955 Install selected shim pack Lubricate pin ion front and rear bearings Insert pinion stem and bearing assembly in carrier Apply a light coat of sealer in carrier bore at seal area and install new seal with Tool C 3656 until driver bottoms on pinion front bearing Fig 31 Seal installed Support pinion gear in car rier and start companion flange wit
13. RAW bata aes Driver Axle Shaft Inner Oil Seal 5845 or C310 reso Lr Er ESSERE E Puller Universal Wheel and Hub La EE Driver Axle Shaft Outer Seal C8906 EE Driver Axle Shaft Outer Seal End Brake Support DD 996 or DIO85 Installing Sleeve Pinion Bearing DD 914 8 lcd Ring Medium Reducer use with DD 914 89 19 D02 Desarollo aid Wrench Differential Case Cap Remover and Installer DD 993 L aeoiceio orrena rere n Puller Pinion Oil Seal DD 908 aaa Installing Tool Companion Flange or Yoke DDSI005 19 ehh A er ene EROR Driver Differential Case Side and Cross Shaft Roller Bearing TIGHTENING REFERENCE Foot Pounds Axle Shaft Mute 145 minimum Brake Support Plate to Housing Mounting Bolt Nuts oooooooooo o 35 Differential Carrier to Axle Housing Bolt Nuts unnnnnannanannunenu nenna 45 Rear Axle Drive Gear Bolt Nuts A8 Differential Bearing Cap Bolt Nuts rn S 110 Pinion Shaft Companion Flange Nut 2 0 0 cee cee eee eee eect een 240 minimum 4 REAR AXLE CHRYSLER SERVICE MANUAL Section II REAR AXLE l DRIVE GEAR ASSEMBLIES Cleaning and inspection of parts after dis assembly is very important Metal chips not cleaned from housing and carrier after a fail ure may cause excessive part wear and future The rear axles Figs 1 and 2 are semi float ing type with two pinion differentials and hy poid drive gear and pini
14. a ee eae e mc e dU 2 93 No Drive Gear Teeth 41 No Drive Pinion Teeth 14 Type Recommended Multi Purpose Gear Lubricant SUR BID uo uut eed ee am AM Rer eL M RUE 90 Ate cob wey men dedero ados ed Sa dus 90 Extreme Cold erae nd i a 80 Capacidad rta 31 Pints Wheel Bearings d KEE Tapered Roller Adjustment iria aa Select Shims O aR ERE US Pha er 013 to 018 Road Clearance Full Load 7 4 7 6 T amp C Wago Ee EES 7 4 SOCAN osea doa ix tuii a eg aoa C CR eR UPS Tread Rear iii S dos 59 62 60 35 T amp C Wagon Luar awe pad See Bose EL 59 62 e b 0 EE CHRYSLER SERVICE MANUAL REAR AXLE 3 SPECIAL TOOLS Tool Number Tool Name er crm Puller Rear Axle Shaft and Inner Oil Seal C208 irritada Aa Puller Sets Roller Bearing CA06A EE Wrench Differential Bearing Adjusting o d Driver Axle Shaft Outer Bearing Cup C 3339 or CA O ori Dial Indicator Set E EE Puller Companion Flange or Yoke CA ect ete as dos beet e ee Puller Axle Shaft CGAAn eee CER dou pes Puller Utility Calo dates Sleeve Axle Shaft Oil Seal Outer E e Eege Seene Sleeve Axle Shaft Oil Seal Outer CAT DRED setts cess ota e bee ord dte b dots Gauge Pinion Bearing Pre Load and Cone Angle Setting 0592810 s niei Bae Geman ad velita ndis esa xt Wrench Companion Flange on Yoke Holding 7 830 cd Loa Rei e
15. ading and abnormal clutch opera tion b Improper gear adjustment 35 OVERHEATING OF AXLE UNIT a Lubricant level too low b Bearings adjusted too light c Bearings adjusted too tight d Excessive wear in gears e Insufficient drive gear to pinion clearance 36 LOSS OF LUBRICANT a Lubricant level too high b Clogged breather c Scored or worn parts
16. adjusting axle shaft end play equal thick ness of shims should be removed or installed on both sides of axle housing to maintain the cen tralized position of axle shaft thrust block Remove the tool and install the correct shim pack thickness which has been determined After axle shaft end play has been checked and corrected install brake drum and wheel assembly Tighten axle shaft nuts to a mini mum of 145 foot pounds torque Install cotter keys and hub caps 18 REAR AXLE 16 INNER OIL SEAL AXLE SHAFT REMOVED a Removal Remove inner oil seal with puller Tool C 637 Fig 7 b Installation Drive seal into axle counterbore until it is squarely bottomed Fig 39 The lip of seal is away from drive flange of tool 17 BRAKE DUST SHIELD OIL SEAL a Removal With brake dust shield removed remove outer seal Fig 40 b Installation Install seal with outside marking on seal re tainer toward brake shoe side of brake dust shield 18 BEARING AXLE DRIVE SHAFT a Removal With axle shaft removed remove bearing with puller Tool C 293 Fig 6 b Installation Press bearing on shaft Fig 41 and lubricate bearing rollers with Multi Purpose Gear Lu bricant Install the outer bearing cups with Tool C 413 Fig 38 19 WELDING REAR AXLE HOUSING The axle housing should be completely disas sembled if it is to be welded with arc welding equipment It is also possible to weld the as 56x234 A Fi
17. and increases as car speed increases indicates scored gear teeth due to loss of lubricant ex cessive gear lash or wrong type of lubricant b Gear noise on coast noise is heavy and irregular indicating excessive end play in pinion bearings c Bearing noise on pull or coast a rough grating sound that may change slightly in vol ume as speed changes indicates that the rear axle pinion bearings are chipped cracked scored badly worn and loose or no gear lash 30 CLICKING NOISE IN DRIVE LINE Noise in drive line when vehicle is backed up CHRYSLER SERVICE MANUAL or moved forward Clean axle shaft taper keys and drums Apply a heavy coating of chalk around entire circumference and length of the tapered section of rear axle shaft Install drums and tighten axle shaft nuts 145 foot pounds torque minimum Check universal joints and flange splines Tighten companion flange nut 250 280 foot pounds torque 31 REAR AXLE DRIVE SHAFT BREAKAGE a Improperly adjusted wheel bearings bh Abnormal clutch operation c Misaligned axle housing d Vehicle overloaded 32 DIFFERENTIAL CASE BREAKAGE a Improper differential bearing adjustment b Abnormal clutch operation c Excessive drive gear clearance d Vehicle overloaded REAR AXLE 25 33 DIFFERENTIAL SIDE GEAR BROKEN a Worn thrust washers b Misaligned or bent axle shaft c Overloading vehicle 34 TOOTH BREAKAGE Drive Gear and Pinion a Overlo
18. are en gaged both axles shafts become clutched to the case to a degree that varies with the amount of torque transmitted This in effect locks the axle shafts in nor mal straight ahead driving thus prevents momentary spinning of the wheels when en countering poor traction Refer to Figures 48 and 49 for Power Flow SERVICE PROCEDURES WARNING Before raising a rear wheel off the ground shut off engine set parking brake tightly carefully block front wheel diagonally opposite the one to be removed against both forward and rear ward movement 23 REMOVAL AND INSTALLATION OF DIFFERENTIAL Follow the same procedure outlined under re moval and installation of the conventional rear axle differential 24 DISASSEMBLY Remove axle drive gear Check runout of drive gear mounting flange Replace both case halves if runout exceeds 003 inch NOTE Before disassembling case halves place scribe marks on each half to aid in aligning yo MES E GROOVE GROOVE 58x718 Fig 50 Case Halves Scribed for Proper Reassembly case when reassembling Fig 50 Remove case cap attaching bolts and remove case cap Fig 51 Remove clutch plates Fig 52 noting relation of clutch plates Remove side gear retainer Fig 53 Remove side gear Fig 54 Remove pinion shafts with pinion gears Fig 55 Remove remaining side gear Fig 56 side gear retainer Fig 57 and clutch plates Fig 58 Remove axle shaft s
19. ay from drive gear and with installing Tool DD 1005 install bearing cones Make certain that contacting surfaces of drive gear and flange are clean and free from burrs Position drive gear on case aligning the threaded holes of drive gear with those in the case flange Insert drive gear cap screws through case flange and into drive gear After it has been ascertained that all cap screws are properly started into their respective threads tap gear onto case with a fiber mallet until it seats properly on case flange Position drive gear between brass jaws of vise and alternately tighten each cap screw to 55 foot pounds torque Place differential bearing cups over bearings and install complete assembly in carrier Seat the adjusting nuts in the cap pedestals of car GAUGE BLOCK WRENCH CROSS BORE SP 528 TUBE SP 561 d screw SLEEVE SP 2920 COMPRESSION SLEEVE SP 535 SLEEVE SP 1682 D ba COMPRESSION A CENTRALIZING Q NUT _SP 533 II SP CER SP 2921 WASHER SP 534 Q j dH wes SPACER PL mew 1730 SE E PINION LOCATING SPACER SP 2919 57x438 Fig 21 Special Tool Set C 758 D 3 10 REAR AXLE rier and install caps and bolts Be sure caps are on the same side from which they were re moved Adjust and remove excessive play from bearings Check drive gear for runout as shown in Figure 20 NOTE If there is more than 003 inch runout the differential case should be replaced
20. ecrease torque or remove shims to increase torque After correct pinion setting and bearing preload has been obtained remove drive pinion flange install oi seal and tighten drive pinion flange washer and nut to proper torque Install drive gear with grease marking compound and adjust for correct tooth contact and backlash 10 PINION BEARING PRE LOAD AND PINION SETTING WITH TOOL C 758 D 3 LC 1 LC 2 and Town and Country Wagon Lubricate pinion bearing cones Install locating washer SP 2919 on tool mainshaft Position rear pinion bearing cone on main screw of Tool C 758 D 3 followed by pinion bearing spacer NOTE Spacer has a larger bore at one end install large bore end of spacer next to rear bearing Install sleeve Tool SP 1730 on tool main screw with sleeve bottoming against the tool main screw shoulder Install original shims re moved from drive pinion over the tool main screw and sleeve and against spacer Position the carrier in stand so companion flange is facing upwards Insert tool in carrier Install pinion front bearing and compression sleeve Tool SP 535 Install tool centralizing washer SP 534 followed by the main screw nut Tool SP 533 Hold compression sleeve Tool SP 535 with holding Tool C 784 or C 3281 tighten nut to 240 foot pounds torque Fig 26 With an inch pound torque wrench on the nut of tool rotate wrench several revolutions to seat bearings Fig 24 The correct read ing should be 25 to 35 inch
21. emove the drive gear to case attaching cap screws and remove drive gear Drive gear to case bolts are left hand SCRIBE MARKS fi PUNCH MARKS Fig 10 Marking Caps and Adjusters CHRYSLER SERVICE MANUAL 57x7 Fig 11 Checking Drive Gear Mounting Flange threads turn clockwise to loosen Tap drive gear off case using a fibre hammer To check differential case runout after removal of drive gear mount differential case and bearings with out drive gear in carrier and adjust Remove excessive play from the bearings with adjust ers Mount a dial indicator on carrier mounting face and check the drive gear mounting flange PLATES TOOL 57x8 Fig 12 Removing Differential Case Bearings 57x9 Fig 13 Removing Differential Pinion Shaft Locl Pins runout as shown in Figure 11 Runout should not exceed 003 inch After checking the runout of the assembly remove the differential case assembly from car rier Use Tool C 293 in combination with 3 Number 18 adapter plates behind bearings to pull off the differential bearings from case as shown in Figure 12 If axle is equipped with a Sure Grip differential refer to Paragraph 23 for service procedure Remove differential pinion shaft lock pin by driving pin from case with a hammer and punch as shown in Figure 13 Drive the dif ferential pinion shaft out of differential case using a brass drift and hammer Rotate one differential gear until each pinion ap
22. es It has four pinion gears positioned in the case by two pinion shafts which are at right angles to each other and loose fitting at their intersection Both ends of each shaft have two flat surfaces or ramps which mate with identical ramps in the differ ential case There is additional clearance in the case to permit a slight peripheral move ment of the ends of the pinion shafts within the case 22 OPERATION Fig 47 Torque delivered by the engine is transmitted to the rear wheels via the axle drive pinion PINION THRUST MEMBER S 4 AXLE SHAFT t Ds N Y 77 SNE Se OS E NY EI DIFFERENTIAL SIDE GEAR CHRYSLER SERVICE MANUAL PINION SHAFT DIFFERENTIAL PINION DIFFERENTIAL CASE aan ah ER a PINION THRUST MEMBER DIFFERENTIAL PINION PINION SHAFT 58x260 Fig 46 Sure Grip Differential Cut away and drive gear to the differential case and to the pinion shafts which are rotated by the case The pinion shafts carry the pinion gears around rotating the differential side gears and the axle shafts which are splined to the side gears The friction of the wheels against the road the inertia of the wheels themselves and the aA UH DEER EXE M CLUTCH PLATES aie A dap XQ Kg RAY AXLE SHAFT as LLEN LLAD DIFFERENTIAL PINION SHAFT DIFFERENTIAL PINION 58x259 Fig 47 Sure Grip Differentia Cross Section CHRYSLER SERVICE MANUAL AXLE DRIVE GEAR AXL
23. f contact If improper tooth con tact is evident as indicated by Fig 35 and 36 the pinion should be adjusted either forward or backward maintaining the backlash within Fig 36 Heavy Flank Contact CHRYSLER SERVICE MANUAL Fig 37 Correct Gear Tooth Contact specified limits until correct tooth contact as shown in Figure 37 is obtained With adjust ments properly made correct tooth contact as shown in Figure 37 will result Notice that contact pattern is well centered on the drive and coast sides about Yg inch from edges of teeth When tooth marks are obtained by hand they are apt to be rather smal Under an ac tual operating load however the contact area increases Figures 35 and 36 show improper or incorrect tooth contact To correct such conditions readjust drive gear and pinion as follows a Heavy Face Contact If tooth marking is across the length of tooth narrow and high on the tooth face as shown in Figure 36 the teeth will roll over or gall This type of contact causes excessive wear and noise To correct heavy face contact move the pinion in toward center of drive gear by in stalling a thicker washer behind pinion Read just backlash b Heavy Flank Contact If tooth marking is across the length of tooth but narrow and low on the flank as shown in Figure 36 the teeth will gall or score This type of contact causes excessive wear and noise To correct heavy flank contact move the
24. g 39 Installing Axle Shaft Inner Oil Seal with Tool C 839 CHRYSLER SERVICE MANUAL DRIVER TOOL e BRAKE SUPPORT OIL SEAL 56x178 Fig 40 Removing Rear Axle Shaft Oil Seal from Brake Support with Tool C 839 sembled housing with gas welding equipment if precaution is taken to protect gaskets and heat treated parts 20 REAR AXLE HOUSING ALIGNMENT Rear Axle housings may become bent bowed or warped If not corrected such conditions will cause premature axle failure Disassemble axle assembly and check housing for horizontal and vertical alignment as follows d Checking Axle Housing for Horizontal Alignment Place axle housing in V blocks on surface plate Turn housing until machined surface for carrier mounting is facing UP and perfectly level as shown in Figure 42 Place square REAR AXLE SHAFT BEARING CONE AND ROLLERS 49x714 Fig 41 Installing Axle Shaft Bearing CHRYSLER SERVICE MANUAL REAR AXLE 19 Fig 43 Checking Horizontal Alignment against machined surface of housing end flange and surface plate as shown in Figure 43 Amount of housing misalignment will be in dicated by thickness of feeler gauge between square and end flange at top or bottom A hous ing that checks more than 007 inch should be replaced b Checking Axle Housing for Vertical Alignment With housing in V blocks turn housing un til machined surface for carrier mounting is i
25. h installing Tool C 496 or DD 999 Install plain washer CHRYSLER SERVICE MANUAL concave side of washer down and nut Torque flange nut 240 foot pounds and remove tool 12 DIFFERENTIAL BEARING PRE LOAD AND BACKLASH NOTE The differential bearing pre load and backlash between drive gear and pinion are ob tained after the pinion bearing pre load and pinion are established Place differential and drive gear assembly on the bearing support and snug down the caps Check drive gear for runout on the back face Fig 32 Drive gear runout should be true within 005 inch maximum Make adjustments as follows Using two spanner wrenches Tool C 406 Fig 33 screw out bearing adjuster at back face of drive gear and screw in the opposite adjuster until considerable backlash is obtained This helps align bearing cups Tighten bearing cap lower bolts 110 foot pounds torque leaving top bolts fairly loose This holds bearing cups in line while moving drive gear Screw out adjuster on tooth side of gear until it clears bearing cup Screw in opposite adjuster until only a little backlash remains This will insure bearing cup alignment for final adjustment Turn drive gear a few times by hand to seat bearings With a dial indicator find point of least backlash on drive gear at 90 degree in tervals At least point of backlash screw in adjuster at back face of drive gear until 001 inch appears on indicator Fig 32 Checking Ring
26. he rollers in full contact with thrust ribs on cones Bearings installed in this man ner would allow pinion to walk backward and forward under operating loads This causes a variation in tooth contact pattern resulting in excessive wear and scoring of gears and usually is accompanied by noise On the other hand where the pinion bearing cones are drawn too far into their cups the bearings are over loaded even before they have to withstand operating loads imposed upon them by gears They are apt to burn up under a driving load the rollers might score the cups causing bearings to gall or flake resulting in premature axle failure Correct cone distance is obtained by use of a spacer and washer combination Do not in stall pinion oil seal during pre load and pinion setting operations otherwise there will be an added drag on pinion shaft which would give a false bearing pre load on the torque wrench 57x15 T Fig 24 Seating Bearing Cups and Checking Torque CHRYSLER SERVICE MANUAL 9 PINION BEARING PRELOAD AND PINION SETTING Without using special Tool C 758 D 3 Correct drive gear and pinion adjustment con sists of following Pinion Bearing Pre load Pinion Setting Differential Bearing Pre load and Backlash between Drive Gear and Pinion The final inspection of these adjustments is performed by checking the tooth contact pat terns as described in Paragraph 13 ZN a ED SP 528 SP 2919 S NO
27. ing splines of retainer with internal splined clutch plates Install one side gear Fig 56 Install a lock pin in one of the axle thrust spacers drive pin until pin appears at thrust end of spacer but does not extend beyond thrust face Align the pinion shafts and install spacer and pin through holes in pinion shafts Install the other axle shaft thrust spacer en gaging the lock pin as shown in Figure 59 Press spacer onto the lock pin until the two spacers are in contact Thrust spacers are a loose fit in pinion shafts PINION SHAFTS LOCK PIN n 58x727 Fig 59 Installing Axle Shaft Thrust Spacers 24 REAR AXLE Install the four pinion gears on the pinion shafts and install the shafts and pinions as sembly in position Fig 55 Install side gear Fig 54 side gear retainer Fig 53 and clutch plates Fig 52 Install clutch plates al ternately with one thick plate with tang fac ing side gear retainer followed by an internal splined plate until 5 plates are installed NOTE The thin plate approximately 1 16 inch should be installed so that it will be towards the case cap Install case cap as shown in Figure 51 Make sure that scribe marks are in alignment as shown in Figure 50 Install cap attaching bolts Tighten evenly to 40 foot pounds torque Check the clearance between the pinion mate shaft and the V of the case as shown in Figure 60 Place feeler gauges on both ends of the
28. low dry with compressed air Remove any chips or foreign material from carrier Inspect all machined surfaces for nicks burrs or scratches including inner and outer thrust shoulders of differential case The thrust shoul der on adjusters must be free from burrs so that bearing cups will seat properly Check differential case for cracks fractures distor tion or damage Install a new case if necessary The bearings should be immersed in clean sol vent and rotated by hand until clean After cleaning blow dry with compressed air Do not spin the bearings with air pressure when blowing them dry as they are likely to score due to absence of any lubrication Check bear ings for roughness or brinelling The bearings must run free and show no indication of rough ness or wear Examine bearing cups for pitting scoring or wear Inspect all gears for chipped or worn gear teeth Check the fit of differential gears on axle shaft splines and pinions on pinion shaft Check thrust washers for wear and replace if necessary Inspect axle shafts splines for wear cracks or distortion Replace necessary parts NO 36 PLATES 52x374 Fig 18 Removing Pinion Bearing from Shaft Puller C 293 F2 CHRYSLER SERVICE MANUAL 7 ASSEMBLING THE DIFFERENTIAL CASE AND PINION GEARS If new differential gears are to be installed coat parts with Multi Purpose Gear Lubricant Install a new thrust washer over hub of each gear and install in positio
29. n Fig 45 Checking Vertical Alignment a squared vertical position as shown in Figure 44 Place a square against machined surface of housing end flange and surface plate as shown in Figure 45 Amount of housing misalignment will be indicated by thickness of feeler gauge between square and end flange at top or bot tom A housing that checks more than 007 inch should be replaced To determine amount that axle is misaligned multiply thickness of feeler stock used by the ratio of 4 7 to 1 SURE GRIP DIFFERENTIAL The conventional rear axle delivers the same amount of torque to both axle shafts The driv ing force is therefore limited by the wheel which has the least amount of traction If one of the rear wheels gets on an icy patch or into soft mud its friction against the road lowers suddenly so that the Torque delivered to that wheel is often great enough to overcome fric tion causing the wheel to spin To overcome these characteristics of the con 20 REAR AXLE ventional differential the Sure Grip differential permits the axle shaft whose wheel has the greater traction to develop a considerable amount of torque thus enabling the car to pull out of its difficulty 21 DESCRIPTION Fig 46 The Sure Grip differential is similar to the conventional differential except for the addi tion of friction plates for clutching the differ ential case to the differential gears and a means for engaging these plat
30. n in differential case Insert each of two pinions through the large side opening of case Fig 18 so that pinion shaft holes of two pinions and their thrust washers are properly aligned Rotate gears 90 degrees so that pinion shaft holes of case are in exact alignment with holes in the two thrust washers and pinions From the pinion shaft lock pin hole side of case insert the slotted portion of pinion shaft through case the con ical thrust washer just through one pinion gear Install the thrust block between two pinion gears IMPORTANT The thrust block must be installed so that hole in block is aligned with pinion shaft and with the ground sides facing the two differential gears While keeping all of these parts in proper alignment push the pinion shaft on through until locking pin hole in pinion shaft is in exact alignment with its respective hole in case NOTE Before installing pinion shaft lock pin rotate the differential gears They must turn freely throughout the 360 degree revolution The clearance between each gear and case ranges from 001 to 012 inch This clearance has been established to ascertain free rotation THRUST BLOCK Fig 19 Installing Differential Bearings REAR AXLE 9 Fig 20 Checking Drive Gear Runout Install pinion shaft lock pin through hole in case from the pinion shaft side of the drive gear flange Position each differential bearing cone on hub of case Fig 19 taper aw
31. necessary remove bear ings from the axle shafts using bearing puller Tool C 293 with adapter plate No 13 as shown in Figure 6 Remove the rear axle shaft inner oil seals using puller Tool C 637 Fig 7 to remove the inner seal and Tool C 839 for the outer as shown in Figure 8 Disconnect the rear univer sal joint and drop the prop shaft Remove bolts attaching the carrier assembly to axle housing and remove carrier assembly Clean carrier as sembly in suitable solvent 3 REMOVING DRIVE GEAR AND CASE ASSEMBLY Check gear tooth pattern on drive gear drive gear to pinion backlash before disassembly Fig 9 With carrier assembly mounted in REAR AXLE SHAFT INNER OIL SEAL i Y Y 49x713 A Fig 7 Removing Inner Oil Seal Using Tool C 637 TOOL DRIVER TOOL o BRAKE SUPPORT OIL SEAL 56x178 Fig 8 Removing Outer Axle Shaft Oil Seal with Tool C 839 CHRYSLER SERVICE MANUAL Fig 9 Checking Drive Gear and Pinion Backlash stand mark both differential bearing caps and adjusters if unit is to be checked for a specific noise condition as shown in Figure 10 before removing caps adjusters and drive gear as sembly from carrier NOTE The caps must NOT be interchanged as they are line bored with the carrier at man ufacture 4 DISASSEMBLY AND INSPECTION OF DIFFERENTIAL DRIVE GEAR AND CASE ASSEMBLY Place differential case and drive gear assembly in a suitable fixture and r
32. om washer that was selected in above check Example If mark on pinion shaft indicated 2 a 002 inch thinner washer should be used for final assembly If spacer selected by the use of tool is 090 inch it is necessary to deduct 002 inch The correct washer therefore for final assembly would be 088 inch When correct washer has been selected for drive pinion disassemble tool from carrier Add washer selected to tool between spacer SP 2921 and pinion rear bearing Add spacer SP 2920 and the pinion bearing adjusting spac er that was removed from the axle at disas sembly Insert tool assembly in carrier Slide front bearing on shaft and into position in its cup Install tool spacer nut and washer Tight en tool 240 minimum foot pounds torque as shown in Figure 24 Turn the tool with a speed wrench to permit bearings to seat When bear ings are seated check bearing pre load by re volving tool using an inch pound torque wrench as shown in Figure 27 The correct bearing pre load should be 25 to 35 inch pounds torque If the bearing adjustment does not conform to above specifications it will be necessary to change the adjustment by using a thicker or thinner bearing spacer A thicker spacer should be used if pre load is too great or a thinner spacer if pre load is not sufficient When cor rect spacer has been selected for drive pinion 449x615 Fig 29 Determining Spacer Washer Thickness 14 REAR AXLE bearings
33. on The drive gear and Ss failures pinion on all models are serviced only in matched sets to insure smooth quiet operation Bearing cones and cups should be carefully DR BOLT AND LOCKWASHER WASHER PUE SPACER BEARING ke SE BEARING CONE GUARD Se BEARING CONE ADJUSTER CUP SEAL FLANGE NO E eg SHIMS A NUT Ob ax Ei habe DRIVE GEAR AND AS A x p PINION P C Gaal E Se BOLT i n VK WASHER e SEI Nk Y kg 0 CARRIER BOLT Zaff Lock E gust VAHER di CAP pl BEARING CONE k UNEN E Bareer ADJUSTER BOLT AND LOCKWASHER THRUST WASHER THRUST WASHER 57 x 2 Fig 1 Rear Axle Exploded View LC 1 LC 2 SHAFT THRUST WASHER BOLT AND LOCKWASHER BEARING DIFFERENTIAL CASE FLANGE am DRIVE GEAR PIN LOCK BEARING CONE BEARING CONE ADJUSTER SEAL NUT CUP m i J i x p ng um t e EN 4 D AND PINION Lo Se 6t Ri ull WASHER NC gf lt S d PD a US ao z GUARD j amp 2 A p LS 3 f p ii 4 4 a KD e SIDE GEAR AR T A THRUST WASHER THRUST BLOCK PINION THRUST WASHER BEARING CONE BOLT AND LOCKWASHER GE ADJUSTING WASHER THRUST WASHER 57 x 1 Fig 2 Rear Axle Exploded View LC 3 LY 1 CHRYSLER SERVICE MANUAL checked for discoloration due to overheating and for surface wear Axle housing should also be checked for broken welds or bent sections Rear spring seats should be inspected to make sure they are not broken or loose Axle
34. pacer by pressing out lock pin 25 ASSEMBLY Clean all parts thoroughly Inspect all parts for wear nicks and burrs Replace worn cracked or distorted clutch plates If case is worn it will be necessary to replace both halves Install clutch plates alternately so that an external tanged plate approximately 4 inch thick is installed first followed by an internal CLUTCH PLATES SIDE GEAR RETAINER 58x719 Fig 51 Removing or Installing Differential Case Cap CHRYSLER SERVICE MANUAL CLUTCH PLATES SIDE GEAR RETAINER 58x720 Cap Side SIDE GEAR RETAI SE SIDE GEAR 58x721 Fig 53 Removing or Installing Side Gear Retainer Cap Side SIDE GEAR AXLE SHAFT THRUST SPACER 58x722 Fig 54 Removing or Installing Side Gear Cap Side CHRYSLER SERVICE MANUAL PINION SHAFTS THRUST SPACE a 58x723 Fig 55 Removing or installing Pinion Shafts SIDE GEAR RETAINER ee 58x724 Fig 56 Removing or Installing Side Gear from Differential Case en RETAINER d DIFFERENTIAL CASE ee 58x725 Removing or Installing Side Gear Retainer from Differential Case CLUTCH PLATES 58x726 Fig 58 Removing or Installing Clutch Plates from Differential Case splined plate until 5 plates are installed The thin plate approximately 4 inch should be installed so that it will be toward the case Install one side gear retainer Fig 57 en gag
35. pears at the large opening of case Remove each pinion and thrust washer one at a time as shown in Figure 14 Lift out rear axle drive shaft thrust block PINIONS THRUST WASHERS PINION SHAFT HOLE PEN 57x10 Fig 14 Removing or Installing Pinion Gear 8 REAR AXLE Fig 15 Removing Companion Flange Nut 5 DISASSEMBLY OF DRIVE PINION AND BEARING ASSEMBLY Remove the companion flange retaining nut and Belleville washer Fig 15 and with puller Tool C 452 and flange holding Tool C 784 re move the companion flange as shown in Figure 16 Insert pinion oil seal puller Tool C 748 into seal and remove seal from carrier as shown in Figure 17 Remove pinion bearing washer bearing cone and pre load shims or spacer if so equipped Remove pinion from carrier If necessary remove the rear bearing from pin ion stem with puller Tool C 293 and four adapter plates as shown in Figure 18 Slide the pinion adjusting washer off stem If nec essary remove both bearing cups from carrier housing using a suitable drift Place drift al ternately in the two machined slots in order to drive cups out evenly Clean carrier pinion and related parts in suitable solvent inspect and replace parts as necessary 6 CLEANING AND INSPECTION Clean all parts thoroughly in a suitable solvent Fig 16 Removing Companion Flange CHRYSLER SERVICE MANUAL Fig 17 Removing Drive Pinion Bearing Oil Seal and b
36. rrier Pinion bearing adjusting washers are available from 084 inch to 100 inch in 002 inch steps To select proper thick ness thrust washer proceed as follows It will be noted that face of the drive pinion is etched with plus or minus sign followed by a number ranging from 1 to 4 or zero 0 marking If old and new pinion have the same marking and if old bearing is being used use a thrust washer of same thickness But if old pinion is marked zero 0 and new pinion is marked 2 try a 002 thinner washer If new pinion is marked 2 try a 002 inch thicker washer If bearing cups are to be replaced place the bearing cups in position in carrier and drive cups in place with suitable drift After prop erly positioning bearing cups in carrier as semble drive pinion thrust washer chamfered side down toward gear on drive pinion stem Install rear bearing spacer if so equipped and shims on pinion stem Insert shaft into carrier Install front pinion bearing and uni versal joint flange washer and nut Do not in stall oil seal Tighten rear axle drive pinion flange nut to 240 foot pounds torque Rotate drive pinion shaft after tightening flange nut 57x13 Fig 26 Tightening Compression Nut CHRYSLER SERVICE MANUAL with wrench to properly seat the bearing rol lers in bearing cups Pre load torque required to rotate pinion shaft with bearings oiled should be 25 to 35 inch pounds torque Add shims to d
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