Ford Falcon. Manual - part 57
205-02B-13
Independent Rear Suspension — Full Floating Axle
205-02B-13
DISASSEMBLY AND ASSEMBLY (Continued)
3. A positive (+) number on the drive pinion means
that a thinner shim should be installed to move
the pinion gear away from the ring gear. A
negative (-) number means that a thicker shim
should be used to move the drive pinion closer to
the ring gear.
4. Lubricate all differential parts with the
recommended rear axle lubricant, before they are
installed.
5. To select the correct shim thickness follow these
steps:
NOTE: The exact same rear pinion bearing that is
to be used in the vehicle, is to be used when
using the dummy pinion.
1. Install the front and rear pinion bearing cups
into the axle housing.
2. Fit the pinion bearing cone and rollers to the
dummy pinion tool. Install the dummy pinion
to the axle housing. Fit the pinion front cone
and roller to the dummy pinion. Install the tool
thrust collar and the nut to the dummy pinion.
3. Tighten the nut until a bearing preload of 1.4
to 2.4 Nm (new bearing), 0.7 to 1.2 Nm (used
bearing) is achieved while rotating the dummy
pinion back and forth to ensure correct
seating of the bearing rollers.
4. Position the depth gauge cylinder in the
carrier and fit the bearing caps, tightening
lightly. Determine the size of pinion shim that
will pass between the depth gauge and the
dummy pinion head. Examine the drive pinion
installation marking. The size of the pinion
shim should then be altered as follows:- A
positive (e.g. +0.002 inch) marking means
that this pinion has to be set at this number of
thousandths of an inch further from the drive
gear, i.e. a shim this amount thinner must be
used. A negative (e.g. - 0.002 inch) marking
means that a shim this size thicker must be
used. A zero (0) marking indicates that the
shim selected with the gauge is the correct
one for this carrier/pinion combination.
Position shims are available in .001 in (0.025
mm) increments from .008 to .030 in (0.2 to
0.75 mm).
NOTE: The marking on the pinion is in
Imperial measurement.
5. Remove the tools from the carrier.
6. Remove the rear pinion bearing cup from the
housing.
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