Ford COUGAR 1968 Shop Manual page 107

'ART 4-1
-
General Axle Service
I f the patterns are not correct,
make the changes as indicated. The
pinion need not be disassembled to
change a shim. All that is required is
to remove the pinion, bearing, and
retainer assembly and install a differ-
ent shim. When reinstalling the pin-
ion and retainer assembly of a non-
hunting or partial non-hunting gear
set, be sure that the marked tooth
on the pinion indexes between the
marked teeth on the ring gear (Fig.
25, Part 4-2). Refer to Pinion and
Ring Gear Tooth Contact Adjust-
ment. Section 2.
R E A R A X L E C O M P A N I O N
F L A N G E R U N O U T C H E C K
( A L L A X L E S )
1. Raise the vehicle on a hoist that
supports the rear axle (twin-post
hoist).
2. Remove the driveshaft assembly
(Group 5).
3. Check the companion flange for
damage to the universal joint bearing
locating lugs. If the universal joint
bearing locating lugs on the compan-
ion flange are shaved (worn) or dam-
aged, replace the companion flange
Fig. 3.
4. The rear axle companion flange
runout is checked with a modified uni-
versal joint (checking tool) a dial in-
dicator with 1.000 inch minimum
travel, and a cup-shaped' dial indi-
cator adapter tool (Fig. 4). T o fabri-
cate the checking tool, modify a uni-
versal joint assembly by removing
two bearing cups that are opposite
each other, and cutting or grinding
off one of the universal joint bearing
flanges
(
Fig. 4).
5. Install the cup-shaped adapter
on the dial indicator stem. Install the
dial indicator on the pinion retainer
or pinion nose bumper bracket. Posi-
tion the indicator to allow an indica-
tion a t the ends of the universal joint
bearing cups and the remaining ex-
posed journal of the cross-shaft.
6.
Turn the companion flange so
that the dial indicator cup-type adapt-
er rests on the machined surface of
the bearing cup (Fig. 4). Rotate the
companion flange side-to-side slightly
to obtain a reading indicating that
the bearing cup surface is perpendic-
ular to the indicator cup-type adapter.
This will be the point at which the
dial indicator cup is closest to the
center of companion flange rotation.
I t is also the point at which the dial
indicator hand will reverse direction
as the companion flange is turning.
Set the dial indicator to zero.
FIG. ]-Checking Limited-Slip Differential
7. Carefully retract the dial indi-
cator stem and rotate the companion
flange 180 degrees to position the
machined surface of the opposite uni-
versal bearing under the dial indicator
adapter tool. Again, slightly rotate the
flange side-to-side to position the bear-
ing perpendicular to the dial indicator
adapter. Again, this is the point a t
which the indicator hand will reverse
direction as the flange is rotated.
Record the flange bearing cup run-
out reading obtained from the indi-
cator (Fig. 5).
Rotate the companion flange 90
degrees and position the dial indicator
adapter on the machined end of the
exposed journal (Fig. 6). Be sure the
end surface of the exposed journal is
perpendicular to the indicator cup-
type adapter. This requires that the
cross-shaft be moved fore and aft on
the flange bearing cups. Note the
point at which the indicator hand re-
verses direction.
Rotate the flange as-
sembly side-to-side until the cross-
shaft is perpendicular to the pinion
shaft axis, and the indicator hand
reverses direction. Zero the dial indi-
cator and check the zero point again
by slightly moving the cross-shaft
fore and aft, then rotate the com-
panion flange from side-to-side.
8. With the indicator at zero, care-
fully retract the dial stem and rotate
the flange 180 degrees. Rotate the
cross-shaft 180 degrees on the flange
bearing cups to position the exposed
journal under the dial indicator adapt-
er. Rock the cross-shaft fore and aft
and the companion flange side-to-side
to establish the point at which the in-
dicator hand reverses direction. This
will determine the driveshaft universal
cross-shaft runout. Record this reading
(Fig. 6).
9. Repeat steps 5 through 8 at
least three times and average the in-
dicator readings obtained (Fig. 5).
10. T o determine the total (com-
bined) companion flange runout, it
will be necessary to use the combined
runout chart (Fig. 7). Position a
straight edge a t the amount of flange
bearing cup runout indicated on the
left hand column of the chart. Posi-
tion another straight edge vertically
at the amount of driveshaft univer-
sal cross-shaft runout indicated on
the top of the chart. The point at
which the straight edges cross the chart
indicates the combined rear axle flange
runout. For example:
With an indicated 0.003 inch flange
bearing cup runout and an indicated
0.004 inch universal cross-shaft run-
out (Fig. 7). the combined compan-
ion flange runout will be 0.005 inch
as indicated in the square on the
chart (Fig. 7).
11. If the reading obtained in Step
10 exceeds specifications, reposition
the companion flange 180 degrees on
the pinion shaft and repeat steps I
through 10.
12. If the repeat readings still ex-
ceed specifications, re-position the
flange an additional 90 degrees on the
pinion shaft and check the runout
(Steps 4 through 10).
13. If the runout is still excessive,
replace the companion flange and
check the runout. If necessary, rotate
the new flange on the pinion shaft un-
til an acceptable runout is obtained.
If excessive runout is still evident
after replacement of the companion
flange, it will be necessary to replace