REAR AXLE DATA AND SPECIFICATIONS
Contents
1. REAR AXLE SHAFT 46x140 Fig 7 Removing Axle Drive Shaft and Bearing Using Tool C 499 2 Block brake pedal so it cannot be depressed 3 Disconnect brake line at wheel cylinder 4 Remove the rear axle drive shaft key and install the special sleeve Tool C 757 in the axle bearing outer oil seal before re moving the brake support from the axle housing as shown in Figure 6 5 Remove the shims from each end of the axle housing Shims should be kept sepa rate so that they can be reinstalled in the same position as they came off the axle housing so as to keep the axle shaft thrust block centralized in the differential as sembly Fig 8 Removing Bearing from Axle Drive Shaft t Axle drive shaft 2 tool C 293 C 3 Bearing 6 Remove the axle shafts and bearings from the housing using Tool C 499 as shown in Figure 7 CAUTION Do not allow the axle shaft to drag on the inner oil seal when removing axle from housing The inner diameter of the oil seal is designed with a feather edge to hug the shaft snugly to pre vent oil leak If this edge is enlarged or dam aged in any way the efficiency of the seal will be impaired If axle shaft bearings are to be replaced per form operation in Step 7 7 Remove bearings from the axle shafts us ing bearing puller Tool C 293 C as shown in Figure 8 REAR AXLE SHAFT INNER OIL SEAL 49x713 Fig 9 Removing Axle Shaft Inner Oil Seal Tool2. REAR AXLE 23 for chipped cracked or worn teeth Thrust wash ers and mating surfaces should be inspected for excessive wear Inspect the axle shaft splines for evidence of twisting or cracking Check axle shaft keyway and threaded section for wear Replace any shaft showing signs of torsional or spline dam age Inspect inner and outer axle shaft seals for wear Inspect seal surface of axle shaft for ex cessive wear nicks or scratches that may pos sibly cause seal leaks Wheel hub boss and seal surface of axle shaft should be free of nicks and burrs Replace all damaged or worn parts NOTE Replacing seals regardless of their appearance is good insurance against leakage REMOVAL AND INSTALLATION 4 REMOVAL AND INSTALLATION OF AXLE DRIVE SHAFT AND AXLE SHAFT OIL SEAL Should it become necessary to overhaul the rear axle drain the housing and proceed as follows PULLER TOO 54x660 Fig 5 Removing Rear Hub a Removal 1 Jack up car and remove wheel hub and drum assembly using wheel puller set Tool C 675 as shown in Figure 5 CAUTION Do not strike end of axle shaft to loosen hub be cause of possible damage to axle shaft and roller bearings OIL SEAL STAKED IN THREE PLACES REAR WHEEL BRAKE AXLE SEAL be a PROTECTING SLEEVE 46 x 105A Fig 6 Removing or Installing Brake Support Using Tool C 757 24 REAR AXLE CHRYSLER SERVICE MANUAL PULLER
3. ment c Unmatched drive gear and pinion d Worn teeth on drive gear or pinion e Loose drive pinion bearings f Loose differential gear bearings g Misaligned or sprung drive gear h Loose carrier housing bolts Remedies a If an axle is noisy because of insufficient lubricant it is too late to obtain any benefit by adding lubricant The gears or bearings or both are likely to be damaged Inspect all parts replace damaged parts and check axle and housing assembly for leaks b Check drive gear and pinion tooth contact as outlined in Gear Adjustment for Correct Tooth Contact Paragraph 22 in this Section c Remove unmatched drive gear and pinion Replace with a new matched gear and pinion set Refer to Removal and Inspection of Differential Carrier Assembly Paragraph 7 in this Section d Check teeth on drive gear and pinion for contact as outlined in Gear Adjustment for Cor rect Tooth Contact Paragraph 22 in this Sec tion If necessary replace with new matched set e Adjust drive pinion bearings as outlined in Rear Axle Adjustment Paragraph 17 in this Section f Adjust differential gear bearings as out lined in Rear Axle Adjustment Paragraph 17 in this Section g Check drive gear for runout h Tighten carrier housing nuts to required torque Check for oil leaks 34 LOSS OF LUBRICANT Possible Causes a Lubricant level too high b Worn axle shaft oil seals c Cracked rea
4. tial case runout After bearing caps have been brought up against bearing cups mount a dial indicator with the pointer resting against the back face of the ring gear As the drive gear and case is rotated the runout should not exceed 003 inch If runout exceeds 005 inch the differential case should be replaced 13 ASSEMBLY OF BARREL TYPE DIFFERENTIAL WITH BOLTED ON CASE CAP 1 If new differential side gears are to be installed place a new thrust washer over hub of differential side gear and lay in position in the differential case 34 REAR AXLE CHRYSLER SERVICE MANUAL t LOCK PIN HOLES SHOULD BE ALIGNED HOLES FOR DIFFERENTIAL N PINION SHAFTS SHORT 1 16 INCH APPROXIMATE 52x384 Fig 24 Positioning the Long Pinion Shaft in Case 2 3 4 5 6 Line up the locking pin hole in the long pinion shaft with the hole in the differen tial case pinion boss opposite boss has no pin hole Drive the pinion shaft in case until it protrudes about 146 inch on the inside of case as shown in Figure 24 Place a pinion thrust washer on the pinion so that the concave side faces the pinion Install the pinion and thrust washer on the end of the shaft that protrudes through case Tap shaft in case while holding pin ion up against case until end of shaft is even with edge of pinion Insert the pinion shaft block with punch marked sides facing the short shaft holes Install
5. Install axle shaft keys 12 Connect brake lines to brake cylinder un block brake pedal and bleed brake lines 18 Check the axle shaft end play with dial indicator to make sure it comes within 003 to 008 inch limits as outlined in Para graph 6 14 Install wheel hub and drum assembly Tighten axle shaft nuts to a minimum of 145 foot pounds torque Install new cot ter keys and hub caps 351x866 Fig 13 Axle Shaft Bearing Adjusting Shims Checking Axle Shaft End Play 15 Refill the axle housing and carrier assem bly with Extreme Pressure Hypoid Lubri cant as outlined in Lubrication Section 16 Check and refill master cylinder 17 Check and adjust brake shoes 18 Remove jack from car 5 REMOVING BROKEN END OF AXLE DRIVE SHAFT Remove wheel drum and axle drive shaft as outlined in Paragraph 4 If break is less than about 8 inches from splined end of shaft it will be necessary to remove differential and carrier assembly If break is more than 8 inches from splined end of shaft it will be necessary to re move inner oil seal and snare inner end of axle drive shaft out through housing with a loop CAUTION To avoid damage to rear azle carrier assembly the oil must be drained from the differential housing and the housing cleaned to remove chips and grit before installing the new azle shaft 1 Replace axle shaft and check rear axle end play as outlined in Paragraph 6 2 Replace whe
6. a Misaligned axle housing b Bent or sprung axle shaft c End play in drive pinion bearings d Excessive gear lash between drive gear and pinion e Improper adjustment of drive pinion bear ings f Loose drive pinion companion flange nut g Improper wheel bearing adjustment h Scuffed gear tooth contact surfaces Remedies a Refer to Rear Axle Housing Alignment Paragraph 24 in this Section b Replace bent or sprung axle shaft c Refer to Pinion Bearing Pre load Para graph 20 in this Section d Referto Backlash Adjustment Paragraph 21 in this Section e Adjust pinion bearings as outlined in Rear Axle Adjustment Paragraph 17 in this Section f Tighten drive pinion flange nut g Check axle shaft end play Readjust to bring desired end play clearance of 003 to 008 inch h Check lubricant Replace scuffed gears For correct tooth contact refer to Paragraph 22 in this Section 28 REAR AXLE DRIVE SHAFT BREAKAGE Possible Causes a Improprely adjusted wheel bearings b Misaligned axle housing c Vehicle overloaded d Abnormal clutch operation e Grabbing clutch Remedies a Replace broken shaft and readjust end play to desired clearance of 003 to 008 inch b Replace broken shaft after correcting Rear Axle Housing Alignment as outlined in Paragraph 24 in this Section c Replace broken shaft Avoid excessive weight in or on car 48 REAR AXLE d Replac
7. C 637 8 Remove the axle shaft inner oil seal from housing using Tool C 637 as shown in Figure 9 9 Remove outer oil seal from support plate by driving the seal out of plate with driver Tool C 839 Cleanliness and inspection are vital factors to be remembered when overhauling or repairing a rear axle assembly Clean all parts after disassembly and keep them clean throughout assembly Metal chips or particles of grit or dirt that may drop into the lubricant will cause excessive wear and eventually cause failure of the axle CHRYSLER SERVICE MANUAL REAR AXLE 25 NOTE New oil seals should be installed whenever seals are removed from axle housing and brake sup port plate b Installation Always inspect all parts before assembly and replace those that are worn or scored Check for and remove any burrs nicks scratches or rough spots on mating surfaces of replacement parts that may have been caused by rough handling 1 Install the rear axle drive shaft inner oil seal in housing using special drift Tool C 241 for Model C 70 Fig 10 Installing Axle Shaft Oil Seal Tool C 241 2 Install outer oil seal in brake support plate Secure seal in place by staking in three places as shown in Figure 6 3 Leather seals should be prepared for in stallation by soaking them in light engine oil for 30 minutes Before installing the axle shaft in housing examine the bearing surface of the beari
8. COMPRESSION NUT rier from the gear side 2 Place the front pinion bearing over the main screw followed by adaptor SP 535 washer SP 534 and nut SP 533 Press the bearing cups into place by tightening the tool nut as shown in Figure 33 TOOL CENTRALIZING WASHER AXLE DRIVE PINION BEARINGS TOOL MAIN BODY TOOL GAUGE BLOCK 49 x 610 NOTE Allow the tool to rotate slightly 1n order to Fig 32 Main Body Bearings Spacer and avoid damaging the bearings or cups during Shims Installed Tool C 758 D2 this operation 38 REAR AXLE CHRYSLER SERVICE MANUAL 49x611 Fig 34 Tightening Compression Nut with Foot Pound Torque Wrench CAUTION Do not install the pinion oil seal during the pre load and pinion setting operations Otherwise there will be an added drag on the pinion shaft which would give a false bearing pre load on the torque wrench 17 REAR AXLE ADJUSTMENT To set the drive gear and pinion for quiet opera tion and long life the following adjustments must be made in the order indicated 1 Pinion bearing pre load 2 Pinion setting 49x612 Fig 35 Checking Torque Required to Turn Main Body 3 Differential bearing pre load 4 Backlash between drive gear and pinion Each adjustment is important because each one has a significant effect on the final goal good tooth contact Pinion Bearing Pre load The importance of correct pinion beari
9. MANUAL misalignment will be indicated by the thickness of feeler gauge between square and end flange at top or bottom A housing that checks more than 007 inch should be replaced b Checking Axle Housing for Vertical Alignment 1 With housing in V blocks turn housing until machined surface for carrier mount ing is in a squared vertical position as shown in Figure 51 2 Place square against machined surface of housing end flange and surface plate as shown in Figure 52 Amount of housing misalignment will be indicated by the thickness of feeler gauge between square and end flange at top or bottom A hous ing that checks more than 007 should be replaced 3 To determine the amount that axle is mis aligned multiply the thickness of feeler stock used by the ration of 4 7 to 1 Fig 52 Checking Vertical Alignment 25 WELDING REAR AXLE HOUSING Arc welding of complete rear axle assemblies to repair leaking housings covers loose or broken spring seats and brake line clips has been com mon shop practice for some time However re cent investigations have proven that arc weld ing should definitely not be used for repairing the rear axle housing unless axle is completely disassembled It is possible for arcing electric current to jump the gap and damage roller bearings when there is end play The damage is similar to brinelled bearing marks It is further possible for damage to be done to the faces o
10. adjustments properly made correct tooth contact as shown in Figure 46 will result Notice that the contact pattern is well centered on the drive and coast sides about 14 inch from the edges of the teeth When tooth marks are obtained by hand they are apt to be rather small However under an actual operating load the contact area will spread out the higher the load the greater becomes the contact area 4 Figures 47 and 48 show improper or incor rect tooth contact To correct such condi tions readjust the drive gear and pinion as follows a Heavy Face Contact If the tooth marking is across the length of the tooth narrow and high on the tooth face as shown in Figure 47 the teeth will roll over or gall This type of contact causes excessive wear and noise Fig 47 Heavy Face Contact CHRYSLER SERVICE MANUAL Fig 48 Heavy Flank Contact To correct heavy face contact move the pin ion in toward the center of the drive gear by in stalling a thicker washer behind the pinion Re adjust backlash b Heavy Flank Contact If the tooth marking is across the length of the tooth but narrow and low on the flank as shown in Figure 48 the teeth will gall or score This type of contact causes excessive wear and noise To correct heavy flank contact move the pin ion away from the center of the drive gear by using a thinner washer behind the pinion Readjust backlash Fig 49 Leveling Housing f
11. air CAUTION Do not spin the bearings with air pressure when blowing them dry as damage to the bear ings may result from this practice 3 Check the bearings for roughness or brin elling The bearings must run free and show no indication of roughness or wear 4 Examine the bearing cups for pitting scor ing or wear Inspect all gears for chipped or worn gear teeth Check the fit of the dif ferential side gears on the axle shaft splines and the differential gears on the pinion shafts Check the thrust washers for wear and replace if necessary SBX722 Fig 21 Removing Differential Case Cap Lock Pin 46X 200 Fig 22 Removing Differential Case Cap Using Tool DD 921 NOTE Whenever a differential carrier assembly is removed for rebuilding due to bearing or other failure care must be taken to see that all for eign matter such as grit dirt metal particles etc are removed from the carrier 11 DISASSEMBLY AND INSPECTION OF BARREL TYPE DIFFERENTIAL WITH SCREWED ON CASE CAP Remove drive gear from differential case as out lined in Paragraph 10 and proceed as follows 1 Mount the flange of the differential case in a vise equipped with copper jaws 2 Remove differential bearings with puller On Model C 70 use Number 83 adapter and Number 41 plug puller set Tool DD 914 3 Remove the differential case cap locking pins by center punching and drilling as shown in Figure 21 Remove shell of
12. drive the shaft through the pinion shaft thrust block and pinion shaft block Install the opposite pinion gear and thrust washer Drive the shaft into final position Drive one of the short pinion shafts into either of the remaining holes until the REAR AXLE 35 fj CASE CAP wil pe Eo LOCK PINS CASE CAP USE BALL END PUNCH TO PEEN METAL OVER TOP OF PINS PEEN METAL ON DRIVE GEAR SIDE OF PIN HOLE 51x164 Fig 27 Staking Differential Case Cap Lock Pins 7 8 9 10 11 shaft protrudes about 14 inch on the in side of case Be sure the lock pin holes line up Install pinion gear and thrust washer and continue to drive until shaft enters hole in the pinion shaft block Install the other short shaft washer and gear in the same manner Lock the three pinion shafts in the case by installing three new locking pins in the holes and peen over Clamp the completed assembly in vise and heat the outside surface of the threaded portion of the case with a torch flame as in the disassembly procedure Dip the threaded portion of the cap in gear oil Assemble the thrust washer and the differential side gear in the cap and screw into the differential case with wrench Tool DD 921 as shown in Figure 22 Tighten securely in position with a blunt drift and hammer Drive three new differential case cap lock pins 4 inch below the surface of case Peen the metal of the case over t
13. for rebuilding due to bearing or other failure care must be taken to see that all for eign matter such as grit dirt metal particles etc are removed from the carrier 10 DISASSEMBLY AND INSPECTION OF BARREL TYPE DIFFERENTIAL WITH BOLTED ON CASE CAP a Disassembly 1 Place differential case and drive gear as sembly on bench bend down locking tabs and remove drive gear to case attaching nuts and bolts 2 Use a fiber hammer to tap drive gear off differential case 3 Clean around differential case flange to al low for checking face runout 4 Mount the differential case in the carrier Assemble bearings the adjusting nuts and bearing caps on carrier Adjust and re move excessive play from the bearings Mount a dial indicator on the carrier mounting face and check the ring gear mounting flange for runout as shown in Figure 19 NOTE If there ts more than 005 inch runout during the above check the differential case must be replaced Inspect the bolt holes in the ring gear mount ing flange for wear or out of round If the bolt LOCK PIN DRIVE OUT HOLES EN LOCK PIN Fig 20 Removing the Differential Pinion Shaft Lock Pins holes are out of round the ring gear will creep on the case 5 Remove the differential case from the car rier 6 Fit Number 18 plates behind bearings and pull off the differential bearings using Tool C 293 as shown in Figure 17 Remove the differenti
14. locking tabs and remove drive gear to case attaching nuts and bolts 2 Using a fiber hammer tap drive gear off differential case 3 To check differential case for runout mount the differential case bearings and cup assembly in carrier Install bearing caps and adjusters and adjust excessive J3 REAR AXLE 51x199 Fig 17 Removing Differential Side Carrier Bearings Tool C 293 C play from bearings with adjusters Mount dial indicator on carrier mounting surface and check drive gear mounting flange run out Runout should not exceed 005 inch If there is more than 005 inch runout the differential case should be replaced 4 Inspect bolt holes for wear or out of round if worn or out of round replace case 5 Mount differential case assembly in a heavy vise using copper jaws 6 Install Tool C 293 C on bearings as shown in Figure 17 and remove bearings from differential case b Inspection 1 Check the clearances between the side gears and thrust washers Clearance should be 004 to 012 inch To do this use two feeler gauge blades Slide the blades be tween side gear and thrust washer one blade on each side of gear hub as shown in Figure 18 Try two 004 inch blades they should go in Then try two 013 inch blades these should not go in Now check the opposite side gear the same way 2 Remove differential pinion shaft lock pin from differential case push out pinion shaft
15. re volving the tool using an inch pound torque wrench as shown in Figure 35 The correct bearing pre load should be 25 35 inch pounds torque If the bearing adjustment does not conform to the 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 the pre load is too great or a thinner spacer if the pre load is not sufficient When the correct spacer has been selected for the drive pinion bearings disassemble the tool from the differential carrier housing 10 Slide the pinion washer over the pinion shaft with the chamfered side against the pinion Install the rear pinion bearing using Tool C 3095 and a suitable arbor press See Fig 40 11 Install the pinion in the differential car rier Slide the bearing adjusting spacer bearing and oil slinger over shaft and down into position 12 Install a new oil seal using driver Tool DD 807 as shown in Figure 41 Install the companion flange washer and nut Tighten to 250 minimum foot pounds torque CHRYSLER SERVICE MANUAL 52x383 Fig 41 Installing the Drive Pinion Oil Seal 21 SETTING DIFFERENTIAL BEARING PRE LOAD AND BACKLASH ALL MODELS Differential bearing pre load and backlash be tween the drive gear and pinion are obtained after pinion bearing pre load and pinion set tings as described in Paragraph 20 1 Place the differential bearing cups over the
16. the axle drive shaft thrust block and continue to drive the shaft through the pinion shaft block and rear axle drive shaft thrust block Install the opposite pinion and thrust washer Drive the shaft into final position in case making sure locking pin holes are lined up Drive one of the short pinion shafts into elther of the remaining holes until the shaft protrudes about 4 inch on the inside of case Be sure the lock pin holes line up Install pinion and thrust washer and continue to drive shaft until shaft enters hole in the pinion shaft block In stall the other short shaft washer and gear in the same manner gm DIFFERENTIAL PINION SHAFT LONG 52x623 Fig 25 Tightening Differential Case Cap Screws 7 8 9 10 11 12 13 14 Lock the three pinion shafts into the case by installing three new locking pins in the holes driving the pin ends approximately l4c inch below machined surface of case Assemble the thrust washer and differen tial side gear in the cap Using the attach ing cap screws as guides position cap on differential case and tap into position with fiber hammer Tighten cap screws to 35 foot pounds torque as shown in Figure 25 Instal ring gear and tighten mounting bolt nuts to 40 foot pounds torque Lock the nuts by bending locking tabs Slide the differential bearing spacers over the hubs if so equipped Install the bear ings on the case using Tool DD
17. 1005 as Shown in Figure 26 Place the differential bearing cups over the bearings Install complete assembly in the carrier housing Seat the adjusting nuts in the pedestals of the carrier housing and install the caps and bolts NOTE Be sure the caps are on the same side from which they were re moved Mount a dial indicator with the pointer resting against the back face of the ring gear and check the runout Runout should be true within 005 inch as shown in Fig ure 19 CHRYSLER SERVICE MANUAL 52x385 Fig 26 Installing Differential Bearings 14 ASSEMBLY OF BARREL TYPE DIFFERENTIAL WITH SCREWED ON CASE CAP 1 2 3 4 5 6 If new differential side gears are to be in stalled place a new thrust washer over hub of gear and lay in position in the differen tial case Line up the locking pin hole in the long pinion shaft with the hole in the differen tial case pinion boss opposite boss has no locking pin hole Drive the pinion shaft in until it protrudes about 14 inch on the inside of case Place a pinion gear thrust washer on pin ion so that the concave side faces the pin ion Install the pinion gear and washer on the end of shaft that protrudes Tap shaft and hold pinion until end of shaft is even with edge of pinion Insert the pinion shaft block with punch marked sides facing the short shaft holes and the side marked 1 facing up Install the thrust block and continue to
18. 16 REAR AXLE CHRYSLER SERVICE MANUAL REAR AXLE DATA AND SPECIFICATIONS Rear Axle C 67 C 68 C 69 C 70 C 300 dud tag Ges ata T Semi Floating Semi Floating Semi Floating Semi Floating Semi Floating Gear Type 2ieet onion Er Hypoid Hypoid Hypoid Hypoid Hypoid Ring Gear Diameter 8 25 8 75 8 75 9 62 8 75 Pinion Bearings 2 2 2 2 2 Type A ct Tapered Roller Tapered Roller Tapered Roller Tapered Roller Tapered Roller Adjustment ees Shim Pack Solid Washer Solid Washer Solid Washer Solid Washer Differential Bearings 2 2 2 2 2 d Ste vas cS oes pet E nae Tapered Roller Tapered Roller Tapered Roller Tapered Roller Tapered Roller Adjustment e Threaded Adjuster Threaded Adjuster Threaded Adjuster Threaded Adjuster Threaded Adjuster Drive Gear Pinion Matched Sets Matched Sets Matched Sets Matched Sets Matched Sets Drive Gear Run Out 005 Maximum 005 Maximum 005 Maximum 005 Maximum 005 Maximum Drive Gear and Pinion Backlash 006 to 008 006 to 008 006 to 008 006 to 008 006 to 008 Differential Side Gear Clearance 004 to 012 004 to 012 004 to 012 004 to 012 004 to 012 Axle Ratio eee Standard Standard Standard With Standard 3
19. 3 in 179 in 195 in 181 in 197 in 183 in 199 in 185 in 201 in 187 in 203 in 189 in To check and adjust the pinion bearing pre load refer to Figure 39 and proceed as follows 1 Assemble spacer SP 1371 to the main sec tion of the tool and install spacer SP 1370 Correct pinion bearing pre load should have a drag torque of not more than 25 to 35 inch pounds with the pinion seal removed 2 Slide the pinion rear bearing over spacer SP 1370 and up against spacer SP 1371 3 Insert the tool as assembled into the car rier housing Slide front bearing over the tool shaft and into its proper position in the bearing cup 4 Tighten the tool compression nut so that the torque required to rotate the tool as sembly on the bearings is 25 to 35 inch pounds with the bearings lubricated with hypoid gear oil 5 Assemble the gauge block SP 528 to the main screw Place SP 561 bearing arbor in the differential carrier bearing sup ports as shown in Figure 39 NOTE Remove any burrs or upsets in the bearing sup ports before installing the bearing arbor as the arbor must be securely seated in the bottom of bearing bores Carefully tighten the retaining bolts to 10 foot pounds torque 6 Select a pinion washer of sufficient thick ness so that it will just pass between the gauge block end of the setting tool and the machined surface of the arbor as shown in Figure 38 For example if a 090 in
20. CKWASHER BEARING CONE Qu V4 BEARING CONE GM DIFFERENTIAL CASE NUT LOCK PINION SHAFT POR BOLT AND LOCKWASHER SIDE GEAR BEARING T HRUST BLOCK CONE CARRIER CAP PINION THRUST WASHER WASHER ADJUSTER LOCK DIFFERENTIAL PINIONS PINION THRUST WASHER PINION SHAFT BLOCK SIDE GEAR THRUST WASHER iir e BOLT AND LOCKWASHER CQ LOCKWASHER CASE CAP 52x 600A Fig 3 Rear Axle Exploded View C 68 C 69 including C 67 C 68 Town and Country Wagon JIXV HVdH 06 TWONWW dOIAHdJS HTISAHHO CHRYSLER SERVICE MANUAL REAR AXLE 21 Section I REAR AXLE l DESCRIPTION A modification has been made on the differen tial carrier assembly on the New Yorker elimi nating the axle drive gear thrust screw and thrust pad This change has also been made on Crown Imperial cars produced later in the model year A Belleville lockwasher is now be ing used in conjunction with the drive pinion flange nut on all Chrysler axles replacing the slotted nut and cotter pin formerly used per mitting a more accurate torque setting of the drive pinion flange nut and allowing more ac curate pre loading of the drive pinion bearings These washers have a 024 to 031 inch dish and are marked with white paint on the con vex side of the washer When installing the Belleville washer the convex or painted side of washer should face towards the nut A Belleville washer can also be use
21. HRYSLER SERVICE MANUAL 7 REAR AXLE 37 COMPRESSION 2 Check the bearings for roughness or brin SLEEVE eling The bearings must run free and show no indication of roughness or wear CROSS BORE TUBE D 3 Clean carrier housing thoroughly inspect oil passages and inside of housing for burrs grit or dirt PRESSION X COM o 16 INSTALLATION OF DRIVE PINION BEARING CUPS Place the bearing cups in position in the car 49 x 621 rier Then refer to Figures 31 and 32 and pro ceed as follows GAUGE BLOCK Figs 9 s peciat Tool Setr C 98 D2 1 With the bearing cups squarely in position in the carrier assemble Tool C 758 D2 by Remove any chips or foreign material from the carrier housing Inspect all machined surfaces for nicks burrs or scratches In spect the thrust shoulders in the carrier housing bearing cups to make sure there are no burrs on them The thrust shoulder must pe flat so that the bearing cups will seat properly CAUTION Do not rotate the bearings with air pressure when blowing them dry as damage to the bear ings may result from this practice 52x378 TOOL CROSSBORE TUBE Fig 33 Seating Bearing Cups in Carrier Housing AXLE DRIVE PINION ADJUSTING WASHER OR SHIMS AXLE DRIVE PINION BEARING SPACER AXLE DRIVE PINION BEARING ADJUSTING SHIMS placing the rear pinion bearing over the TOOL COMPRESSION SLEEVE main screw of tool and inserting into car TOOL
22. Oil Seal DOBOT acea REOR iuece ees Driver Pinion Oil Seal Installing DD 91T4 8 ose ERE EY ew AR e EUN Ring Medium Reducer use with DD 914 89 DD 014 80 4 1x hir Gh See SWR AN Plate Set Pinion Bearing Puller Adaptor DD921 rererere ee aces WIRES des Wrench Differential Case Cap Remover and Installer DDiO98 cue SG eae ad A Cae sata Puller Pinion Oil Seal DD 999 x cine dx ple tacta pA e esae Tool Companion Flange or Yoke Installing TIGHTENING REFERENCE Foot Pounds AXLE SHAFT NUITS 4 466640 ERAS d RE ean RO OCA RED RT ea 145 minimum BRAKE SUPPORT PLATE TO HOUSING MOUNTING BOLT NUTS 35 DIFFERENTIAL CARRIER TO AXLE HOUSING BOLT NUTS 45 REAR AXLE DRIVE GEAR BOLT NUTS eee eee 40 DIFFERENTIAL BEARING CAP BOLTS RT E 90 PINION SHAFT COMPANION FLANGE NUT eC y ure eee oe a Ae i ee 240 minimum 68 669 0 70 C 900 ag os ae ea a ocd Saye al hice Mane ee SEES 250 minimum 18 REAR AXLE CHRYSLER SERVICE MANUAL 6VLXxGS uoBbAA Ayuno pup umoj jde x3 9 5 uoissiusup1 paads yum e xy spay By MANOS 43HSV NOINId S U3HSVAM YaHSVM 3201 32018 avio d3HSVAA d3isnfav INOJ GNV JNOD 13S NOINId QNYV YJO YJHSVM INOJ GNV 3NOD d3lsnfav dND aol GNV JINOD INOA GNV 3NOO 1v3S 1O T FLANGE ae GUARD A A me WX E BOLT AND LOCKWASHER CG NA ADJUSTER LOCK CARRIER CAP O ADJUS
23. SLER SERVICE MANUAL REAR AXLE 49 Remedies a Replace gears Examine other gears and bearings for possible damage Replace parts as needed Avoid excessive weight in car b Replace gears being careful to examine remaining parts for possible damage Avoid erratic clutch operation c Replace gears Examine remaining parts for possible damage Replace parts as required d Replace gears Examine other parts for possible damage Drive gear and pinion back lash should be 006 to 008 inch Refer to Gear Adjustment for Correct Tooth Contact Para graph 22 in this Section 33 REAR AXLE NOISE Rear axle noises are generally divided into three groups 1 Gear Noise on Pull If the noise is of a heavy pitch and increases as the car speed is increased it is an indication of scored teeth due to loss of lubricant incorrect mesh of teeth or wrong type of lubricant 2 Gear Noise on Coast If noise is heavy and irregular it is an indication of scored teeth as a result of excessive end play in pinion bearings or by incorrect adjustments 3 Bearing Noise on Pull or Coast This in dicates bearings are chipped cracked scored badly worn or loose or the pinion is improperly positioned Bearings that are badly worn or broken will make a gravelly rough grating sound that may change slightly in volume as speed changes Possible Causes a Insufficient lubricant b Improper drive gear and pinion adjust
24. Speed Trans No Drive Gear Teeth No Drive Pinion Teeth With PowerFlite 3 54 No Drive Gear Teeth 39 No Drive Pinion Teeth 11 Type Recommended Ex Press Hypoid Ex Press Hypoid Summer 90 zt Winter 90 5 5 i Extreme Cold 80 Capacity 2 renean 314 Pints 315 Pints 5 Pints 3 Pints Including T amp C Wagon Limousine T amp C Wagon Wheel Bearings EVDO a4 eeu date fiho on Tapered Roller Tapered Roller Tapered Roller Tapered Roller Adjustment Select Shims Select Shims Select Shims Select Shims Axle End Play 003 to 008 003 to 008 003 to 008 003 to 008 Road Clearance full load T amp C Wagon NA Seda rianan a a Uo ur bii Tread Rear T amp C Wagon NA Seda Aiuto dae ERR AVR Windsor Town and Country Wagon Models use an 8 75 diameter ring gear CHRYSLER SERVICE MANUAL REAR AXLE 17 ADDITIONAL SPECIAL TOOLS REQUIRED FOR SERVICING THE REAR AXLE Tool Number Tool Name a CANGA Dr Wrench Differential Bearing Adjusting n per EE Dial Indicator Set RC PEE Puller Companion Flange or Yoke CAPT Bir ests eae vede pEEES S TS E Sleeve Axle Shaft Oil Seal Installing 05 15 2 9p PEE Pinion Bearing Pre load and Cone Angle Setting Gauge 71 PETERE Companion Flange on Yoke Holding Wrench B30 x reddat ue Gol oot asc a e a dd As Driver Axle Shaft Inner
25. TER A d d OIL SLINGER Y BEARING CUP BEARING CUP PINION SHAFT SPACER P dd CARRIER PINION SHAFT BEARING CUP FILLER PLUG DRIVE GEAR AND PINION BEARING ADJUSTING SHIMS DRIVE PINION ADJUSTING WASHER PINION THRUST WASHER BOLT AND m di LOCKW ASHER DIFFERENTIAL PINIONS BEARING CONE NUT NUT LOCK SIDE GEAR THRUST WASHER PINION SHAFT DE GEAR Pup Vi 3i ARN M e BEARING CONE peus P S d We BEARING CUP DIFFERENTIAL CASE PINION THRUST WASHER DIFFERENTIAL PINIONS d PINION THRUST WASHER AUN ADJUSTER LOCK PINION SHAFT BLOCK Qe BOLT AND LOCKWASHER e SIDE GEAR THRUST WASHER CARRIER CAP CASE CAP Cy LOCK WASHER SE S 4 BOLT 52x614C Fig 2 Rear Axle Exploded View C 67 PowerFlite Equipped Cars Except Town and Country Wagon TV NVI 3O0IAH3S HTISAHHO 6LI dIXV HV4H LOCK WASHER FLANGE OIL SLINGER BOLT AND LOCKWASHER BEARING CUP ADJUSTER LOCK CARRIER CAP ADJUSTER DRIVE GEAR AND PINION Saw BEARING CUP CARRIER BEARING CONE WASHER y OM FILLER PLUG DRIVE PINION PINION SHAFT ADJUSTING x WASHER a O LPINIONCSRUTEY N M SAT BEARING ADJUSTING SPACER lt gt ae BEARING CUP Ais BEARING CONE m N BN SIDE GEAR THRUST WASHER Maaa A pp PINION THRUST WASHER 9 WV NERS KY gr DIFFERENTIAL PINIONS A hd l p PINION THRUST WASHER d a Me H Kd soc GEAR BOLT AND LO
26. al bearing spacers 7 Remove the differential cap to case bolts and tap the cap lightly with a soft hammer to remove 8 Remove the three differential pinion shaft lock pins by driving them out of the case with a hammer and punch as shown in Figure 20 9 Drive the long pinion shaft out of the dif ferential case using a brass drift and ham mer NOTE This shaft can be identified as having only 1 retaining pin 10 Lift out the rear axle drive shaft thrust block 11 Drive the short pinion shafts out of the case and lift out the pinion shaft block NOTE The short pinion shaft sides of the block are punch marked for identification 12 Lift out the differential pinion gears slide gears and thrust washers b Cleaning and Inspection 1 Clean all parts thoroughly in a suitable sol vent and blow dry with compressed air Remove any chips or foreign material from 32 REAR AXLE CHRYSLER SERVICE MANUAL the carrier housing Inspect all machined surfaces for nicks burrs or scratches In spect the thrust shoulders in the carrier housing bearing cups to make sure there are no burrs on them The thrust shoulder must be flat so that the bearing cups will seat properly Check the differential case for cracks fractures distortion or damage Install a new case if necessary 2 The bearings should be immersed in clean solvent and rotated by hand until clean After cleaning blow dry with compressed
27. amage Drive gear and pinion are replaceable in sets only 4 Check tightness of drive gear to differen tial case bolts Tighten if necessary 5 Check drive gear runout with gauge C 430 Runout should not be more than 005 inch 6 Check differential bearing pre load and backlash as outlined in Paragraph 22 NOTE Careful inspection of pinion bearing pre load will assist in determining cause of noisy axle Improper drive pinion position will cause a noisy axle 8 REMOVING DIFFERENTIAL CASE AND DRIVE GEAR ASSEMBLY FROM CARRIER All Models Refer to Figures 2 3 and 4 Disassemble the differential case assembly as follows 1 Mount the carrier assembly in stand Mark both differential bearing adjusters and caps so they may be reinstalled in approxi mately the same position at assembly Fig 16 SCRIBE MARKS 52x371 Fig 16 Marking Bearing Caps and Adjusting Nuts NOTE Bearing caps must NOT be interchanged They are lined bored with the carrier housing when manufactured 2 Remove the bearing cap bolts caps adjust ing nuts and bearing cups and lift the dif ferential case and drive gear assembly out of carrier NOTE Clean drive gear bearings bearing cap drive pinion and inside of carrier assembly as out lined in Cleanliness Paragraph 2 9 DISASSEMBLY AND INSPECTION OF CAGE TYPE DIFFERENTIAL a Removal 1 Place differential case and drive gear as sembly on bench bend down
28. and remove differential side gears When reassembling the ground surfaces 49x722 CHRYSLER SERVICE MANUAL Fig 18 Checking Differential Side Gear Clearance 3 4 5 6 of the thrust block should be turned toward the axle shaft Clean all parts thoroughly in a suitable solvent and dry with com pressed air The bearings should also be immersed in clean solvent and rotated un til clean Check differential side gear and pinion teeth bores and spherical back of pinions pinion cross shaft thrust washers and thrust surfaces inside the differential case for wear or damage If any of the above mentioned parts are worn so that they will affect the operation of the differential they should be replaced Inspect the fit of the differential side gears in the hub of the differential case If they are excessively loose the gears or case should be replaced Examine the surfaces of differential case cone and roller bearings and the bearing cups for pitting and wear Assemble cups in bearings and rotate If the bearings are rough or drag on rotation the bearing rollers may have a flat spot If so the bear ing should be replaced Make sure the oil passages in the differen tial carrier are clear clean and unob structed uL p a CHRYSLER SERVICE MANUAL REAR AXLE 3 1 52x375 Fig 19 Checking Ring Gear Mounting Flange Runout NOTE Whenever a differential carrier assembly is re moved
29. bearings and install complete assembly in the carrier housing 2 Seat the adjusters in the pedestals of the carrier housing and install the caps and bolts NOTE Be sure the caps are on the same side from which they were removed 3 Mount a dial indicator with the pointer resting against the back face of the ring gear and check the runout Runout should be true within 005 inch as shown in Fig ure 42 In order to make certain that the differential bearings and cups are properly seated proceed as follows 4 Using spanner wrench Tool C 406 as shown in Figure 44 turn the right hand bearing adjuster clockwise until considerable back lash exists between the ring gear and the pinion Back off the adjuster several turns CHRYSLER SERVICE MANUAL REAR AXLE 43 52x386 Fig 42 Checking Ring Gear Runout 5 Tighten the lower pedestal bolts to 90 foot pounds leaving the top bolts slightly loose This holds the bearing cups in line while moving the ring gear 6 Mount the dial indicator on the carrier so that the plunger rests against one of the ring gear teeth as shown in Figure 43 Make certain that the indicator is properly positioned so that the plunger will accurate ly indicate the exact amount of backlash 7 Check the backlash between the ring gear and the pinion at 90 degree intervals as the ring gear is rotated Stop at the point of last backlash 8 Turn the left hand bearing adjus
30. ch washer can be inserted but a 092 washer cannot be forced between the two surfaces by hand the 090 inch washer should be used even though it might feel loose Check the end of the drive pinion as it should indicate the amount that should be added or subtracted from the washer that was selected in the above check As example if the mark on the pinion shaft indicated 4 2 a 002 inch thinner washer should be used for the final assembly If a spacer se lected by the use of the tool is 090 inch it is necessary to deduct 002 inch Therefore the correct washer for final assembly would be 088 inch When the correct washer has been selected for the drive pinion disassemble the tool from the differential carrier housing 7 Add the washer selected to the tool be tween the spacer SP 1371 and the pinion rear bearing Add the spacer SP 1370 and the pinion bearing adjusting spacer that was removed from the axle at disassem bly Insert the tool assembly in the carrier housing 8 Slide the front bearing on the shaft and into position in its cup Install the tool spacer nut and washer 9 Tighten tool to 250 minimum foot pounds torque as shown in Figure 34 Turn the tool with a speed wrench to permit the bearings to seat When the bearings have 42 REAR AXLE PRESS REAR BEARING CONE DRIVE PINION 52x382 Fig 40 Installing Bearing on Pinion Shaft been seated check the bearing pre load by
31. d with a slotted type nut providing the tightening speci fication for the Belleville washer is used The tightening specifications for use with the Belleville type washer are 240 minimum foot pounds torque for the Windsor DeLuxe Models and 250 minimum foot pounds torque for the New Yorker and Imperial Models NOTE The thread form on the differential bearing ad justers on the 1955 New Yorker and Custom Imperial Models except for the Crown Im perials are changed and are not interchange able with the 1954 adjusters The axles as shown in Figures 1 2 3 and 4 though different in design are of the semi floating type with a hypoid ring gear and pinion The differential drive pinion and axle shafts are earried on adjustable taper roller bearings The rear cover is welded to the axle housing neces sitating the removal of the differential assembly in order to adjust the differential bearings To insure quiet smooth operation the ring gear and pinion are serviced only in matched sets 2 CLEANLINESS Cleaning parts after disassembly is a very im portant procedure Parts must be kept clean all through assembly Tiny metal chips bits of dirt or foreign particles mixing with the lubri cant are liable to cause excessive wear or axle failure if not cleaned from parts and housing Whenever the rear axle carrier assembly is removed from car for overhauling the as sembly and parts except bearings should be cleaned in a s
32. e broken shaft after checking for other possible causes Avoid erratic use of clutch e Replace broken shaft Refer to Clutch Section IV to correct this condition 29 DIFFERENTIAL CASE BREAKAGE Possible Causes a Improper adjustment of differential bear ings b Excessive drive gear clearance c Vehicle overloaded d Erratic clutch operation Remedies a Replace broken case and examine gears and bearings for possible damage At reassem bly adjust differential bearings as outlined in Rear Axle Adjustment Paragraph 17 in this Section b Replace broken case and examine gears and bearings for possible damage At reassem bly adjust drive gear and pinion backlash to required specification of 006 to 008 inch as outlined in Rear Axle Adjustment Paragraph 17 in this Section c Replace broken case and examine gears and bearings for possible damage Avoid ex cessive weight in or on car d Replace broken case After checking for other possible causes examine gears and bear ings for possible damage Avoid erratic use of clutch 30 DIFFERENTIAL SIDE GEAR BROKEN AT HUB Possible Causes a Excessive axle housing deflection b Misaligned or bent axle shaft c Worn thrust washers Remedies a Replace damaged gears Examine other gears and bearings for possible damage Check Rear Axle Housing Alignment as outlined in Paragraph 24 in this Section CHRYSLER SERVICE MANUAL b Replace dama
33. ed View C 70 1 Differential bearing cup 2 Differential bearing cone 3 Differential pinion shaft lock pin 4 Differential pinion shaft long 5 Differential case cap lock pin 6 Differential pinion shaft short 7 Axle drive gear 8 Axle drive pinion 9 Axle drive pinion inner bearing washer 10 Axle drive pinion bearing cone rear 11 Axle drive pinion bearing cup rear 12 Axle drive pinion bearing spacer 13 Carrier caps 14 Differential bearing adjuster lock screw 15 Differential bearing adjuster lock 16 Differential bearing adjuster 17 Axle drive gear thrust screw pad 18 Axle drive gear thrust screw check nut 19 Axle drive gear thrust screw 20 Axle drive pinion bearing cup front 21 Axle drive pinion bearing cone front 22 Axle drive pinion bearing oil slinger 23 Axle drive pinion bearing oil seal 24 Companion flange and oil seal guard 25 Companion flange nut washer 26 Companion flange nut 27 Carrier cap stud 28 Carrier 29 Filler plug 30 Differential bearing cap stud nut and lockwasher 31 Differential pinion thrust washer 32 Differential pinions 33 Differential pinion shaft block 34 Rear axle drive shaft thrust block 35 Differential side gear 36 Differential case cap 37 Differential gear thrust washer 38 Axle drive gear bolts 39 Differential case 40 Axle drive gear bolt nut lock 41 Axle drive gear bolt nuts CHRYSLER SERVICE MANUAL
34. el hub and drum assembly and tighten axle shaft nuts to a minimum of 145 foot pounds torque 6 SETTING AXLE SHAFT END PLAY Rear axle shaft end play is adjusted by the use of adjusting shims Fig 13 that are bolted between the axle housing ends and the brake support plates The shims are available in thick nesses of 005 010 0125 015 and 030 inch The correct axle end play is 003 to 008 inch One or more shims may be required to obtain correct end play 1 Preparation for setting axle shaft end play consists of removal of axle drive shafts It is not necessary to remove the bearing cones from the axle drive shafts unless they are to be replaced Clean parts after dis assembly and inspect bearing cups cones and rollers for signs of surface failure 2 The axle drive shaft thrust block has an elongated hole to allow the block approxi mately 14 inch total lateral motion in the assembly The thrust block must be located so that the elongated hole is approximately centered on the long differential pinion shaft To adjust the axle end play the operation can be started from either side of the axle housing These instructions will be confined to the case of starting at the left side Install the left axle drive shaft and bearing cone assembly without lubricant Drive in the bearing cup as far as it will go using Tool C 418 in order to prevent damage to the axle housing This will thrust the block as far to the rig
35. er Thickness 4 Slide the pinion washer over the pinion shaft with the chamfered side against the PINION LOCATING WASHEx 49x615 pinion Install the rear pinion bearing using Tool C 3095 and a suitable arbor press 5 Install the pinion in the differential carrier Slide the bearing spacer bearing pre load shim pack bearing cone and oil slinger over shaft and down into position 6 Install a new oil seal using driver Tool DD 807 as shown in Figure 40 Install the companion flange washer and nut Tighten to 240 minimum foot pounds torque 20 PINION PRE LOAD AND PINION SETTING C 68 C 69 C 70 AND C 67 TOWN AND COUNTRY WAGON The above models use a large bearing at the rear of the drive pinion The shoulder is close to the front bearing so the enlarged section of the pinion shaft performs the function of spacing the pinion bearings FN APINION BEARING PRELOAD SPACER PRE DETERMINED PINION LOCATING 1327832 OR CORRECT SIZE WASHER 1327853 OR CORRECT SIZE pem Fig 39 Setting Pinion Bearing Pre load with Tool C 758 D2 P Plug SP Spacer CHRYSLER SERVICE MANUAL REAR AXLE 41 Adjustment of bearing pre load is left to a thick spacer approximately 34 inch available in various thicknesses and selected to give pre load within the limits specified Pinion bearing spacers are available in fifteen different sizes as follows Spacer Thickness 175 in 191 in 177 in 19
36. f the drive gear and pinion as well as to the differential Side gears and pinions if conditions are just right for the existence of sufficient backlash gap on these parts to cause arcing Grounding of arc welding equipment is not effective in preventing damage Instead of arc welding equipment gas welding equipment Should always be used on rear axle housing un less the unit is completely disassembled CHRYSLER SERVICE MANUAL REAR AXLE 4 SERVICE DIAGNOSIS 26 REAR WHEEL NOISE Possible Causes a Wheel loose on axle shaft b Worn drum or axle shaft keyways c Wheel hub bolts loose d Insufficient bearing lubrication e Scored wheel bearing cup or cone f Defective brinelled wheel bearing g Excessive axle shaft end play Remedies a Check keyways for possible damage Re set drum and tighten nut to 145 foot pounds minimum torque b If keyways in hub and axle shaft show ex cessive wear replace hub and axle shaft to correct this condition c Tighten loose wheel hub bolts d Check bearings for possible damage and replace if necessary Refer to Lubrication Sec tion for proper lubrication e Check rear wheel bearings If scored or show signs of wear they should be replaced f Defective or brinelled bearings must be re placed Check rear axle shaft end play g Readjust axle shaft end play to bring de sired clearance of 003 to 008 inch 27 NOISE IN REAR AXLE ASSEMBLY Possible Causes
37. ged gears Check axle shafts for alignment and examine other gears and bearings for possible damage c Replace damaged gears Examine other gears and bearings for possible damage Replace thrust washers that are badly worn Side gear to thrust washer clearance should be from 004 to 012 inch 31 SCORING OF DIFFERENTIAL GEARS Possible Causes a Insufficient lubrication b Improper grade of lubricant c Excessive spinning of one wheel d Excessive loads Remedies a Replace scored gears Scoring marks on the pressure face of gear teeth or in the bore are caused by instantaneous fusing of the mat ing surfaces Scored gears should be replaced Fill rear axle to required capacity with Extreme Pressure Hypoid Lubricant SAE 90 winter and summer or with SAE 80 below 10 degrees F b Replace scored gears Inspect all gears and bearings for possible damage Clean out and re fill axle with Extreme Pressure Hypoid Lubri cant SAE 90 winter and summer or with SAE 80 below 10 degrees F c Replace scored gears Inspect all gears pinion bores and shaft for scoring or bearings for possible damage d Replace scored gears Inspect all gears bearings pinion bores and shaft for scoring or possible damage Avoid excessive weight in or on car 32 TOOTH BREAKAGE DRIVE GEAR AND PINION Possible Causes a Overloading b Erratic clutch operation c Ice spotted pavements d Improper adjustment CHRY
38. he pins with a ball end punch as shown in Fig ure 27 Install the differential bearing cones on the case using Tool DD 1004 Check the case runout as shown in Figure 19 36 REAR AXLE CHRYSLER SERVICE MANUAL 52x372 52x373 Fig 28 Removing the Companion Flange Fig 29 Removing Drive Pinion Bearing Oil Seal 15 REMOVAL OF AXLE DRIVE PINION FROM CARRIER ALL MODELS NOTE When using Tool C 293 C use Number 36 plates also a Removal 1 With the carrier assembly mounted in stand remove the companion flange retain ing cotter pin nut and washer 6 Remove both bearing cups from carrier assembly with a suitable drift Be sure to drive both cups out evenly 2 On all models remove drive pinion flange b Cleani dl i with utility puller Tool C 549 dix LS RE 1 Clean all parts thoroughly in a suitable uu solvent and blow dry with compressed air 3 Remove the pinion shaft oil seal Use Tool DD 998 to remove drive pinion oil seal from differential carrier assembly Refer to Fig ure 29 4 Remove the oil slinger bearing cone spacer and shims if so equipped pinion adjusting washer bearing cone and pinion from car rier housing 5 To remove or install the rear bearing from or on drive pinion use special Tool DD 914 for Model C 70 and Tool C 293 C for Fig 30 Removing Bearing from Axle Drive Pinion all other models Fig 30 1 Bearing 2 Pinion 3 Tool C 293 C C
39. ht as it can go as shown in A Figure 14 CHRYSLER SERVICE MANUAL REAR AXLE 27 3 If the left bearing cup is now withdrawn about 1 inch the thrust block will be ap proximately centered on the differential pinion shaft Axle operation is not affected by mislocation of the thrust block unless the block bears against the differential pinion shaft in which case the end play of the left and right axle shafts may be dif ferent and wheel thrust will be imposed upon the differential bearings a condition that should be avoided With the left bearing cup remaining at its innermost position as shown in Figure 14 lay a straightedge across the end of the axle hous ing Measure the distance from the straightedge to the bearing cup face to the nearest 4 inch The example shown in B Figure 14 shows a measurement of 345 inch j m I e 9 5 a c ante img E ee T STRAIGHT EDGE One eighth inch minus the above measure ment gives the thickness of shims required at the left end of the housing to center the thrust block For the above example a shim 14 inch thick would center the thrust block A 030 inch shim is close to this thickness but a good prac tice is to use about a 020 inch shim which is less shim than the thickness required for centering the thrust block 4 Remove the left axle shaft grease the bear ing reinstall the shaft and bearing Using the correct thickness of
40. ined up with the holes in the differential case before pressing the gear on the case 18x72 Fig 23 Removing Differential Pinion Shaft Lock Pins REAR AXLE 33 1 Press gear on case Install attaching bolts and tighten to 40 foot pounds torque 2 Install the differential side gears with their thrust washers the differential pinions and their thrust washers and the differen tial pinion shaft Check the differential side gear clearance Fig 18 If clearance cannot be obtained with the old thrust washers and gears install necessary new parts to obtain the correct clearance 3 After clearance has been obtained remove pinion shaft gears and thrust washers Coat the shaft and other parts moderately with Extreme Pressure Hypoid oil and re assemble parts in differential case 4 Line up the locking pin hole in the pinion shaft Enter the shaft in pinion shaft hole in case Assemble side gears and thrust washers in hub of case and pinion gears thrust block spacers and thrust block on shaft Press shaft into case 5 Install pinion shaft locking pin in case and press pin in place peening the metal of the case over the ends of pin to retain pin in place 6 Install differential bearings on differential case using Tool DD 1004 7 Install bearing cups on bearings and mount the differential gear assembly in carrier 8 Assemble bearing caps and bearing adjust ing nuts in carrier and check the differen
41. kness of the wash er that slides between the cross bore gauge bar and the gauge block with a slight drag This washer will be the correct size for as sembly provided the pinion has no correc tion indicated on the small end of the pin ion head In manufacture after the pinion is lapped in with the gear the position of the pinion for best tooth contact is etched on the small end of the pinion head as a or number This number is the num ber of thousandths of an inch between the best bearing position and the standard position A 2 would indicate that the pin ion should be located 002 inch farther TOOL GAUGE BLOCK A9x613 Fig 36 Installing Gauge Block on Main Body than the standard setting away from the drive gear This amount 002 inch should be subtracted from the washer thickness of the washer that slides between the cross bore and gauge block For example if the gauge indicated that a carrier and rear pinion bearing combination required a pin ion washer 090 inch thick the washer to be used in the assembly is not known until the pinion is inspected for its position mark If it is marked 0 the spacer to be used in this example is 090 inch If the pinion is marked 2 the spacer should be 088 inch thick If the pinion is marked 2 the spacer to be used is 092 inch thick Fig 37 Installing Cross Bore Gauge Bar 40 REAR AXLE CHRYSLER SERVICE MANUAL Fig 38 Checking Spacer Wash
42. l and bearings at intervals to help line up bearing cups and avoid possible damage to the bearings CHRYSLER SERVICE MANUAL REAR AXLE 39 1 2 3 4 5 With bearing cups in carrier slide rear bearing cone and spacer over main body of tool and insert in carrier Slide adjusting shims and front bearing cone over main body as shown in Figure 33 Place compression sleeve centralizing washer and compression nut over main body and tighten to 240 minimum foot pounds torque as shown in Figure 34 Remove torque wrench and with a speed wrench rotate main body of tool to seat bearings properly Use an inch pound wrench to read the torque required to turn main body as shown in Figure 35 Desired torque should be from 20 to 30 inch pounds It may be necessary to add or remove shims to obtain desired torque In this case loosen up the assembly and add or remove shims as re quired 19 SETTING DRIVE PINION C 67 EXCEPT 1 2 3 TOWN AND COUNTRY WAGON Place gauge block on top of body and tighten in place as shown in Figure 36 gauge block takes place of drive pinion Assemble cross bore gauge bar to carrier bearing supports as shown in Figure 37 Tighten cap screws to hold bar in place The distance between gauge block and cross bore gauge bar determines thickness of spacer washer to be used as shown in Fig ure 38 The pinion washer to be used is ob tained by finding the thic
43. ng cups for wear and pits also the surface of the axle shaft on which the oil seal wipes to make sure that it is smooth and free from tool marks and burrs If necessary dress down the surface of the shaft with a stone or fine emery cloth to make a smooth bearing surface for the oi seal NOTE Stone or emery polish lines should run around and not along shaft REAR AXLE SHAFT 49x714 Fig 11 Installing Axle Shaft Bearing Tool C 158 4 To install the axle shaft first replace the bearing on axle shaft with special Tool C 158 Fig 11 and moderately lubricate axle bearings with hypoid lubricant Care fully insert the axle shaft in the housing making sure the shaft and differential side gear splines align 5 Install the axle drive shaft outer bearing cup with special driver Tool C 418 Fig 12 6 Install shims in same manner as removed to maintain the central position of axle shaft thrust block 7 Install special sleeve Tool C 757 in the axle bearing outer oil seal before mounting brake support to the axle housing Fig 6 to protect seal from being damaged by axle shaft keyway during installation 8 Clean mating surfaces of axle housing flange and brake support Fig 12 Installing Axle Drive Shaft Bearing Cup Tool C 413 26 REAR AXLE CHRYSLER SERVICE MANUAL 9 Install new gaskets 10 Install brake support plates and tighten attaching nuts to 35 foot pounds torque 11
44. ng pre load cannot be over emphasized The selection of washers to give the desired pre load should be carefully made 1 Where pinion bearings are installed with out pre loading the cones are not drawn far enough into their cups to bring the rollers in full contact with the thrust ribs on the cones Bearings installed in this man ner would allow the pinion to walk back ward and forward under operating loads This causes a variation in tooth contact pattern resulting in excessive wear and scoring of gears which usually is accom panied by noise 2 On the other hand where the pinion bear ing cones are drawn too far into their cups the bearings are overloaded before they have to withstand operating loads imposed upon them by the gears They are apt to burn up under a driving load the rollers might score the cups causing bearings to spall or flake resulting in premature axle failure 18 SETTING DRIVE PINION PRE LOAD C 67 EXCEPT TOWN AND COUNTRY WAGON With the use of special Tool C 758 D2 Fig 31 items 1 and 2 pinion bearing pre load and pinion setting can be pre determined thus sav ing considerable time and labor incurred in the old trial and error method Also the pinion bearing cups can be installed with this tool Install eups in housing Assemble the bearing cones and tool in carrier without the bearing spacer Tighten the main nut drawing cups into their proper position NOTE Turn the too
45. or Checking Alignment REAR AXLE 45 23 INSTALLATION OF AXLE ASSEMBLY Check carrier housing flange and flange face on differential housing for nicks and burrs 1 Mount the differential carrier to the axle housing using a new gasket Tighten the mounting nuts to 45 foot pounds torque 2 Reinstall rear axle shafts brake supports and check axle end play as outlined in Paragraph 4 Connect brake tubes bleed brakes install rear wheels and tighten rear axle shaft nuts to a minimum of 145 foot pounds torque Install new cotter key 3 Reinstall propeller shaft and fill the rear axle differential with the correct viscosity Hypoid oil Refer to the Lubrication Sec tion 24 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 described below a Checking Axle Housing for Horizontal Alignment 1 Place axle housing in V blocks on sur face plate 2 Turn housing until machined surface for carrier mounting is facing UP and Is per fectly level as shown in Figure 49 3 Place square against machined surface of housing end flange and surface plate as shown in Figure 50 Amount of housing 49x625 Fig 50 Checking Horizontal Alignment 46 REAR AXLE Fig 51 Squaring Axle for Vertical Alignment CHRYSLER SERVICE
46. pedestal bolts recheck the backlash As a result of this method of adjustment the carrier pedestals have been spread the dif ferential bearings have been pre loaded and the backlash between the ring gear and pinion has been correctly set CAUTION Whenever the adjustment of the differential as sembly is changed to obtain correct tooth con tact re adjust the differential bearing pre load and the backlash between the ring gear and pinion Checking Tooth Contact If all the adjustments have been correctly made the gears will be properly meshed and quiet in operation Proper tooth contact is essential for quiet gear operation and long life Therefore it is necessary that the tooth contact be checked with gear marking compound before the differ ential carrier assembly is installed in the axle housing 22 GEAR ADJUSTMENT FOR CORRECT TOOTH CONTACT 1 If improper tooth contact is evident as in dicated by Figures 47 and 48 the pinion should be adjusted either forward or back ward maintaining the backlash within specified limits until correct tooth contact as shown in Figure 46 is obtained 2 Check tooth contact by means of the gear marking compound applied to the drive gear teeth as shown in Figure 45 Apply load against the back face of the drive gear with a round bar as the drive pinion Fig 46 Correct Gear Tooth Contact is rotated This leaves a bare area the size shape and location of contact 3 With
47. pin left in hole with a punch The differential case cap is 001 to 002 inch larger than the differential case body in which it fits The case must be expanded by heating for easy removal of case cap The case will be dam aged if any attempt is made to remove cap without heating CHRYSLER SERVICE MANUAL Heat the outside of the case not cap with a torch Keep the flame moving around the case to assure even heating Try a piece of ordinary soft solder on the case from time to time When the solder starts to melt at approximately 360 to 400 degrees F the case will be as hot as it can get without damaging the thrust washers When the case is just hot enough to melt soft solder loosen cap with a blunt drift and a heavy hammer and quickly unscrew the cap from the case with Tool DD 921 as shown in Figure 22 The parts can now be immersed in oil to cool for subsequent handling 4 Remove the three different pinion shaft lock pins by driving them out of the case with a hammer and punch as shown in Figure 23 5 With a drift and hammer drive the long pinion shaft out of the case Then remove the thrust block Now drive the short pin ion shafts out of the case and lift out the pinion shaft block 6 N Remove the differential pinions side gears and thrust washers from the case 12 ASSEMBLY OF CAGE TYPE DIFFERENTIAL When installing drive gear to differential case be sure the holes in drive gear are properly l
48. play equal thick nesses of shims should be removed or installed on both sides of the axle housing to maintain the centralized position of the axle shaft thrust block After the axle shaft end play has been checked or corrected install the brake drum and wheel assembly Tighten axle shaft nuts to a minimum of 145 foot pounds torque Install cot ter keys and remove jack from car 7 REMOVAL AND INSPECTION OF DIFFERENTIAL AND CARRIER ASSEMBLY d Removal 1 Remove wheel hub and drum assembly and rear axle shafts as outlined in Paragraph 4 and proceed as follows 2 Disconnect rear universal joint and drop propeller shaft NOTE All accumulation of grit dirt and other foreign matter deposited on the differential and carrier assembly around the attaching bolt nuts should be cleaned off before the assembly is removed from the housing to prevent them falling into the housing gears or bearings when the as sembly is removed b Inspection 1 Make sure the companion flange or yoke nut is tight and has not moved from its original position 2 Check the backlash between the drive gear and pinion gear See Figure 15 Backlash should not be less than 006 inch or more than 008 inch 3 Inspect the surfaces of the drive gear and CHRYSLER SERVICE MANUAL REAR AXLE 29 541 1 Fig 15 Checking Backlash Between Drive Gear and Pinion Tool C 430 pinion teeth for nicks burrs scoring or other d
49. protrude beyond the housing end face 6 Hold a straightedge firmly against the outer face of the right bearing cup Using a set of feeler gauges measure accurately the distance between the housing face and the straightedge This measurement gives the thickness of the shim that would give zero end play if it were used in the assem bly The shim thickness to be used is ob tained by adding 003 inch to the above measurement If this gives a thickness that cannot be built up from existing shims use the next larger shim combination This insures that the end play will be greater than 003 inch For an example of end play setting assume the right bearing cup face protrudes 038 inch beyond the end face of the housing Shim thick ness required for 003 inch end play is 038 inch 0083 inch 041 inch This cannot be ob tained with existing shims so 0425 inch is used which is obtained with one 030 inch and one 0125 inch shim The end play is then 0425 inch minus 038 inch equals 0045 inch 7 Remove the right axle shaft and lubricate CHRYSLER SERVICE MANUAL the bearing Install axle shaft bearing and shim pack as determined in Step 6 and complete the assembly 8 If the dial indicator shows less than 003 inch or more than 008 inch end play re move the brake support plate and oil seal and add or remove shims as required to obtain the desired axle shaft end play CAUTION When adjusting axle shaft end
50. r axle housing d Worn drive pinion oil seal e Scored and worn companion flange Remedies a Drain excess lubricant by removing filler plug allowing lubricant to level at lower edge of filler plug hole 90 REAR AXLE b Replace worn oil seals Prepare new seals before installation See Paragraph 4 c Refer to Welding Rear Axle Housing Paragraph 25 in this Section d Replace worn drive pinion oil seal Prepare new oil seal before installation See Para graph 21 e Replace worn or scored companion flange and oil seal Prepare new oil seal before installa tion 35 OVER HEATING OF UNIT Possible Causes a Lubricant level too low Incorrect grade of lubricant Bearings adjusted too tightly Excessive wear in gears ao Insufficient drive gear to pinion clearance CHRYSLER SERVICE MANUAL Remedies a Refill rear axle allowing lubricant to level at lower edge of filler plug hole b Drain flush and refill rear axle with Ex treme Pressure Hypoid Lubricant SAE 90 winter and summer or with SAE 80 below 10 degrees F c Readjust differential bearings to required pre load d Check gears for excessive wear or scoring Replace as necessary e Readjust drive gear and pinion backlash from 006 to 008 inch Check gears for possible Scoring NOTE Oil seals may be destroyed by excesswe heat Replace cracked or hardened seals
51. shims or shim as determined in Step 3 install the left brake support plate The bearing cup should not be driven all the way in during this operation As the brake support plate is drawn up tight it will push the bearing cup in to the correct position This com pletes the work on the left axle DIFFERENTIAL PINION SHAFT THRUST BLOCK 51x187 Fig 14 Adjusting Axle Shaft End Play 28 REAR AXLE CAUTION Use clean shims Clean mating surfaces Pres ence of rust or grit will result in incorrect measurement 5 Install the right axle drive shaft and bear ing without lubricant Bearing should be clean and dry Using Tool C 413 drive the bearing cup in as far as it will go while rotating the axle shafts to seat both bear ings properly If the proper procedure has been followed as outlined in Step 4 the left bearing cup will be up firmly against the left brake support plate and the right bearing cup bearing cone right axle shaft thrust block left axle shaft and left bear ing cone will move as a unit until the left bearing is seated It is important that the axle shafts be rotated during this opera tion Now the end play in the bearings will be zero and the rotation of the axle shafts will require more effort The right bearing cup should then protrude beyond the hous ing end Leaving 010 inch out of the left shim as described in Step 3 will help to assure that the right bearing cup will
52. ter clock wise until only 001 inch backlash exists be tween the ring gear and the pinion Be sure that the right hand adjuster is kept screwed out so that the bearing cup can move with out interference 9 Make certain that the left hand bearing adjuster is in position where the nut lock and attaching bolt can be installed Tighten the upper left hand bearing cap bolt to 90 foot pounds torque NOTE In order to properly pre load the bearings the entire procedure must be very carefully per formed Therefore it 1s important to complete the operation with 001 inch clearance between Fig 43 Checking Backlash between Ring Gear and Pinion the ring gear and the pinion before the upper bolt is tightened 10 Turn the right hand adjuster clockwise until the dial indicator shows a backlash of 006 inch between the ring gear and the pinion as shown in Figure 43 Considerable effort will be required to turn the adjusting nut to the last notch or two How ever this is necessary to insure adequate pre load The adjustment should be performed so that the adjuster lock and attaching bolt can be installed 52x388 Fig 44 Adjusting Differential Bearings 44_ REAR AXLE CHRYSLER SERVICE MANUAL aa 346x255 Fig 45 Applying Gear Marking Compound to Gear Teeth 11 Tighten the right hand bearing cap at taching bolt to 90 foot pounds torque and recheck the other three After final tightening of all
53. uitable cleaning solvent to remove dirt and hardened lubricant from the assembly before inspection Bearings should be soaked in clean kerosene or any other good quality bear ing cleaning fluid NOTE Gasoline should never be used for eleaning parts since parts cleaned with gasoline have a tend ency to rust The bearings should be immersed in clean solvent and rotated by hand until clean After cleaning blow dry with controlled compressed air 3 INSPECTION The inspection of rear axles consists of visual inspection for damaged or excessive parts wear Parts that are worn pitted or scored must be replaced Scratches or rough spots on mating surfaces should be stoned out if possible If spots or scratches cannot be stoned out without damaging part part should be replaced Bear ings and bearing cup should be examined for cracks chips and discoloring due to overheating or excessive wear Bearings should be lubri cated and assembled in bearing eup rotated by hand to check for roughness and then wrapped in cloth and stored until ready for use Axle housing should be inspected for broken welds missing or loose housing to carrier at taching bolts damaged threads bent or cracked housing Inspect spring seat welds to make sure they are not broken or loose Repair or replace as required Drive gear and pinion should be inspected 22 REAR AXLE CHRYSLER SERVICE MANUAL 52x608 A Fig 4 Rear Axle Explod
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