REMOVAL & INSTALLATION

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1 REMOVAL & INSTALLATION AXLE SHAFTS & BEARINGS Removal CAUTION: Failure to turn off air suspension power before raising vehicle may result in unexpected inflation or deflation of air springs. DO NOT reconnect battery cable or turn air suspension switch to ON position until vehicle is lowered and slight vehicle weight exists on all wheels. 1. Raise and support vehicle. Remove wheel assemblies. Remove calipers and rotors. DO NOT allow calipers to hang by brake hose. Always support caliper with wire connected to frame. Remove housing cover, and drain lubricant. Remove differential pinion shaft lock bolt and pinion shaft. See Fig Remove ABS wheel speed sensor to prevent damage during axle shaft removal (if equipped). Push axle toward center, and remove "C" locks. Remove axle shaft. Use care not to damage axle seal or ABS sensor ring (if equipped). Using a slide hammer and puller, remove bearing and seal as a unit. Saturday, November 29, :17:01 11:17:06 AM Page Mitchell Repair Information Company, LLC.

2 Installation Fig. 2: Exploded View Of Axle Assembly (Mustang Shown; Others Similar) Courtesy of FORD MOTOR CO. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

3 1. Lubricate bearing with rear axle lubricant. Install wheel bearing and seal into axle housing using proper sized driver. Ensure seal is not damaged during installation. If seal becomes cocked during installation, remove and replace it with new one. Lubricate seal lips with multipurpose lubricant. 2. Install "O" ring on splined end of axle shaft. Install axle shaft in axle housing, using care not to damage oil seal. Install "C" locks on axle shafts. Pull axle shafts outward to seat locks in counterbore of differential side gears. 3. Apply thread sealant to pinion shaft lock bolt. Install pinion shaft and lock bolt, and tighten to specification. See TORQUE SPECIFICATIONS. Ensure housing cover sealing surfaces are clean and free of burrs. Apply 1/8-3/16" bead of silicone sealant on housing cover. NOTE: Housing cover assembly must be installed within 15 minutes of application of silicone sealant. 4. Install housing cover, identification tag and retaining bolts. Using crisscross pattern, tighten retaining bolts to specification. See TORQUE SPECIFICATIONS. 5. Install ABS wheel speed sensor (if equipped). Refill axle with gear lubricant. See LUBRICATION. CAUTION: If axle with Traction-Lok differential was drained, add 2 ounces (.06L) of Friction Modifier (F3TZ-19B546-MA ) to the fluid level. DRIVE SHAFT Removal Mark rear drive shaft yoke and companion flange for installation reference. Remove flange bolts, and disconnect drive shaft from companion flange. Pull drive shaft rearward until slip yoke clears transmission extension housing and seal. Temporarily install appropriate plug in extension housing to prevent fluid leakage. Installation 1. Lubricate slip yoke with lubricant. Remove plug from transmission extension housing. Inspect housing seal for damage, and replace if necessary. Install drive shaft. DO NOT allow slip yoke to bottom on output shaft with excessive force. 2. Install drive shaft so scribed marks on rear drive shaft yoke and companion flange align. This ensures original drive line balance. When installing a new drive shaft, align factory-made Yellow paint marks on drive shaft with Yellow paint mark on companion flange. Install bolts, and tighten to specification. See TORQUE SPECIFICATIONS. PINION COMPANION FLANGE & OIL SEAL CAUTION: Pinion flange and oil seal replacement affects bearing preload. Preload must be carefully reset during reassembly. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

4 CAUTION: Failure to turn off air suspension power before raising vehicle may result in unexpected inflation or deflation of air springs. DO NOT reconnect battery cable or turn air suspension switch to ON position until vehicle is lowered and slight vehicle weight exists on all wheels. Removal 1. Raise vehicle. Remove wheels, calipers and rotors. DO NOT allow calipers to hang by brake hose. Always support caliper with wire connected to frame. Remove drive shaft. See DRIVE SHAFT. 2. Using an INCH-lb. torque wrench, measure and record torque required to rotate pinion through several revolutions. Hold companion flange, and remove pinion nut. Mark companion flange and pinion shaft for installation reference. Using Companion Flange Remover (T65L-4851-B ), remove companion flange. Pry pinion oil seal from axle housing using small pry bar. DO NOT damage sealing surface of axle housing. Installation 1. Ensure all sealing surfaces are clean and free of burrs. Lubricate pinion oil seal lips with multipurpose lubricant. Using Seal Installer (T79P-4676-A ), install pinion oil seal. If pinion oil seal becomes cocked during installation, remove and replace oil seal. 2. Check pinion shaft and companion flange splines for burrs. Coat companion flange splines with small amount of gear lubricant. Align scribed marks on companion flange and pinion shaft. Install companion flange on pinion shaft. Coat washer side of new pinion nut with gear lubricant. Install pinion nut and washer. CAUTION: DO NOT hammer or use power tools on companion flange. 3. Using Companion Flange Holder (T78P-4851-A ), hold companion flange and gradually tighten nut. Rotate pinion until correct preload is obtained. If original preload is less than specification, adjust preload to specification. See the AXLE ASSEMBLY SPECIFICATIONS. If original preload is greater than specification, adjust preload to original preload value. 4. If desired preload is exceeded, install new collapsible spacer, and retighten pinion nut until proper preload is obtained. To complete installation, reverse removal procedure. Fill axle with gear lubricant. See LUBRICATION. REAR AXLE ASSEMBLY Removal CAUTION: Failure to turn off air suspension power before raising vehicle may result in unexpected inflation or deflation of air springs. DO NOT reconnect battery cable or turn air suspension switch to ON position until vehicle is lowered and slight vehicle weight exists on all wheels. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

5 1. Raise and support vehicle under rear frame crossmember. Remove housing cover, and drain lubricant. Remove wheels, calipers and rotors. Using wire, secure calipers to vehicle frame. Remove ABS wheel speed sensor (if equipped). Remove axle shafts. See AXLE SHAFTS & BEARINGS. 2. Mark drive shaft and companion flange for installation reference, and disconnect drive shaft at companion flange. Disconnect axle vent from axle housing at brake junction block (if equipped). Disconnect brakeline from axle housing clips. 3. Support rear axle assembly. Disconnect lower shock absorber studs from mounting brackets on axle housing. Disconnect upper arms from mounting on axle housing. 4. Lower rear axle assembly until coil springs are released. Remove coil springs. Disconnect and remove lower arms from axle housing. Lower rear axle assembly and remove from vehicle. Installation To install, reverse removal procedure. Apply Loctite to threads holding axle vent and brake block to axle housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS. OVERHAUL REAR AXLE ASSEMBLY NOTE: Differential case and drive pinion may be serviced with housing installed in vehicle. Disassembly 1. Raise and support vehicle under rear frame crossmember. Lower hoist until axle drops down to within working range. Remove housing cover, and drain lubricant. 2. Mount a Dial Indicator (4201-C) on axle housing, and measure ring gear backlash and runout. See Fig. 6. Record readings for reassembly purposes. Ensure ring gear runout and backlash variation between teeth are within specification. See the AXLE ASSEMBLY SPECIFICATIONS. Replace ring gear and pinion if backlash variation is excessive. 3. Remove axle shafts. See AXLE SHAFTS & BEARINGS under REMOVAL & INSTALLATION. Remove drive shaft. See DRIVE SHAFT under REMOVAL & INSTALLATION. NOTE: Bearing cups, caps and shims must be installed in original positions. 4. Mark one bearing cap for reassembly reference. Note arrow position on bearing cap for reassembly reference. Loosen bearing cap bolts and bearing caps. Pry out differential case, bearing cups and shims until they are loose in bearing caps. Remove bearing caps and differential. Mark component location for reassembly reference. 5. Remove pinion nut and companion flange. See PINION COMPANION FLANGE & OIL SEAL under REMOVAL & INSTALLATION. Drive pinion from front bearing using soft-faced hammer. Remove pinion from rear of axle housing. Pry oil seal from axle housing. 6. Remove front bearing. Remove pinion bearings if damaged. Mount bearing puller on pinion, and press Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

6 pinion from bearing. Remove pinion shim located behind bearing, and measure and record shim thickness. NOTE: DO NOT remove pinion bearing cups unless damaged. If bearing cups are replaced, bearings must also be replaced. 7. Bearing cups in axle housing may be removed using brass drift and hammer. Tap alternately on each side of bearing cup during removal to prevent bearing cup from binding in axle housing. 8. If ring gear runout exceeds specification, install differential case with bearings and cups in axle housing without pinion assembly. Install a.265" (6.73 mm) shim on left side of differential case. Install left bearing cap and bolts finger tight. 9. Apply pressure on ring gear toward left side to ensure bearing has seated in cup. Shim right side until slight drag is felt. Install bearing cap and bolts. Tighten bolts to ft. lbs. ( N.m). Rotate differential case to ensure free rotation. 10. Install dial indicator, and check ring gear runout. If runout is within specification, excessive runout was caused by improper bearing preload. If runout is still excessive, remove differential case. 11. Mark ring gear and differential case for reassembly reference. Remove ring gear bolts. Tap ring gear from differential case. Install differential assembly in axle housing as in step 8). 12. Recheck runout on differential case flange. If runout is within specification, install new ring gear and pinion. See AXLE ASSEMBLY SPECIFICATIONS. If runout is not within specification, inspect differential case and bearings for damage. 13. If bearings are not damaged, replace differential case and bearings. Remove differential side bearings using a puller. Mark differential case and ring gear for reassembly reference. Remove pinion gears, side gears and thrust washers. Cleaning & Inspection 1. Clean all parts in cleaning solvent. Dry components using compressed air. DO NOT spin dry bearings. Coat all bearings with light coat of gear lubricant to prevent corrosion. Inspect all bearings and cups for damage. 2. Check bearings for smooth rotation after installation in cups. Inspect all gears and thrust washers for chipping and flaking. Inspect differential case bearing shoulders for damage from bearing removal. 3. Using micrometer, measure thickness of all thrust washers. Replace thrust washers if not within specification. See the AXLE ASSEMBLY SPECIFICATIONS. 4. Inspect companion flange for seal and bearing contact area wear and damage. Replace any worn or damaged components. When replacing ring gear and pinion, note original factory shim thickness to adjust for variations in both carrier casting and original gear set dimension. NOTE: Ring and pinion gears must be replaced in matched sets. Reassembly 1. If new components were installed, check gear set assembly using Pinion Depth Gauge (T79P-4020-A ) to determine correct pinion shim thickness. See PINION DEPTH under ADJUSTMENTS. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

7 2. Install new bearing cups in axle housing if necessary. Bearing cups must be seated in bores so a.0015" (.038 mm) feeler gauge will not fit between bearing cup and bottom of bore. 3. Install necessary shims on pinion to obtain correct pinion depth. Press inner bearing on pinion shaft. Ensure bearing is seated against shims. Lubricate pinion bearings with gear lubricant. Install pinion in axle housing. Install new collapsible spacer and outer pinion bearing. 4. Verify sealing surfaces are clean and free of burrs. Using Seal Installer (T79P-4676-A ), install oil seal. Remove and replace oil seal if it becomes cocked during installation. Lubricate oil seal lips with multipurpose lubricant. 5. Check pinion shaft and companion flange splines for burrs. Coat companion flange splines with small amount of gear lubricant. On used pinion, align scribed marks on companion flange and pinion shaft. Install companion flange on pinion shaft. Coat washer side of new pinion nut with gear lubricant, and install pinion nut. 6. Using Companion Flange Holder (T78P-4851-A ), hold companion flange and gradually tighten pinion nut. See TORQUE SPECIFICATIONS. DO NOT hammer or use power tools on companion flange. Rotate pinion and check pinion bearing preload often until correct preload is obtained. See PINION BEARING PRELOAD under ADJUSTMENTS. NOTE: If desired preload is exceeded, install new collapsible spacer, and retighten nut until proper preload is obtained. 7. Lubricate all parts with gear axle lubricant. Place side gears and thrust washers into differential case. Place pinion gears and thrust washers exactly opposite each other in differential case openings, and mesh with side gears. 8. Install ring gear using new mounting bolts. Apply Loctite to bolt threads. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Press new bearings onto differential cases using proper sized sleeve. Ensure bearings are fully seated on differential cases. 9. After proper shims have been chosen to obtain proper ring gear backlash and bearing preload, differential assembly may be installed. See DIFFERENTIAL BEARING PRELOAD & RING GEAR BACKLASH under ADJUSTMENTS. 10. Install differential assembly and bearing cups in axle housing. Install bearing caps and bolts. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS. 11. Check ring gear backlash and gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Gear tooth contact pattern does not need to be checked if pinion depth gauge is used and backlash is correct. Pinion depth and ring gear backlash may be adjusted to obtain proper gear tooth contact pattern. 12. Once all adjustments are correct, install axle shafts, housing cover, brake drums or calipers, and rotors (if equipped). Install wheels. Install drive shaft. Fill axle housing with gear lubricant. See LUBRICATION. ADJUSTMENTS PINION DEPTH 1. Assemble Pinion Depth Gauge (T79P-4020-A ). See Fig. 3. Install aligning adapter,.89" (23 mm) gauge disc for 7 1/2" ring gear or 1.88" (48 mm) gauge disc for 8 3/4" ring gear, and screw. Place rear pinion Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

8 bearing over aligning disc and into bearing cup of carrier housing. 2. Install front pinion bearing into front bearing cup. Place handle onto screw, and tighten to 20 INCH lbs. (2.25 N.m). See Fig. 4. Ensure pinion depth gauge is properly installed and tightened. Fig. 3: Assembling Pinion Depth Gauge (All Models) Courtesy of FORD MOTOR CO. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

9 Fig. 4: Installing Pinion Depth Gauge (All Models) Courtesy of FORD MOTOR CO. 3. Apply a light film of oil to pinion bearings. Rotate gauge block several times to seat bearings. Rotational torque on gauge block assembly should be 20 INCH lbs. (2.25 N.m) with new bearings. Final position of gauge block should be 45 degrees above axle shaft center line. See Fig Clean differential bearing bores thoroughly, and install gauge tube. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS. Use flat pinion shims as a gauge for shim selection. Hold gauge block in proper position, and measure clearance between gauge block and gauge tube. 5. Correct shim selection is accomplished when a slight drag is felt as shim is drawn between gauge block and gauge tube. Shims are available in various thicknesses. Install correct shim on pinion for reassembly. Pinion bearings must be installed in same locations as during pinion depth measurement. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

10 Fig. 5: Final Position Of Pinion Depth Gauge (All Models) Courtesy of FORD MOTOR CO. PINION BEARING PRELOAD 1. Place pre-selected shim on pinion. Press bearing onto pinion until bearing and pinion shim are firmly seated against shoulder of pinion. Install new collapsible spacer on pinion. 2. Lubricate bearings with axle lubricant. Install front pinion bearing in housing. Install new pinion oil seal. Lubricate pinion oil seal. 3. Insert companion flange into seal, and hold firmly in place. From rear of axle housing, install pinion into companion flange. Install new pinion nut. 4. Gradually tighten pinion nut while holding companion flange. Rotate pinion in both directions several times to seat bearings. Using INCH-lb. torque wrench, rotate pinion and check pinion bearing preload. Tighten pinion nut to specification while measuring pinion bearing preload. See TORQUE SPECIFICATIONS. 5. If pinion bearing preload exceeds specification before reaching specified torque, replace collapsible spacer. See AXLE ASSEMBLY SPECIFICATIONS. Install new pinion nut, and repeat procedure. DO Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

11 NOT loosen pinion nut to reduce pinion bearing preload. DIFFERENTIAL BEARING PRELOAD & RING GEAR BACKLASH 1. With pinion depth set and pinion installed, place differential case and gear assembly with bearings and cups into axle housing. Install a.265" (6.7 mm) shim on left side (ring gear side) of differential. 2. Install left bearing cap and bolts finger tight. Select largest shim that will fit with a slight drag, and install it on right side (pinion gear side) of differential. Install right bearing cap. Tighten all cap bolts to specification. See TORQUE SPECIFICATIONS. 3. Rotate ring gear to ensure free operation. Check ring gear backlash. See Fig. 6. Ring gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS. If ring gear backlash is zero, go to step 4). If ring gear backlash is not within specification, go to step 5). If ring gear backlash is within specification, go to step 7). Fig. 6: Measuring Ring Gear Backlash (All Models) Courtesy of FORD MOTOR CO. 4. Add.020" (.51 mm) to shim size on right side, and subtract.020" (.51 mm) from shim size on left side. Check ring gear backlash. If ring gear backlash is within specification, go to step 7). If ring gear backlash is not within specification, go to next step. 5. Increase shim thickness on one side, and decrease shim thickness on opposite side by same amount. See Fig. 7. See BACKLASH-TO-SHIM THICKNESS CONVERSIO N table for approximate shim Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

12 change. BACKLASH-TO-SHIM THICKNESS CONVERSION Required Change In Backlash - In. Required Change In Shim Thickness (mm) - In. (mm).001 (.03).002 (.05).002 (.05).002 (.05).003 (.08).004 (.10).004 (.10).006 (.15).005 (.13).006 (.15).006 (.15).008 (.20).007 (.18).010 (.25).008 (.20).010 (.25).009 (.23).012 (.30).010 (.25).014 (.36).011 (.28).014 (.36).012 (.30).016 (.41).013 (.33).018 (.46).014 (.36).018 (.46).015 (.38).020 (.51) 6. Install shim and bearing caps. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS. Rotate ring gear several times. Recheck ring gear backlash. If ring gear backlash is within specification, go to next step. If ring gear backlash is not within specification, repeat step 5). 7. Increase both left and right shim sizes by.006" (.15 mm), and reinstall for correct bearing preload. See DIFFERENTIAL SHIM SIZE table. Ensure shims are fully seated and ring gear assembly turns freely. Using marking compound, check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

13 Fig. 7: Adjusting Ring Gear Backlash (All Models) Courtesy of FORD MOTOR CO. DIFFERENTIAL SHIM SIZE Color No. Of Stripes Shim Thickness In. (mm) RED ( ) RED ( ) ORG ( ) ORG ( ) ORG ( ) ORG ( ) ORG ( ) YEL ( ) YEL ( ) YEL ( ) YEL ( ) YEL ( ) WHT ( ) WHT ( ) Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

14 WHT ( ) WHT ( ) WHT ( ) GRN ( ) GRN ( ) GRN ( ) GRN ( ) GRN ( ) PNK ( ) PNK ( ) PNK ( ) PNK ( ) PNK ( ) BLU ( ) BLU ( ) BLU ( ) BLU ( ) GRY ( ) GRY ( ) AXLE ASSEMBLY SPECIFICATIONS AXLE ASSEMBLY SPECIFICATIONS Application Specification In. (mm) Companion Flange Runout.010 (.25) Differential Case Runout.003 (.08) Differential Side Gear Thrust Washer Thickness ( ) Maximum Ring Gear Backlash Variation Between Teeth.004 (.10) Nominal Pinion Shim Thickness.030 (.76) Pinion Gear Thrust Washer Thickness ( ) Ring Gear Backlash ( ) Ring Gear Runout (Maximum).004 (.10) INCH lbs. (N.m) Pinion Bearing Preload (With Oil Seal) New Bearings ( ) Original Bearings 8-14 (.9-1.6) TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

15 Axle Vent (14-24) Bearing Cap Bolt (95-122) Drive Shaft-To-Companion Flange Bolt (95-129) Housing Cover Bolt Metal Cover (38-51) Plastic Cover (24-38) Oil Filler Plug (20-41) Pinion Nut 7 1/2" Ring Gear Minimum 140 (190) 8 3/4" Ring Gear Minimum 140 (190) Pinion Shaft Lock Bolt (20-41) Ring Gear Attaching Bolt (1) (95-115) Upper & Lower Arm-To-Rear Axle Assembly Bolt Exc. Mustang ( ) Mustang (95-136) Wheel Lug Nut ( ) (1) Apply Loctite to bolt threads. Saturday, November 29, :17:01 AM Page Mitchell Repair Information Company, LLC.

DIFFERENTIALS & AXLE SHAFTS

DIFFERENTIALS & AXLE SHAFTS 2001 Chevrolet Camaro 2000-01 DRIVE AXLES General Motors Differentials & Axle Shafts Chevrolet; Camaro Pontiac; Firebird DESCRIPTION & OPERATION Drive axle is a semi-floating,