Ford COUGAR 1968 Shop Manual page 113

PART 4-1
-
General Axle Service
4-9
P I N I O N R E T A I N E R -
R E M O V A B L E C A R R I E R
T Y P E A X L E O N L Y
Be sure that the pinion bearing
cups are seated. Remove any chips
or burrs from the mounting flange.
Clean the groove for the O-ring seal
and all libricant passages. 1f the
CUDS
were removed. examine the bores
ca;efully. Any nicks or burrs in these
bores must be removed to permit pro-
per seating of the cups.
C A R R I E R H O U S I N G
FIG.
74-Checking Ring Gear
Runout-Removable Carrier Type
Axle
flange from the pinion. The end of
the flange that contacts the front
pinion bearing inner face (both inte-
gral and removable carrier) as well
as the flat surface of the pinion nut
counterbore must be smooth. Polish
these surfaces i f necessary. Roughness
aggravates backlash noises, and
causes wear of the flange and pin-
ion nut with a resultant loss in pinion
bearing preload.
Make sure that the differential
bearing bores are smooth and the
threads are not damaged.
Remove any nicks or burrs from
the mounting surfaces of the carrier
housing.
D I F F E R E N T I A L C A S E
Make sure that the hubs where the
bearings mount are smooth. Care-
fully examine the differential case
bearing shoulders, which may have
been damaged when the bearings
were removed. The bearing assem-
blies will fail i f they do not seat firm-
ly against the shoulders. Check the
fit (free rotation) of the differential
.side gears in their counterbores. Be
sure that the mating surfaces of the
two parts of the case are smooth and
free from nicks or burrs.
L I M I T E D - S L I P D I F F E R E N T I A L
P A R T S
Inspect the clutch plates for un-
even or extreme wear. The dog-eared
clutch plates must be free from burrs,
nicks, or scratches which could cause
excessive or erratic wear to the bond-
ing material of the internally splined
clutch plates. The internally splined
clutch plates should be inspected for
condition of the bond, bonding ma-
terial, and wear. Replace the bonded
plates if their thickness is less than
0.085 inch or if the bonded material
is scored or badly worn. Inspect the
bonded plate internal teeth for wear.
Replace them, if excessive wear is
evident. Bonded plates should be re-
placed a s a set only.
Examine all thrust surfaces and
hubs for wear. Abnormal wear on
these surfaces can contribute to a
noisy axle.
Inspect the Bellville spring for
proper free height of 114 inch.
FIG.
75-Rear Axle Diagnosis Guide
EXCESSIVE REAR AXLE
N O I S E (ALL REAR AXLES)
Since gears are in mesh, some rear
Noise caused by a worn or dam-
axle noise is normal. However, exces-
aged wheel bearing is often loudest
sive noise often indicates the begin-
when the vehicle is coasting at low
ning of other troubles in the axle.
speeds, and it usually stops when the
A road test can help determine brakes are gently applied. To find the
whether the noise is being caused by
noisy bearing, jack up each wheel and
trouble in the rear axle or in other check each bearing. for roughness,
parts of the vehicle. Before road-testing while the wheel is rotating, provided
the vehicle, make sure that the tire.
that the vehicle is equipped with a
pressures and the rear axle lubri- conventional differential.
cant level are normal. Then drive the
vehicle far enough to warm the axle
If all possible external sources of
lubricant to its normal operating tem-
noise have been checked and elimi-
perature.
nated, and the noise still exists, road-
With the vehicle stopped and the
test the rear axle under all four driv-
transmission in neutral, run the engine ing conditions-drive, cruise, float,
at various speeds. If the noise still and coast. Any noise produced by the
exists during this test, it probably sidegears and pinions in the differen-
comes from the engine or the exhaust tial case will be most pronounced on
system. turns. A continuous whine under a
To determine if the noise is being light load between 20 and 35 miles
caused by the rear axle or the tires, per hour indicates rough or brinnelled
drive the vehicle over several different pinion bearings. If the tone of drive,
types of road surfaces. Smooth as- coast and float noise differs with
phalt or black-top roads minimize speed and i f the noise is very rough
tire noises. Tire noises may be elimi- and irregular; worn, rough or loose
nated by cross-switching the tires. differential or pinion shaft bearings
Snow tires often cause noises not are indicated. Remove, disassemble,
heard with conventional tires.
and inspect the axle.