Ford COUGAR 1968 Shop Manual page 136

GROUP 4
-
Rear Axle
E 1473-A
FIG. 26
-
lnstalling Pinion a n d
Retainer
E1474-A
FIG. 27
- lnstalling
Oil Seal
FIG. 28
-
lnstalling U-Joint
F l a n g e
spline can be inserted in the side
gear spline to check for free rotation
of the differential gears.
5 . Insert two 7/ 16 (N.F.) bolts two
inches long through the differential
case flange, and thread them three
of four turns into the ring gear as a
guide in aligning the ring gear bolt
FIG. 29
-
Checking Pinion Bearing
Pre-load
holes. Press or tap the ring gear into
position.
6.
Install and tighten the ring gear
bolts evenly, and torque them alter-
nately across the gear to specification.
7. If the differential bearings have
been removed, press them on as
shown in Fig. 30.
8. Apply a thin coating of lubri-
cant on the bearing bores so that the
differential bearing cups will move
easily.
9. Place the cups on the bearings.
If the gear set is of the non-hunting
or' partial non-hunting type, assemble
the differential case and ring gear
assembly in the carrier so that the
marked tooth on the pinion indexes
between the marked teeth on the
ring gear as shown in Fig. 31.
In almost every case of improper
assembly (gears assembled out of
time), the noise level and probability
of failure will be higher than they
would be with properly assembled
gears.
When installing the hunting type
gear set (no timing marks) assem-
ble the differential case and ring gear
assembly in the carrier without re-
gard to the matching of any particu-
lar gear teeth.
10. Slide the assembly along the
bores until a slight amount of back-
lash is felt between the gear teeth.
11. Set the adjusting nuts in the
bores so that they just contact the
bearing cups. T h e . nuts should be
engaged about the same number of
threads on each side.,
12.
Carefully position the bearing
caps on the carrier. Match the marks
made when the caps were removed.
13. Install the bearing cap bolts
and alternately torque them to spec-
ification.
14. I f the adjusting nuts do not
turn freely as the cap bolts are tight-
ened, remove the bearing caps and
again inspect for damaged threads
or incorrectly positioned caps. Tight-
ening the bolts to the specified torque
is done to be sure that the cups and
adjusting nuts are seated. Loosen
the cap bolts, and torque them to only
25 ft-lbs. before making adjustments.
1 5 . Adjust the backlash between
the ring gear and pinion as outlined
in Part 4-1, Section 2.
16. Be sure to make a final tooth
pattern check before installing the
carrier assembly in the axle housing.
ASSEMBLY AND
INSTALLATION O F LIMITED-
S L I P DIFFEWEN'l.IAL CASE
I. Place the side gear and thrust
washer in the differential case (Fig.
32). Lubricate all parts liberally with
axle lubricant during assembly.
2.
With a soft-faced hammer,
drive the pinion shaft into the case
only far enough to retain a pinion
thrust washer and pinion gear.
3.
Place the second pinion and
thrust washer in position, and drive
the pinion shaft into place. Carefully
line up the pinion shaft lock pin
holes.
4. Install the pinion shaft lock pin.
The lock pin must not extend beyond
the surface of the case.
5 . Insert two 2-inch 7/16 (N.F.)
bolts through the differential case
flange, and thread them three or four
turns into the ring gear as a guide
in aligning the ring gear bolt holes.
Press or tap the ring gear into po-
sition.
6. Clamp the differential case in a
soft-jawed vise. Install the differential
outer side gear on the differential pin-
ion gears. 'Place the clutch hub on the
side gear. Place the thrust washer on
the hub Fig. 33.
Limited
-
Slip
Clutch Plate Insicillation
Prior to clutch. plate installation,
the friction b o n d 4 plates must be
soaked in C6AZ-19580-C (ESW-
M2C104-A) differential lubricant
for approximately 112 hour. In
addition, the differential lubricant
must be liberally applied to all com-
ponents to be assembled.
I . Place the clutch hub into posi-
tion in a soft-jawed vise.
2. First, install a steel clutch plate