Ford Falcon. Manual - part 54

205-02B-1 

Independent Rear Suspension — Full Floating Axle 

205-02B-1

SECTION : 205-02B Independent Rear Suspension

— Full Floating Axle

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS  

PAGE

SPECIFICATIONS

 Specifications  .......................................................................................................................205-02B-2

DESCRIPTION AND OPERATION

  Description And Operation  ..................................................................................................205-02B-4

  Drive Unit Identification  ......................................................................................................205-02B-4

  Drive Unit Differential  .........................................................................................................205-02B-4

 Conventional 

Differential 

....................................................................................................205-02B-4

  Limited Slip Differential  ......................................................................................................205-02B-4

  Diff and Pinion Bearings  ....................................................................................................205-02B-4

  M78 & M86 IRS (Sedan)  ...................................................................................................205-02B-4

GENERAL PROCEDURES

  Drive Unit Oil Change  ..........................................................................................................205-02B-8

  In Vehicle Torque Check  .....................................................................................................205-02B-8

  Differential Case Preload Setting  ........................................................................................205-02B-8

  Backlash and Tooth Contact Setting  ...................................................................................205-02B-8

IN-VEHICLE REPAIRS

  Pinion Oil Seal Replacement  ...............................................................................................205-02B-9

REMOVAL AND INSTALLATION

 Half Shaft  ...........................................................................................................................205-02B-10

  Drive Unit Assembly  ..........................................................................................................205-02B-10

 Differential Assembly  .........................................................................................................205-02B-10

DISASSEMBLY AND ASSEMBLY

  Inner Axle Shaft Seal Replacement  ..................................................................................205-02B-11

  Pinion & Pinion Bearings  ...................................................................................................205-02B-11

  Drive Pinion Selection — Shim Selection  ..........................................................................205-02B-12

205-02B-2 

Independent Rear Suspension — Full Floating Axle 

205-02B-2

SPECIFICATIONS

General Specifications

Description

Specification

Description

Specification

Backlash variation

0.05 mm max.

between teeth.

Rear Axle Lubrication

(Level with bottom of filler plug hole with vehicle at

Maximum ring gear run

0.13 mm

curb height.)

out (assembled)

Model 78

Limited slip differential

Selective shim

adjustment. (separate

CONVENTIONAL

cone type)

Grade

SAE 90 Hypoid

Limited slip differential

Non adjustable

Ford Specification

ESW-M2C108-A

(integral cone type)

Capacity

1.70 litre

Limited slip differential torque

LIMITED SLIP

New:

80-140 Nm

Grade

SAE 90 EP

Used:

50-130 Nm (Separate

Ford Specification

ESW-FM2C-1006-B

cone type)

Capacity

1.60 litre + 100ml

45-130 Nm (Integral cone

Sturaco 7098 Additive

type)

Model 86

To be constant within 6

Nm (continuously

CONVENTIONAL

rotating)

Grade

Mobilube SHC ID

Ford Specification

ESZ-FM2C190-A

General Specifications

Capacity

1.9 litre

Item

Specification

LIMITED SLIP

Spring Rate

Grade

Mobilube SHC ID

E169 SWB

28N/mm

Ford Specification

ESZ-FM2C190-A

E169 XR and FPV

38 N/mm

Capacity

1.86 litre + 40ml

E169 SFLPG

32 N/mm

Duraphos Mobil M3022

E169 Fairmont Ghia

30 N/mm

BEARING PRELOADS

E169 Heavy Duty

32 N/mm

BEARING PRELOADS

E169 Sport SFLPG

34 N/mm

New Bearings Nm

E169 T Series

TBA

Differential

E169 LWB

28 N/mm

— Measured without axle

1.1-2.8

Design Load

shafts or pinion

E169 SWB

4800 N

Pinion

E169 XR and FPV

4140 N

— With oil seal

1.4-2.4

E169 SFLPG

5576 N

— Without oil seal

1.4-2.0

E169 Fairmont Ghia

4660 N

Used Bearings

E169 Heavy Duty

5860 N

Differential

E169 Sport SFLPG

5145 N

— Measured without axle

0.5-1.4

E169 T Series

TBA

shafts or pinion

E169 LWB

5400 N

Pinion

Design Height

5400 N

— With oil seal

0.7-1.2

E169 SWB

190 mm

— Without oil seal

0.7-1.0

E169 XR and FPV

201 mm

ADJUSTMENTS

E169 SFLPG

190 mm

Pinion bearing preload

Collapsible spacer

adjustment.

E169 Fairmont Ghia

190 mm

Differential bearing

Selective spacer

E169 Heavy Duty

190 mm

preload adjustment.

E169 Sport SFLPG

190 mm

Pinion depth of mesh

Selective shim

E169 T Series

TBA

adjustment.

E169 LWB

190 mm

Backlash between ring

0.13 to 0.18 mm

gear and pinion.

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205-02B-3 

Independent Rear Suspension — Full Floating Axle 

205-02B-3

SPECIFICATIONS (Continued)

Torque Specifications

Description

Nm

Ring gear bolts (L.H. Thread)

140

Bearing cap bolts

55

Differential case bolts (L.S.D.)

40

Rear cover bolts

30

Axle bearing retainer plate bolts

45

Spring ’U’ bolt nuts (Wagon)

60

* Track arms to body

75

* Track arms to pivot link

75

* Pivot link to axle housing cover

15

* Suspension arms to axle housing

75

* Suspension arms to body

75

* Shock absorber to spring plate

75

Caliper to bracket pin nuts

20

Splash shield screws

10

Shock absorber to spring plate nut

45

Stabiliser bar clamp bolt

20

Universal joint bolts

10

Vent - Rear axle housing

15

Pinion flange nut — Tighten to achieve

—

specified bearing pre-load
Filler Plug

30

Drain Plug

30

Screw Adjusters (IRS) — Tighten to

—

achieve differential bearing preload
Final drive assy rear mounting bolt

200 

± 40

Final drive assy front mounting bolt

140 

± 28

* Items marked thus are to be tightened with the

vehicle in the curb load position.

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205-02B-4 

Independent Rear Suspension — Full Floating Axle 

205-02B-4

DESCRIPTION AND OPERATION

Torque is transferred from the drive shaft to the rear

Description And Operation

axle assembly via the companion flange which is

splined to the hypoid pinion. The torque is then

Drive Unit Identification

transferred from the pinion through the ring gear,

A label identifying the drive unit assembly part

differential case, pinion spider, differential pinions and

number, model, serial number, and final drive ratio is

side gears to the axle shafts. The differential case

fixed to the carrier casting.

houses two cone type clutches which are integrated

with side gears. These cones are splined to the axle

IRS final drive units (3.23 or 3.45:1) have a 7 3/4 inch

shafts, their tapered faces bearing on the differential

(189.9 mm) diameter ring gear.

case.

 CAUTION: IRS drive units use a synthetic

Thrust springs pre-load the gears/cones, forcing the

lubricant that is not compatible with standard

tapered face of the cones into contact with the

polyacrylic pinion seals. Viton pinion seals must

differential case. The partial locking action, due to the

be used in this axle.

spring load on the cones is automatically increased by

the inherent separating forces between the side gears

A metal tag carrying the words ’HIGH

and pinion. This locking action directs portion of the

PERFORMANCE USE APPROVED LUBRICANT

driving force to the wheel with the greater traction.

ONLY’ is attached under the filler plug for LSD. A

Decal is also attached to the right hand front door

When the rear wheels are under extreme unbalance

hinge pillar. (LSD only).

tractive conditions, such as one wheel on dry road

and the other in mud or ice, with the conventional

Drive Unit Differential

differential, wheel spin will occur if over acceleration is

attempted. However, with the limited slip differential,

The drive unit should be removed from the vehicle for

when the tendency for wheel spin occurs, the friction

overhaul. Before disassembling the unit the following

generated between the cones and the differential

inspection should be carried out:

case transfers portion of the driving force to the

1.  Remove the rear cover, clean and visually inspect

non-spinning wheel. in the event of continued

the moving parts for chipped or scuffed surfaces.

spinning a whirring sound is produced due to

NOTE: The differential bearing lock plates are

over-running of the cones; such a condition or sound

removed when the ABS location mounts are

does not indicate failure of the unit.

removed.

Axle shaft end play is pre-set and is not adjustable.

2.  Use a torque wrench to check the ring gear bolt

Oil seals are located between the inner axle shafts

and pinion flange nut torques.

and the screw adjusters.

3.  Check the run-out and backlash. Refer to Section

Diff and Pinion Bearings

205-00.

Construction design is a single row, pre-set tapered

4.  Carry out the Gear Tooth Contact Pattern Check

roller bearing capable of accepting thrust loads in

outlined in Section 205-00.

either direction and radial loads in any combination.

Conventional Differential

The tapered roller unit type bearing consists of five

basic parts: the cup or outer race, the cup rib ring, the

The four pinion gear split differential case and the

cone, or inner race, the tapered rollers which roll

drive pinion are mounted in opposed taper roller

freely between the cup and cone, and the cage which

bearings in the carrier. Differential bearing preload

serves as a retainer to maintain the proper spacing

adjustment is provided by the screw adjusters Pinion

between the tapered rollers grouped around the cone.

bearing preload is provided by a collapsible spacer.

When the bearing is manufactured, the cup and rib

Torque is transferred from the drive shaft to the drive

ring are bonded together with an adhesive to facilitate

unit assembly via the companion flange which is

bearing handling and installation. Since the cup and

splined to the hypoid pinion. The torque is then

rib ring are clamped together in the axle housing,

transferred from the pinion through the ring gear,

there is no need for a permanent bond. When the

differential case, differential pinion cross shaft,

bearing is serviced the cup will usually be separated

differential pinions and side gears to the axle shafts.

from the rib ring.

Axle shaft end play is pre-set and is not adjustable.

Oil seals are located between the inner axle shafts

M78 & M86 IRS (Sedan)

and the screw adjusters.

NOTE: A label identifying the drive unit assembly part

number, serial number, final drive ratio and model is

Limited Slip Differential

fixed to the carrier casting.

The four pinion gear split differential case and the

Two different model final drive units are used in sedan

drive pinion are mounted in opposed taper roller

vehicles:

bearings in the carrier. Differential bearing preload

adjustment is provided by the screw adjusters. Pinion

M78 final drive units are fitted with 3.23 or 3.45

bearing preload is provided by a collapsible spacer.

7.75" (197mm) diameter gear sets, with or without

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