Ford Falcon. Manual - part 49

205-02A-20 

Rear Drive Axle / Differential — Beam Axle 

205-02A-20

REMOVAL AND INSTALLATION (Continued)

2.  Start the splined end of the shaft into the

3.  Remove cover plate screws, cover plate. Clean

differential and start the bearing cone assembly

sealant from cover faces.

and seal into the housing.

3.  Line up the retaining plate to the retaining plate

bolts and push the axle into the housing as far as

possible.

4.  Start the bolts onto the tube flange holes and

tighten to finger tight only. Then tighten the bolts

to 20 Nm in a diagonal sequence. The bolts

should be tightened in such a manner to assure

that the seal and bearing cone assembly are

drawn evenly against the cup in the housing.

Refer to Specifications section for tightening

torque required on retaining plate bolts.

5.  Install the disc on the axle flange.

Install the brake caliper.

Route the park brake cable and connect to park

4.  Remove differential bearing caps. Note letters

brake. (Refer to Section 206-05.)

stamped on the bearing caps and the cover face

Replace ABS sensor (if fitted).

of the housing. Letters are to correspond in

horizontal and vertical positions. This is very

6.  Replace the road wheel and lower the vehicle.

important at time of assembly.

7.  Tighten the wheel nuts. (Refer to Section 204-04.)
8.  Check the park brake adjustment. (Refer to

Section 206-05.)

M86 Limited Slip Differential

Special Tool(s)

Spreader

E9255

Indicator Set or Equivalent

5.  Mount spreader to housing. Locate a dial indicator

with a magnetic base on cover face as shown.

Removal

Locate tip of indicator on housing as shown.

NOTE: On Dana Spicer axles it is recommended that

6.  Set dial indicator at zero ("0"). Turn forcing screw

the complete axle assembly be removed from the

of spreader until indicator records .015" (.38 mm).

vehicle when it becomes necessary to remove the

M86 LSD from the housing.

 CAUTION: Do not spread carrier in

1.  Remove wheels, brake drums, brake backing

excess of 015" (.38 mm).

plate screws and axle shafts. Brake backing

7. Remove 

Indicator.

plates can normally be wired to frame without

loosening the hydraulic brake line connection at

the wheel cylinder if desired. Use caution to avoid

damage to brake line.

2.  Remove axle assembly and place in rack or stand

to serve as a holding device.

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205-02A-21 

Rear Drive Axle / Differential — Beam Axle 

205-02A-21

REMOVAL AND INSTALLATION (Continued)

8.  Remove differential using two pry bars as shown.

Use caution to avoid damage to ring and pinion. It

will not be necessary to remove the differential

bearings at this time, however, the bearing cups

should be marked or tagged to indicate from

which side of the case they were removed. After

differential case has been removed, remove

spreader.

Axle Housing and Differential

Assembly

Removal
1.  Loosen the rear wheel nuts.
2.  Raise the vehicle and support it on the axle.
3.  Remove the rear wheels.
4.  Detach the shock absorbers from the spring

plates as follows. (Refer to Section 204-02B.)

5.  Support the vehicle on the underbody. (Refer to

Section 100-02.)

6.  Mark the relationship of the driveshaft and the

pinion flanges and disconnect the driveshaft from

the pinion flange. (Refer to Section 205-01.)

7.  Detach the park brake cable from the drum (park)

brake and remove from rear axle

Remove the calipers and suspend from the

underbody. Leave the hydraulic lines attached.

Remove the discs.

Remove ABS sensor (if ABS fitted).

Remove the splash shields. (Refer to Section

206-04.)

Remove the axle shafts as described in this Part.
NOTE: Do not strain the brake lines and/or hoses.

(Refer to Section 206-04.)

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205-02A-22 

Rear Drive Axle / Differential — Beam Axle 

205-02A-22

REMOVAL AND INSTALLATION (Continued)

8.  Remove the ’U’ bolts, spring plates and the lower

spring insulator. (Refer to Section 204-02B.)

9.  Remove the axle housing from the vehicle.
10. Drain the oil from the axle housing through an

axle tube.

Installation
1.  Position the axle housing on the springs. Ensure

that the insulators are correctly located on the

springs. Install the ’U’ bolts, lower insulator,

spring plate and ’U’ bolt nuts. (Refer to Section

204-02B.)

2.  Install the axle shafts as described in this Section.
3.  Install the splash shields.

Item

Description

4.  Install ABS sensor (if ABS fitted).

1

Screw (Torque to 6Nm)

Install the discs.

Install the calipers.

2

Tube - Rear axle housing vent

Route the park brake cable and connect to rear

3

Clip

drum (park) brake.

4

Screw

5.  Align the marks on the driveshaft and the pinion

5

Clip

flanges and connect the driveshaft. (Refer to

6

Clamp

Section 205-01.)

7

Tube assy. - Brake fluid

6.  Raise the rear axle and install the lower shock

absorber to the spring plate (Refer to Section

204-02B.). Install the rear wheels.

7.  With the vehicle in the curb load position fill the

axle to the bottom of the filler plug hole with the

correct oil.

 CAUTION: Use of unspecified lubricant

may lead to premature gear failure.

8.  Lower the vehicle and tighten the wheel nuts.

(Refer to Section 204-04.)

9.  Check park brake adjustment. (Refer to Section

206-05.)

Item

Description

1

Screw  -  M6

2

Shield

3

Bolt  -  M12

4

Caliper

5

Rotor

6

Axle Assy.

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205-02A-23 

Rear Drive Axle / Differential — Beam Axle 

205-02A-23

REMOVAL AND INSTALLATION (Continued)

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