Rearaxle

Rearaxle
Repairsand 1976-
Maintenance
 Contents

Page
Specifications 1
Specialtools 2

Sparepartsillustrations
Rearaxleassembly 6
Differential 7
Limitedslip differential B

Descriptions
Flearaxle
Diflerential 10
Limitedslipdifferential 'tl

Serviceprocedutes Op.No.
On vehiclerepairs
- C h e c k i nl gi m i t e sd l i pd i f f e r e n t i .a. l. . . . 12
- C h e c k i n ge n df l o a o t f a x f es f r " f U
t e " r i n g. . . . . . . . . . - B1_83
Beplacrng pi'1ron seal c1-c7 14
R e p l a c i nagx l es h a f bl e a r i nagn ds e a .| . . . . . . . . . . . . . D1-D21

Removingrearaxle 21

O i s a s s e m b l irnega ra x l e. . . . . . . . . . . . . . . . . . . . . . . . . F1-F13 25
- D i f f e r e n t i a l w i t hl oi m
u ti t e sdl i p. . . . . . . . . . . . . . . . . . F14-Fj7 28
D i f f e r e n twi ai lt hl i m i t e sdl i p. . . . . . . . . . . - . . . . . . . . . . . F18_:F22 29
- C l e a n i n ign, s p e c t i o n -.. -.. . F2g

Assemblingdillerenlial
- Differential
withoutl i m i t e d s l i p . -. . . . . . . . . . . . . . - . .
- Differential
with limi t e d s | i p. . . . . . . . . . . . . . . . . . . . . . . G8 G9 34
- Installing
pinion . . G10-G27

Installingdifferential H1-H20 40
Inslallingrearaxle 11 I17

TP 30039/2
3000.06.81

Printedin USA
 Specilications

Specifications

Rearaxle Metric USmeasurements

qear ax e. type Semi-floating
Track . . 1 3 5 0m m 53.1s',

Finaldrive
Tvpe Hypoid

Reduction ratio
Type1030 3.73:1 : 1, 4 . 1 0 : 1
3 ,. 9 1
Type1031 3.54:1,3.73:1
Wa p. ringgea' max.0.08 mm 0.0032'
Backlash............ 0 . 1 3 - 0 . 1m 8m 0.005-0.007'

Pre-loadingon pinionbearings
n e wb e a f l n g s . . . . . . . . . 25M50 Ncm 21-39in.lbs.
used bearings 6 0 1 1 0N c m F10 in.lbs.
P.e-loadingon oifferenLial bearngs 0.13-0.20 rnm 0.00H.008"

Lubricant
OLa iry.standarddi'fere'rial . . A P tG L - 5( M i rL - 2 1 0 5 - B )
I m.reds ip oiffprentral APIGL-5(l\lilL-2105-B) withadditive
for limitedslipdifferential
Viscosrlyrormal opa'arirg co'1ditiors. . SAE90
when temperatureis steadiy below
l 5 " F - 1 0 " Cu s e SAEBO
'1.35 USqts
Capacity:Type
1030 1.3lrters
Type1031 1.6liters 1 . 7U Sq t s

Tighleningtorques Nm ft.lbs.
Caps 50 70 35-50

Ring gear:standardbolt heads 70-80 50-58

flangedbolt heads. 90 110 65-80

Wheelruls.. 1 0 01 4 0 70-100

F l a n g en u t s .8 8 6 2 6( 3 / 4 "U N F ) . . . 240-300 175-220

946831(3/4"UNF) . . 200-250 145-180
947855(M20| l5) 2A0 250 145-180

Gtoup46
Specialtools
Specialtools

1801 Slandardhandle 2714 Fixlure

1845 Presstool3/4'-16UNF removing/installing rearaxle
installing driveflange 2779 Socket
2261 Pullel removing propeller shaft
rounddriveflange 2806 Drift
2284 Dialgaugeholder insialling sealon drivef ange
adjusting finaldrive 2809 Holder
2337 Tool plateanddialgauge
removlng carrrer 2838 Presstool
2392 Puller rernoving/installing driveshaltbearing
rearpinionbearing andsnapflng
2393 Measuring tool 2840 Adlustingring
adjusting pinion(ill.at 2284) pinionheight(ill.at 2685)
2394 Expandingtool 2841 Wrench
removing/installing
differential
2395 Drift
limitedslip for adjustingrings2840,2685and
2689(ill.at 2685) 0)
2842 Sleeve
installing rearpinionbearing installing rearpinionbearingouter
2404 Wrench ring(ill.at 2395)
installing
(ill.at 1845)
frontpinionbearing 2843 Otill
removing rearpinionbearingouter
O)
2483 Puller r i n g( i l l .a t 1 8 0 1 )
differential carrierbearings 2844 Puller
2524 Workstand rearpinionbearing(ill.at 2392)
2522 Fixture 2845 Presstool
2595 Adlustingrings installng pinronbedri']qourer'rngs
differential (ir.at 2686)
2598 Dritt 2846 Socket
removingtearpinionbearingouter removing propeller shaft(ill.at 2779)
r i n g( i l l a
. t1 8 0 1 ) 2917 Extractor
2599 Drilt brakepads
r e m o v i n g ' r opnitn i o nb e a n go u l e r 4112 Drilt
ringand installing differential instalingdifferential carrierbearings
carrierbearings 5009 Drift
2600 Measuring fixture installing driveshaftinnerseal
for adjusting rings2595,2685,2687, 5010 Ring
2689and 2840 installng bearingandsnapringon
260'1Relainer driveshaft(ill.at 2838)
torexpanding tool2394(ill.at 2394) 5069 Puller
2685 Adlustingring Pinionseal
ptnton 5149 Wrench
2686 Presstool instaliing/removing drivef lange
instalJing pinionbearingouterrings 5156 Presstool
2709 Extractor instalingdriveflange(ill.at 1845)
driveshaft 5157 Wrench
for adjusting ring(ill.at 2685)
5214 Ring
(fortool 521515216)
5 2 1 5P u l t e r
p i n i o nb e a r i n (1030
g axle)
5216 Puller
pinionbearing(103'1 axle)

Group46
Rearaxle
 Speclal ioo/s

1801Siandardhandle 1845Piesstool3/4'-16UNF 2261Puller

2598 Drift installing
driveflange round drivef ange
removingrearPinionbearing 2404 wrench
outerrrng frontpin on
inslalling
2843 Drilt beanng
removingrearPinionbearing 5156 Presstool
outerring installlng
driveilange

\ t
2284 Dialgaugeholder 2337 Tool 5215 Puller(1030)new
finaldrive
adjusting removtng
carner rearpinionbearing
2393Measuringtool 5216 Puller(1031)new
pinion
adjusting rearpinionbearing
5214 Ring

2395 2483
2842

2394 Expanding tool 2395 Drift 2483Puller

removing/installing
limited rearpinion
installing differential
carrierbearings
slipdifferential lreanng
2601 Holder 2842Sleeve
forexpanding tool2394 rearpinionbearing
installing
outerring
Graup46
Rearaxle
3
 Specla/tools

2520Worksland Adlustingrings Drift

2522Fixture differential removing frontpinionbearing
outerringandinstalling
difierential
carrierbearings

2685 Adiustingring
prnron
2840 Adlustingring
p i n i o nh e i g h t
2600Measuring tixture 2686 Presstool
2841Wrench pinionbearingouter
for adjustingrings2595,2685, installing
for adjustin g rings2840,2685
2687, 26A9and 2840 flngs
and2689 2845 Presslool
5157Wrench pinionbearingouter
lnstalling
for adjustingring
rings

g"
2709 Exlractor 2/14 Fixlure 2779 Socket
driveshaft rearaxle
removlng/installing propellershaft
removing
2846 Socket
removing shaft
Propeller

Grouq46
4 Reataxle
 Specia/tools

2806 Drift 2809 Holder 2838 Presstool

installingsealon driveflange plateand d al gauge removlng/installing
driveshaft
bearingandsnapring
5 0 1 0R i n g
installing
bearingandsnapring
on driveshaft

o
112

lr,rl

Extractor Drift 5009 Drift

0raKepaos installing
differentialcarrier installing
driveshafiinner
oearngs seal

5069Puller 5149Wrench
pinionseal installng/removing
driveflange

Gtoup46
SparePartslllustration

ALTI ALT 2

ii
')
@l

or&-,

s i
I

Rearaxleassembly

Gtoup46
Reataxle
 SparePartslllustration

Differential
(Finaldrive)

o
o

o
,-:1
c

[-..,\6

\@

Gtoup46
SparcPaftslllustrction

I
qI

o
o
{z-vtD
'/ ,' \t ,
\
r\ I
..*, x
 DescrtPtton
Description,
rearaxle

2. Tralingarm

5. Stabilizer

o The rearaxle is connectedto the body by 1wo

trailingarnrs(2).Longitudinalforcesaretransfer
redby tworeactionrods{3)andtransversal torces
by a track rod (Panhardrod) (4).Trailng arms,
reactionrodsand trackrod areattachedto body
andrearaxleby replaceable rubberbushings.
llost vehicles(not wagons),are equippedwith a
rearstabilizer(5)fittedbetweenthetrailingarms.

TheoLiterendsoi ihe driveshaftsarejournaled

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

Graup46
Description Description,
ditferential
shrmsa
, d j u s tb a c k l a s h
differential
gears nnggearteeth,
I
20

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

lhe rlnqgear

nnggear

3 0 iu
,',
oeannq
only)
{produclion

shims,adlustpin on
beafng pre oad
\ /

Thefinaldriveis of the hypoidtype,whichmeans p nions on a trunnionand two side gears in

that the drivepinionliesbelowthe centeroTrne
rrng gear-lt consistsof pinion,ring gear and
differentialgear.Gearbacklashand diiferenta
carrierbearir1glensionareadjustedby shimsin-
sidethedifterential carrierbearings.
Differential carrierand ring gear assemblyare
journaledin the finaldrivehousingby iwo taper
rollerbearings. The ring gearis attachedto the
differeniialcarrierby bolts.Thedifferentialgears
in the diiferentialcarrierconsistof two oevel
Group46
whichdr ve shaitsarecarriedby internalsplines.
The differentialgearsarejournaledso thai they
can rotateand permitthe driveshaftsto rotateat
d fierentspeedswhenlhe car is beingdnvenin
curvesThereis a thrustwasherundereachof
thediffereniiagears.
Thepinon bearings arelaperro er bearings. The
axial locaton oi the p nion relativeto the ring
gear s adjusledby shimsunderthe outerraceof
the rearp n on bearings.

Limitedslip differential
brake",'antispin")
{"Differential
Exceptlor thedifferential
assembly,
the
design
isthesameasforstandarddifferential.
,/!
lai
\?
1 D i f f e r e n t i ac a f i i e r ,s m a e r s e c t i o n
2 D i s c si n t e r n a l t e e t h
3 D i f f e r e n i i asl i d eg e a rr e i a l n e r
4 D i f f e r e n l l apl i n l o nq e a r
Descrtptlon
#
tr
5 Spider
6 D i f f e r e nat l carrier largerseclion
7 D i l f e r e n i i asl i d eg e a r
8 D l s c s ,e x t e r n a, t e e t h
Twoshaltsmakeup ihe spiderfor the differential
plniongears.On the sidewhereit is againstthe
ditferential carrier,each shaft has a V-shaped
bevel.Thedifferential carrieris correspondingly
designed. WhenpowerfroTnthe enginestartsto
drivethevehicle, theshafts(A)g ideup the bevel-
lod re.es. in rhe differerrialcarrer. lhis com-
presses the frictionplatesbehindthe differential
sidegearsso that the ditferential assemblybra-
k e s T h eb e v eal n g r eo r l h ed ' r e ' e r r i acl a r , r ei.s
designed andchosenin sucha waythatthediffe-
rental gearsare not entirelylocked,but max.
75% of enginetorquecan be transmittedto a
driveshaft.
Group46
11
 .t
On-vehiclercpairs
- Limitedslipdilfercntial-

Onvehiclerepairs
Checkinglimitedslip differential

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

A2

Jack up the vehicle

At one of the rearwheels.Blockthe other.Place
gearleverin neutral.Release parkingbrake.Re-
movethewheel.

A3

Placetool ovel wheelstuds 0

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

GtouP46
a
",.u_
?i::nl:::::::;
Checkingendfloaton axleshaftbearing

Theendfloatfor the axleshaftscannotbe adjus-

reo.
However, it may be necessaryto determine
whethertheendf loatiswithinacceptable
limits.

B1

Jack up vehicleand removewheel.

Removebrakepads.
Usepuller29lTif necessarv.

B2

Installmeasuringequipmenl,
a. Usetool 2809to clampan iron plateagainst
ih6 hr.l6 ^.lin6r'< h^<c

b. Usea dabof greaseto placea steelballin the

centerholeof the axleshaft.

c. Placethe standtor the dialgaugeon the iron

plate.Placethe dial gaugemeasuringpoint
(whichmust havea flat surface)againstthe
steelball.

B3

Measureend float,
The end float shouldbe 0.01-{.35mm = 0.004
-0.0'i4".
To obtain total end float, the axle shaft must be
rotatedat leastonerevolution in bothdirections.
NOTE:
Priorto installation,
bearingsfor the axleshafts
have considerablygreater clearance.lt is
reduced at installation.
Repeaiprocedure for otheraxleshaft.

Gtoup46
Rearaxle 13
 on-vehiclerepairs

Replacingpinionseal(onvehicle)

Disconnecldriveshaftat pinion
use socket2779or 2846.
Check conditionof pinion and bearings.lf found
to be loose,the final drlve is to be removedand
overnauteo.

Removeflangenut,
a{
Usewrench5149.

t:-l

Remove
llange.
U s ep u l l e r 2 2 6 1 .

b
2261

R e m o v es e a l .
UseextractorS069.
Alsoremoveprotecting
shield.

5069

Group46
14
 On vehiclerepairs

2806
Installnew seal
Usedrift2806.
Packthe newsea springwith 9rease.Otherwise
t h es p r i n gm i g h tj u m po u l o f p o s i t i o o
n u n n gI n -
stalat on.Also grease theseallips.
ll ustration:
I = Seal
2 : springwith layerof grease

Installllange.
Usetool1845or 5156.
Torques:
nut88626(3/4"UNF):24H00 Nm
= 175 220ft.lbs.
1845
5156 nut946831
(3/4"UNF):20G-250
Nm
= 150-185
ft.lbs.
(M20x 1.5):20G-250
nut947855 Nm
= 150-185
ft.lbs.

Reconnectdriveshaft.
tJsetool 2779or 2846.

Group46

tc
On-vehiclercpairc

Replacingaxleshaftbearingand seal

Preparations.
Jackupvehicle.
Removerearwheel.
USAN,4odels: guard.
removecollision

Removebrakepalts.
Detachbrakelineandbracketfromrearaxle.
Removebrakecaliper.Hangit out ol waywith a
lengthof steelwire to preventdamageto brake
pipe.

Removebrakediscs,
Parkingbrakemustbe in thefull releaseposition.
Bemovethe two Phillipsheadscrewsand lift off
the brakediscs.Tapon the insideof the discwith (
a plastichammeror similartool if necessary.

Removeparkingbrakeshoes
Unhookand removethe springsusing brake
springpliers.

Grouq46
Bearaxle
 an vehiclereqatrs

Disconnectparkingbrakecables.
Pressout the lock pin securingthe brakecabes
to the levers.Use3mm punchif the pin doesnot
faLlout.

D6
r:.try
t'

Freebearingretainers.
Rernovefour bolls (hex15mm)to free bearing
retatners.

D7

Remove axle shafts.

Pul axleshaftsout of rearaxleassernbly
using
pul er tool 2709.

D8

Removeinnerseal.
Usetool2337.

D9

2838
R e m o v i ncgi r c l i pb, e a r i n ga n db e a r i n g
reiainerplate.
a Placetoo 2838in a v se. F x shaft n tool.
b; Adjust too so that jaws come between
bearingand seal The seal l\,4UST NOT come
betweentoo and bearrng.
c. Pressoii circlip and bearing.
d. Opentoo . Removeparts.
e D r s c a r (o r c p l l V U S N O I b e ' e u . e d .

Gtoup46

17
 On vehiclerepairs

Dl0

Preparebearingand sealsfor
installation.
The new bearingshoLtldbe completetyfltledw th
h gh quality wheel bearing grease. press in
greaselrom one side until greasecornesout on
the other.
Also greasethe new seals.Fill the space berween
the ips with grease.

2838
I n s t a l l i nbge a r i n gr e t a i n e rb,e a r i n ga n d
circliD.
LJsetool5010to presson the bearinq.

D12

CIeanthe interotof the rear axletuDe.

D13
0 (

I n s t a liln n e rs e a l .
Usetools5009and 1801. (

D14

Install axle shaft.

Installscrewsfor bearingretainer.
Torque:30-50Nm = 22-36tt.lbs.
InstaI brakeshoereiainingsprings

Graup46
'18
 on-vehiclerepais

Dl5

Attachbrakecablesto levers.
Lubrlcateall joints and shoe contactsurfaces
withheatresistantgraphitegrease.
Pressin pinsecuringbrakecablesto levers.

D16

Installparkingbrakeshoes.
Inspectbrakelining.Referenceappropriate
ma-
nualforderaledoroceduTesas neuessarv

D17

lnstallbrakediscs.
Installdiscs and secure with two Phillips head

D18

Adjustparkingbrake.
Loosencableat parkingbrakeleverto remove
anytensionon cables.
The adjustingscrew is accessible
throughash
trayhousing.
Use17 mm socketand extension. Adjustso that
brakeis fully appliedbetween2-3 notchesof
brakelevermovernent.

Gtaup46

19
 I
on vehiclerepairs

D19

Installblakecaliper.
Attachbrakelineandbracketto rearaxle.
Usenewscrewsfor brakecaliper.

D20

Installcollisionguard.
tJSAmodels.
D21

Installwheels.
Torque:120t 20 Nm :87 :! I ft.lbs.
0 (

0(
(

Group46
20
 Removingrearaxle
Removingrearaxle

Raisevehicle on lift and remove real

wheels.
pipebelowthe rearaxle,remove
Withexhaust
exhaustpipefrom front to rear
intermediate
muftler.
E2

Trailingarm frontends.
Loosenthe reiainingboltsslightly(toa ow the
trailingarms to rotatefreelyat the front ends
whenremovinglhe rearaxle).
E3

Removestabilizerbar.
Removerear retainingbolts (hex 19mm)on
eachside of bar.
Removefront bolts (hex l7mm) on each side
and let stabilizerbar down.

E4
Remove rod (Panhardrod).

R e m o v ec o l l i s i o ng u a r d s .

Group46

21
 rearaxle
Removing

On rearaxle.
Disconnectthe venti ation hose.
Removeclampsho ding brakepipes.
Djsconnectthe brake pipes from rear axle and
secureout ot way to preventdarrageto pipes.

(
Removebrakecalipers.
Removetwo bolts (hex 17mm)and free the brake
ca ipers(leftand rrght).
Removebrake I ne clamp to allow some freedom
ol movementfor the caliper.
0 (

Hook the brake calipers to their respective

s o ri n g sr o o r e v e ntlh e b r a l . el r r e s ' r o n b e c o m i a g
drstorted.

E8

Removebrakediscs.
Parkingbrakemust be ln the fu I releaseposition.
Removethe two Phillipshead screws and lifi off
the brakediscs Tap on the insideof the disc with
a plastc hammeror simi ar tool ii necessary. 0 (

0 (

E9

Removeparkingbrakeshoes.
lJnhookand removethe springs using brake
sPringPllers.

Grcup46

22
,
Removingrearaxle

Disconnectparkingbrakecables.
Pressout the lock pin securingthe brakecables
to the evers.Use3 mm ounchif the oin doesnot
fallout.

driveshaltfrom pinion
Oisconnect
flange.
Usetool2779or 2846.

E12

Delachparkingbrakecablestrom reat
axte.
1. Screw
2. Cable
3. Plastictube(onlyremoveif the rearaxleis to
be replaced).

Disconnect
the reactionrodsat the real
axte.

GrouP46
Rearaxle
23
 Removingreat axle

E14

Placelixture2714underlear axle-
Therearaxlebossshouldreston the lixtureloop.

I
I
El5
(

Disconneclthe leal shockabsorbersat

the upperatlachments.
Installspringcompressor
Compress
5040on the springs.
the springsuntilthe shockabsorbers
o(
canbedetached.
Thenremovethespringcompressor.

E16

Removethe screwsholdingthe rear

axleto the tlailingarms.

ol
E17 @(

Bemovethe rear axle.

n
v

GtouP46
Reataxle
24
 Disassembling
rearaxle

Disassembling
rearaxle

Placerearaxle and fixture2522on work

I stand2520.
Bottomof finaldrivehousingtowardstandand
I piniondown.

D
D
*

Removeaxle shatts.
a. Usetool 2709to pull out axleshafts.
b. lJsetool 2337to removeinnerseals.

Removeditferentialhousingcover.
Bemoveten screwsihex 13 mm) to free cover.
fl
\}

Bearingcaps.
Checkthat bearingcapsare markedlor proper
alignmentwith carrier.lf Ta'ks are'nissingor
difficultto see,markbothsidesto ensurecorrect
reinstallation.
Removefour screws(hex'16mm)to freebearing
caps.
Disassemblingrcat axle

Installtool2394.
Placelool 2394w|lh rera.ners2601or hoLsrng.
Alignpinson tool with holesin housing.Screw
retainer
boltsinlohousing.
Tighten the tensioningscrew until tool fits
securelyin holes.Thentightenscrewslowlyuntil
thedifferential
assemblycanbe removed.
DONOTexceed3 1/2turnson thescrew.

F6
0(
Removedifferentialassembly,
Usetool2337.
Release tensionon tool 2394to preventcarrier 0 (

distortion.
Thenrernovetool2394.
Turnthe rearaxleanddraintheoil.

Removeflangenut.
Usewrench5149and suitabe socket.

o(
Q, (

Removeflange.
Usetool2261.

Group46
T Disassembling rcat axle

F9

Removepinion.
Usea plaslichammerto knockout the pinron.
To preventdamage,hod the pinion wrth one
handas it isdrivenout.

F10

D
Removepinionbearing.
Usestandardhandle1801and 2599to remove
frontpinionbearing,
washerand
seal.

lf necessary:
Removeteal p i n i o nb e a r i n go u t e rt i n g .
Rear axle type 1030:use standardhandle1801
and tool 2598.
Rear axle type 1031:use standardhandle1801
and lool2843.

It necessary:
Remove rearpinionbearing.
Bearaxle type 1030:use tool 5215
Rearaxletype1031:|rsetool52'16
andtool52'14.
See nextpagefor instructions on howto applythe
tool.(Superseded
tool illuslrated).

Group46

27
 Di sassembIi ng di ffete nti aI
- Withoutlimited slip-

F13

1.
Pushpulleroverrollersand pressdownthe lock
nng.
2.
Tightenpullerscrewsuntil rollersare flushwith
edgeof innerraceandpuller.
3.
Driveout lockring.

Differential
withoutlimitedslip
Removedifferentialcarlierbearing.'
Usetool2483.Careshouldbetakennot to dama-
o(
ge shimpack.Putit asidewithremovedbearing.
'1.
Placepullerover bearingon ring gear side of
carrier.IVlakecertainthat groovein tool catches
on rollers.
Presslockringdownon tool.
2.
Tightenpulleruntilbearingisoff carrier.
3.
Usea hammerto knockoutihe lockring-
Repeatfor other bearing.Record positjonof
bearingsand shimsto facjlitateinstallation
on

F15
o.{
Removeling gear.
o(
Placedifferential
assembly in visewith protected
jaws.
Remove lockplate(A)forringgearscrews.
Removeten ring gear retainingscrews(hex 17
mm)to freeringgear.
lf ring gearis tight, threadscrewsin partway.Tap
M 44rL4 r \?^{ rr\,i.\l^U screwstopushring gearoff.
Discardthe screws.New screws MUST be used
whenassembling_

Group46
Rearaxle
2A
 D isassembli ng d ifferential
' With limited slip -

F16

Removedifterentialgearshalt.
Drive out lock pjn. Drive oui dilferentiat qear
snan.

Removedifferentialgears.
Placethe differentialassemblyon stub drive
shaft.Rollout the smalldifferential
gears.Liftout
thelargedliferential
gears.

Differential
with limitedslip
F1B

Removeditterenlialcarrierbearings.

I Usetool2483.Careshoud betakennot to dama-

g es h i n p a ck D u r i t , s i d e \ /h r a r r o v e o b e a r i ' 1 g
1.
Placepu ler over bearingon ring gear side of
carrier.Nlakecertainthai groovein tool caiches
on rol ers Presslockringdownor1tool.
2.
Tightenpulleruntilbearingis off carrier.
3.
Usea hammerto knockoutthe lockring.
Repeatfor other bearing.Record positionof
bearngs and shimsto facilitateinstallation on
newcarrier.

Group46
 D isassembl
ing diffetentiat
- Cleaning,inspectian-

F19

Markposilionot parts.
Draw line-upmarkson differentialgear shafts
carrierso that partsare installed
and differential
in thesamepositionwhenreassembled.

Removebolts.
Removethe boltswhichholdthe differential
car-
nertogether.
NOTE:
Rear axle type 1030 has bolts with left-hand
Inreaos.
0
F21

Litl otf diflerentialcarrier.Litt out

ditferentialgear plates. C(
F22
Removering gear.
Remove bolts.Lilt out ringgear-
Dlscardold bolts.Newonesmustbe usedwhen
reassemDIng.

F23

Cleaning,inspectionof paris.
Cleanall partsthoroughly.
Checkall bearingracesandbearings.
Races,rollersor roller retainersmust nor oe
scratched or damaged. Replace as necessary.
o(
Checkpinionand ring gearfor tooth damage.
Most common damageis from sejzingqear
teeth,see illustration.
Damagesare causedby contaminated or low
qualityoil, incorrecttooth flank clearanceor
laultytoothcontact.

Gearseizure

Gtoup46
30
 D isassemblin g d if fetent ial
Cleaning, inspection

fu@
b,qf.,t'.;& u t
Checkthe differental gearsfor tooth damage.
lf anygearis damaqed, the completeset of four
malchedgearsmust be repaced,
ffiI,;:,ffiHI Washersfor the differentialgears (flat or thrust)

w
\,JA
ul
Y
shouldbe replaced.For the largedifferential
gearsonythrustwashers, P/N1232436-4,
side
areused.

\/
)f
srdegear washer caTrier
1232436-4

0 p r n t o nu t Checkthe drivetlangesectionwhich goes into

theseal.Replacef wornorscored..
driveflange

The p nion nut loses its self-lockingcapacityaf-

ter be ng removeda couple of iimes. Replaceas

A I sealsshould be replacedany time the diffe-

rentialis disassembled.

Checktherearaxlecarrierforcracks.
Checkbrackets for trailingarmsandtrackrodfor
llrokenwe ds and/ordamages.
I
,' !-t I

Graup46

31
 AssembIi ng ditlercntial
- Withoutlimited slip
r
Assemblingdifferential

The utmostcleanliness mustbe observedwhen Bearingsmustbe oiledand rotatedseveraltimes

assembling
the finaldrive.Dirtin a taperedroller underloadbeforemeasuring bearingclearance
bearingcan resultin enlirelyincorrectmeasure- or pretoao.
ments.

Ditlerentialwithoutlimitedslip

Constructtool.
Bolts,nutsand washersaccordingto the follo-
wing Iistingare recommended
gears.
difterential
to helpinstallthe
o(
Two bolts
Two nuts
Fourwashers
1/2"x3-1/2"(M12x90)
1/2"(M12)
1-3l8"x1/8"(34x3 rnm)
o(
Cut two washersas shownso that they can be
fittedoverthebolts.

G2

Fitthrustwashersand largedifterential
gears.
Placeonewasherandnui on eachbolt.
Pushin theboltwiththe headfirst.
Installtheslottedwasher.
o(
G3
e{
1
I Compress.
Tightenthenutsto compress
thethrustwashers.

\
\-=

GrouP46
Bearaxle
32
-
Assembl ing d iff etential
without limiteclslip-

G4

I n s t a lsl m a l ld i f f e r e n t i ag le a r sa n d
thrustwashers.
Roll n smalldifferentialgearsand thrust washers
as an assemby.

Removebolttools.

G6

lnstalldifferentialgear shalt.
lnstal shaft and ock p i n . P u n c ht o l o c kthe lock
pin.

G7

Reassemblediff erential.
InstaI ringgearon carrer assernbly.
Makesure
contact arefreeof burrs.
sLrriaces
Use new bolts. The bolts are tightened to yield
limit and cannotbe reused.
[Jse a ternate side pattern for tightening bolts.
Torqueto:
Standardbolt head:7H0 Nm = 50-58 ft.lbs.
Flangedbo t head:90-110Nm :65-80 ft.lbs.

O p e r a t i o n sG 8 a n d G g c o n t a i n s p e c i a l
assemblyinstructionstor limited sllp differ-
enllat.
Common installation insttuclions continue
w i l h o p .G 1 0 .

Group46
 Assem
bli ng dif ferential
_ t imito.t .ti^.till -

Differential
with limitedsliD
Inspecting Reassemble
differential
Beforeinspecting, washall partsthoroughy in Installring gearon carrierassembly.Makesure
solvent.Thencheckthe partscarefulyfor wear, contactsurfaces arecleanandfreeof burrs.
cracksor oiher damage.Faultypartsshoutdbe
Use new bolts and lock fluid. The bolts are
replaced.lf any of the discsrequirereplacement
to yie d limitsandcannotbe reused.
tightened
becauseof abnormalwear,all the discsshoud
be replaced at thesarneilme. Usealternatesidetightening pattern.
Torqueto:
Standardbolthead:70-€0Nm - 50-58tt.lbs.
Flangedbo t head:90-1'10 Nm = 65-80ft.lbs.

fr
t-
ttl I
H
H
e

E I I I
I
I
Il,!
On prevous differentialswhere

I
boih the differentialside gears
2 \ and the differential gear retai
3 ners have splines for the drive
shafts,the spl nes must be alg-
\
ned with the help of the drive
i shaftswhen the bolts are tighte-

I
1. Bot
2. Differenlialhousing
3 . D i s c , 1 5m m = 0 . 0 6
(
5 . D i s h e d l s c , 24 m m = 0 . 1 " f,?
6 F l a ld i s c , 2 . 4
7. HUb
m | l f= 0 1 "

8 . L a r g ed i f f e r e n t i agl e a r s
L Shalls
Y
l0 I
10. Sma ldilferenliag l ears

Installshafts,gearsand discs
Lubricateeach part beforeinstallation.
Place the discs and other parts n the order
shown in il ustrationin the ring gear half of the
differental housing.
A ign the dlscs and fit the smaller half of the
differentialcarrier.
Installthe bo ts. Torqueio:
60-75 Nm = 44-55 ft.lbs.

Group46
34 Rearaxle
 Assemblingrearaxle

I n s t a l l i npgi n i o n
Gl0

Installtoolson pinion
2685 2841 Use extremelyline emery cloth to clean the
2a4A p i n r o sn h o u l d e r
Installadjustingr ng and wrench [/]akesurethe
ocking screwol the adjuslingring is n open
posrtron.
Finaldrive T0 3 0 1031
Adjusting
rlng 2685 2840
Wrench 2841 2841
or (5157) (s157)

Positionpinionin carrier
Screw (1) on the adjustingring (2) m!st face the
Iargepartof the carrier.
Make sure the pin on the adjustingr ng is In the

G
\

Measurement
A
The pinion must have a set distance (A) to the
flng gear center line. Due to tolerances In the
manufacturing,there are deviationsfrom the set
distance.These deviationsare indicated on the
pinion.The deviationis alwaysplus and in hund-
redthsof amillimeier.The plus sign is omitted.

0 Conversiontable m ll metersto inches

mm nches Trm inches

0.20 0.0079 0.31 0.4122

o.21 0.0083 a.32 0.4126
o.22 0.0087 0.33 0.0130
o.23 0.0091 0.34 0.0134
0.24 0.0094 0.35 0.0138
o.25 0.0098 0.36 0.0142
0.26 0.0102 4.37 0.0146
o.21 0.0106 0.38 0.01s0
0.28 0.01'10 0.39 0.0154
0.29 0.0114 0.40 0.0157
0.30 0.0118

Group46
Assemblingrearaxle

G13

Checkingpinionlocation
use:
- dialindicator
- indicatorretainer
2284
- measuring tool2393
Measuring of two pans:
lool 2393consists
a piniongaugeandan adjuster fixture.

G14
ZEROIN LOCATION

Alignmeasuringtools
Locatethe indicatorretainer
so thatthe dialindi
catortip touchestheadjuster
fixture.
o(
(

22A4
It_., Measuredistanceto piniongauge
Move the indicator retainerso that ihe dial
catortip touchesthe piniongauge.
Thepiniongaugeshouldreflectthe figureindica-
ted on rhe pinion.for example:rf lhe pinronis
marked0.33,the piniongaugeshouldlie0.33mm
belowtheadjuster fixture.
Adjustby turningthe wrenchof the ninionuntil
thedialindicatorshowscorrectreading. Q
lJsethe lockingscrewto lockthe wrench.Remo-
ve measuring toolsandpinion.
Gl6 o(
Shimthickness,rear pinionbearing
Positionrear pinion bearing assembly(3) in
measuring fixture2600.Installplate,springand
nut (flat side up). Rotate plate and bearing
assembly backandforthseveraltimes so thatthe
rollersassumecorrectpositions.
Positionadjustingring(1)in the measuring fixtu-
re.lJseretainer 2284anddialrndicator r2l
Positionthe dial indicatortip againstthe adjus-
ting ring (1)andsetto zero.Thenchangethe tip
locationto thebearingouterring.Thedialindica-
tor nowshowsrequired thickness of shims.
Remove bearingandmeasuring lixture2600.

Gtoup46
rI Assemblingrearaxle

I
M e a s u r es h i mt h i c k n e s s
Usemicrometer.
NOTE:
It is very difflcui to obtainabsolutelycorrect
shimthickness. are permit-
Followingdeviations
Ieo:
- 0.02mm = 0.0008"
+ 0.05mm = 0.002"

G18

0
Installrearpinionbearingon pinion
Usetools:
0 2395for Type1030
2842forType1031
NOTE:
Firsttimea rearpinionbearingis removed,
there
is a spacerwasherunderthe rearpinionbearing
innerring.LtrrustNOTbe reinstaled.

G19

Installpinionbearingrings
Positionshirn just determinedf o r r e a r p i n i o n
oeanng.
0 outerringsfor pinionrearand front bear-
l11stal
ings.
LJse
toolsl
2686forType1030

0 2845forType1031

G2A

Installpinion
P o s i t o np n i o n .I n s t a l t h r e es h i r n s0 . 7 5m m =
0.03"thlck andlrontpinionbearing.
Instalwrench2404andpressioo lS45(alt.5156)
o n p i n i o nf r o n te n d .P r e s isn p i n i o n
NOTE:
f usinga nut runner,pressthe p nionforwardso
that it doesnot hit the bearingraceswith impact

GrauP46
37
 Assenblingrearaxle

Installpinionnut
Removetool 1845.Lei wrench2404 remainin
place.
Installpinionnut.Torqueto 250Nm : 185ft.lbs.

G22

Ol
Shimthickness,frontpinionbearing
Installpiniongauge,dial indicatorreta,nerand
d i a li n d i c a t oPr .u l ld o w nt h ep i n i o nw h i l et u r n i n g
back and forth at the sametime.Zero the dial
In0tcalor.
Pressthe pinionup whi e turningbackandforth.
Readthediallndicator.

G23

Adiustshim packthickness
Tapthepinionto rerroveit.
Newbearngs:
- remove shims accordingto dial indtcator
readingPLUS0,09mm = 0.0035".
Previouslyusedbearing:
rernoveshims accordingto dial indicator
readng PLUS0.07mm = 0.0028" o(
G24

Installpinion
Positionpinion. lnstal shim pack determi11ed for
lro.r pr'1,onoed irg. Installlronrp nion beari'1g.
Installwrench2404and presstoo 1845(att.5156)
on piniolrfront end. Pressrn pinion.
NOTE:
lf usinga nut runner,pressthe pinlon forwardso
that i does not hit the bearingraceswith impact
iorce.

Group46
38
I
 Assemblingrearaxle

G25

I n s t a lpl i n i o nn u t
Remove10011845. Let wrench 2404 renaln in
place
Instal washerand nut.Torquenut tol
250 Nm = 185ft.lbs.

''I G26

Checkpinionbearingpreload
Usetorquegauge.Correcipreload:
Newbearingsr 250-450Ncm= 21-39in.lbs.
U s e db a a r i r g s6 0 - 1 1 0N c m- 5 l 0 | l b : .

r-/

G27
2284

C h e c kp i n i o nl o c a t i o n
Use dial indicator,telairet 2284 and measuring
tool2393
Zero-setthe dia indicalor againsi the adluster
IIXIUTE,
S h i f t h e d i a li n d i c a t ot ro t h e p i n i o ng a u g ea n d
checkthepinionbearng.
Pinlon ocatlonmust not deviatefrom correct
p o s i ot n m o r et h a n :
-0.02mm-00008"
+ 0.05mm - 0.002"

Group46
Assemblingrearaxle
- lnstallingdiffetential-
Installingdifferenlial
H1

Installadiustingrings
Oiladjusting
rings2595-Installon differential.
Black-oxldized
adjustingringon ringgearside.

H2

Oilbearingseatsin rearaxle.
Positiondifferentiaandadjusiingringsassembly
In rearaxle.

H3
Ad,ustbacklash
Adjustthe adjustlngringsapartuntilihe differen-
tialis heldfirmlyb!t notpreloaded.
Positionthe dial rndicator.Set the tip approx.3
mm = 1/8"fromthe endof a ringgeartooth.
Holdthe pinionand movethe ringgearbackand
forth. Note the backlash.Allowedbacklashis
E 0.12-0.18
as near0.15
mm = 0.005-0.007',but shouldbe set
mm :0.006"aspossible.
Adjust by turning both adjustingrings in the
samedirection.

Attercorrectbacklashis obtained
Locktheadjustingringsin position.
Removeditterentialand adjustingringsassem-
oty.

H5

Determineshimthickness
NOTE:
Alwaysremember thesideon whichbearings and
shimsareto be installed.
Position the cenieringplateon nreasuring fixture
2600.Positiona bearing(3)in the measuring fix-
ture. Installplate,springand nut (flat side up).
Rotateplate and bearingassemblyback and
forth severaltimes so that the rollersassume
correctposition.
Posilionadjustingring (1)on measuringfixture.
Instalretainer 2284anddialindicator(2).
Positionthe dlal indicatortip againstthe adjus-
iing ring (1)andset to zero.Thenchangethe lip
locationto the bearlng.Notethe dia indicaior
reaorng.

GtouP46
 Assembling rearaxle
lnstallingdiflerential-
H6

Measureshimlhickness
Totalshimthicknessshouldbe
lJsemicrometer.
notedvaluePLUS0.07mm = 0.0028".

Repeatprocedurefor olher side

H8

Installbearingoppositering gear
Installdeterminedshim pack. Use drilt 4'112
whenpressing on thebearing.

H9

Installbearing,ringgearside
Installlock plate (A) for ring gear bolts,deter-
minedshimpackandbearing.
Usedrifl4l l2 to presson the bearing.
Use drift 2599on the bearingoppositeside to
preventdama9es.

H10

Installditferentialassembly
Use retainers2601 to positionexpandingtool
2394on rearaxlehousing.Expandtool untilit fits
securelyin holes in housing.Then tightenthe
screwan additional3 3.5turns.
Positiondifferential
wiih bearingouter rings in
rearaxleho0sing,
Bemoveexpanding tool2394.

Group46
ReatAxle 41
 Assemblingrearaxle
- lnstallingdilferential

H11

Installbealingcaps
Check markings.Torque bolts to 50-70 Nm
: 35-50ft. bs.

Hl2

Check backlash
Allowedbacklashis0.12{.18mm = 0.00H.007"
but sho!ld be as near0,15mm = 0.006"as poss-
lble.
Remove
wrench2402,

H13

I n s t a lol i l s l i n g e r

Installnewoil seal
Packspringof new oil sealwith grease.Other-
o(
wise the coil may jump out of positiono u n n g
installation.
Greasesealinglips.
1.Oilseal
wilhgrease
2. Spring
tJsedrift2806to installtheoil seal.

Installpinionflange Hl5
Usepresstool1845(or5156).
Installnut Ht6
Torques:
Nut 88626(3/4"UNF)24G.j00Nm
- 17s-220ft.lbs.
Nut946831 (3/4"UNF)200-250Nm
: 145-185ft.lbs.
Nut947855(N,,120
x 1.5) 200-250Nm
: 145 1B5ft.lbs.

Gtoup46
42
I Assembling rear axle
- In stalIi ng d i f feren ti al

I n s t a lgl a s k e ta n dc o v e l
....5009
'1801
H18

Installdriveshaftseals
Usedr it 5009and handle1801.
NOTE:
Fil spacebet\,!eensealinglips with grease.
Also iil space between roller reta ner and
bearinginner ring with grease.

H19

Installdrive shafts
Torqueboltsfor bearingreiainerto 30-50Nm
= 2240 ft.lbs.

H20

Fillwithcorrectlubricanl
Capacity:
1030:1.3lilers: 1.35USqts.
1 0 3 11: . 6l i t e r s: 1 . 7U Sq t s .
F i n a d r i v eo i l S A E9 0 ,A P IG L - s( M l L L 2 1 0 5 8
orc).

GrouP46

43
lnstallingrearaxle Installingrearaxle
1

Prepareinstallation
Positionrearaxlein fixture2714.Positionfixture
andrearaxleundervehicle.

12

Attachtrailingarms
Installtheboltsfingertight.
Alsoinstallthebrackets
for thesiabilizer
bar rear
attachments.

Attachlhe rearshockabsorbers
at the
upperattachments
Installspringcompressors
5040andcompress
thespringsso thattheshockabsorbers
canbe
installed.
Makesurethewiresholdingthe brakecalipers
do notbecomeinvolved.
Remove thespringcompressors.

14

Removethe fixture

Group46
Rearaxle
 lnstallingrcat axle

Atlachreactionrods
Donottighlen.

16

Attachparkingbrakecablesat the reat

axle
1.Screw
2. Cable
3. Plastic
tube

17

Connectdrive shattto flange

Usesocket2779or2846.

Connectparkingbrakecables

Group46
Reataxle
lnstallingrearaxle

l9

Installparkingbrakeshoes

r1oo tl

Installbrakediscs
Installscrewsretaining
brakediscs

111

Installbrakecalipers

112

Connectbrakelines
Attachbracketsand clampssecuringthe brake
lrnes.
Hookon retainingspringsof parkingbrake
cablesto the upperclamps.
:r13
Reconnectthe venlilationhoseto the
rearaxle

Group46
Bearaxle
 lnstallingrear axle

114

Installcollisionguards

115

Installthetrackrod (Panhardrod)

o I n s t a ltlh e s l a b i l i z ebr a r

117

RearEndTorque.
Lowerandrockthecarbeioretighlening.
UseTorque
SpecsChart.
 Rear end torqu€s

:,/

Nm ft. lbs.
Reaction rod:
A Bodyanachment..... 85
B Rearaxle sttachm€nt 85 62
Trsd< rod (Ponh6rd.odl:
Rearaxleattachment
D Bodyattachment..... 85
Roar spdng:
Upperattachment
F Low€rattachment,... 14
Shod<ab6orb6r:
G Upperattachment
H Loweranachm€nt....
Trailingarm:
I Bodyattachment..... 115
F Bearattachment(: E ring lower Sttachment)
't9
Strbilizor:
J Front Sttachmenr(= shock ab6orb€r)
K R e a ar t t a c h m e .n. t, , . . . . . . . . . . . . . . . . . .
Who6ls:
Nuts,tight€ned .. ... . .. ... . .. ,,..
cris!-cross 115 ... ... 85
 lalional
Irstitutefor
luT0trl0ItvE
SERVIGE
ETCEIIEIGE

VOLVO
SUPPORTS VI)LUNTARY
MECHANIC
CERTIFICATIOI{
lY THE .t.A.S.E.
o.ly)
{U.S.A.