Drive Axles 7 ARROW/COLT Arrow Colt DESCRIPTION Rear axle is of the bonio type, vilizing the removable carrier style differential Light weigh! construction joins split tubular housings for each side with center covers welded to axle hous- ing. Final drive is of the hypoid style. Axle shafts are semi- floating type supported with bearings af their respective ends in oxle housing, Bearings are fied to axles with pressure type bearing retainers. Pinion bearing preload, side bearing preload, end pinion depth adjustments are made with shims ‘while differential side geors are adjusted with spacers. REMOVAL & INSTALLATION AXLE SHAFTS & BEARINGS. Removal ~ 1) Raise and suitably support rear axle housing 50 rear wheels clear ground. Remove rear wheel and broke back plate nuts, then disconnect wheel cylinder brake line. Fix suitable puller set (CT-1003 & C-637) to lug studs and work slide hommer until axle shaft is free to be withdrawn. Set brake back plate with parking broke attached out-of way. Us: ing suitable foo! (C-637 with hook) remove axle shaft ol seal 2) To remove axle bearing proceed os follows: Grind down bearing retainer ot one point until retainer thickness is .O4+ (06" (1.0-1.5 mm), then chisel ground portion and remove Fetainer. Using suitable bearing puller or press (CT-1120) remove bearing from axle, 3) Using a diol indicator, inspect axle shaft deflection in three spots (se illustration). Replace axle shaft if specifications ore exceeded ‘Axle Shaft Deflection Table Application Std. Value Service Limit Point "Ar 0.004? ns 008" (0-10 me). (10 mm) Point 002" (08 mm) Point" 08" +75" (19.0 mm) + 2077 __. (205 mm) Fig. 1 Measuring Axle Shalt Dellection 4) Rear axle bearing should be replaced when bearing noise js detected, when beoring axiol free ploy exceeds .014-016" (.26-.41 mm) ori bearing radial free play exceeds .001-.002" ((03:.04 mm) at approximately 11 lbs. (5.0 kg) measuring force 55) Inspect wheel hub bolts for tightness and bearing outer retainer for deformation, replace defective parts os necessary Installation ~ 1) Fit ovter bearing retainer fat side against shalt splined end, then install bering and inner bearing retainer. Seat bearing retainer with smaller chamfered side directed to the bearing. Ensure bearing is completely seated, 2) Lightly coat lips of oil seal ond using suitable oil seal installer (DT-10078 & CT-1008) ft axle shaft oil seal in rear ‘oxle housing, 13) Using pockings and shims in proper sequence, set clearance between bearing and outer bearing retainer to 00-01" (.0 25 mm). 4) Corefully insert axle shaft assembly into axle housing using care not to damage seal. Slightly turn oxle shaft until splines Tine up with ditferential side gears. Align packing oil holes with outer bearing retainer and tighten bearing retainer to ‘le housing flange. Connect brake line to wheel cylinder and bleed air from system, we = Zale Shaft Wheel Hub Bolt Outer Bearing Retainer Bearing Retoiner Bolt Fig.2 Exploded View of Axle Shaft Assembly DIFFERENTIAL CARRIER Removal ~ Drain oil rom rear oxle differential housing, then disconnect propeller shaft. Pull out both rear axle shafts op proximately 21/,". Remove differential geor housing mounting nuts and withdraw the differential gear carrier. It may be necessary 10 tap outside of housing to break gear corrier loose. Installation ~ Lightly coat each bearing ond gear with cil Apply sealing compound on packing and oxle housing seat, then ‘asiemble gear carrier to axle housing with nuts and tighten, Fil differential gear housing with .96 quart of suitable multi-purpose geor oil (API GL-5). ‘ipo 200 Rapa ema Campa74 Drive Axles ARROW/COLT (Cont.) Differential Corrier Axle Housing Fig. 3 Removing Differential Gear Housing OVERHAUL DISASSEMBLY Differential Gear Assembly ~ 1) Remove bearing carrier cop and lever gear case assembly from housing. Using Sultable. bearing, puller tool (C-293-P & C2999) pull differential side bearing. Keep right and left bearings and shims in sequence for reassembly. Fig. 4 Removing Differential Side Bearings 2) Remove ring geor lock plote tabs and loosen bolts in diagonal sequence, then remove ring gear. Drive out pinion shatt lock pin from ring gear back side using @ punch; pull out pinion shoft and pinion. Pinion side gears ond spacers ore now accessible, Note placement of pinion side gear and spacers and ensure they are reassembled in some position Pinion Disassembly ~ 1) Hold end yoke with suitable tool (C-3281) and remove lock nut, then remove end yoke. Us ing © wheel puller, force ovt drive pinion with adjusting shim, rear inner bearing race, spacer ond preload adjusting shim, opr 200 Bearing Puller ‘Assembly Drive Pinion Fig.5 Removing Drive Pinion Bearing 2} With suitable bearing puller (C-293-P & C-293-39) remove reor beoting inner race ond at same time, pul off drive pinion ‘adjusting shim. Using suitable drift, remove front drive pinion bearing outer race and oil seal, Repeat some procedure 10 remove bearing outer race. Fig.6 Removing Drive Pinion Front Bearing Outer Race INSPECTION Check differential geors for correct tooth contact and replace geors if wear is excessive. Inspect bearing foces for roughness fr score marks and replace, if necessary, bearing assembly. Ensure splines of side geors ond rear axle shafts fit correctly. ‘Check clearance between pinion gears and pinion shatt, f wear is excessive, replace components — To check gear tooth contact using paint impression ‘method, refer to beginning of this ection.Drive Axles 1 ARROW/COLT (Cont.) Side Bearing ‘Side Bearing Adjusting Shim Front Drive Pinion Bearing Drive Pinion Depth Adjusting Shim fear Drive Pinion Bearing rive Pinion Spacer Preload Adjusting Shim Final Gear Set Packing Differential Case Adle Housing Fig. 7 Exploded View of Colt Separate Housing Rear Axle Assembly REASSEMBLY & ADJUSTMENT Case Assembly ~ 1) Install thrust washers (spacers) behind side geors in their original position and assemble pinion and Side geors in differentil, Inert both pinion gears, with pinion washers attached, so they mesh with side gears. It may be necessary to slightly rotate pinions to achieve desired meshing Insert drive pinion shaft. Fig. 8 Checking Differential Pinion and Side Gear Backlash 2) Check pinion and side gear backlash os shown in illustration. If backlash is beyond 0.003" (0-.08 mm) adjust by selecting @ side gear thrust washer (spacer) of correct size. If backlash is to be adjusted, ensure right and left sides ore equally shimmed. 3) Thoroughly clean all dirt from ring gear mounting surface of differential case. Install bolts and lock washers. Tighten bolts alternately in o diagonal sequence and bend over lock ‘obs. Ensure lock washers are in contact with case rib ofter final torque has been performed, Drive Pinion ~ Using o suitable drift ond hammer or a press, seat front and reor bearing outer races info gear carrier en Suring that outer races do not cock. Ensure bearing races are completely seated before proceeding. Install shim between Arive pinion ond rear bearing. Using sitoble bearing instoller {(CT-1075) press bearing onto drive pinion shaft. If drive pinion tand bearings ore scheduled to be reused, shims should be Feplaced with new ones of some thickness. in instances where the gear set is Yo be replaced, install new shims thot are the same thickness 0s the used shims on drive pinion = When determining the desired thickness of shim pack, amount of compression (sinkage) of shim pack ond weor of the bear- ing (where old bearing is reused) must be taken info con- sideration. Drive Pinion Depth — Instoll drive pinion spacer, front bearing, washer, end yoke and washer in order of removal. Fit pinion shaft retaining nut and slowly tighten nut, continuously Checking, until pinion bearing preload is 6:9 INCH Ibs. (7-10 ‘emkg) with oil seal not installed, Place svitable cylinder gauge ‘on inside bearing pedestals of gear carrier housing. Place a block gauge on top end of drive pinion and slip @ feeler gouge between the two gouges to obtain the correct clearance. The clearance between gauges should be .0118" (.300 mm). This is the standard height and ony deviation from this height will be marked on the head of the pinion shaft and side of ting gear. To calculate the correct pinion height, add fr subtract the variation value from the standard height. [ELE — Stomped volves are in hundredth millimeters. Add or subtract the correct amount of shims a: necessary. Pinion Beoring Preload This adjustment must be performed after the setting of the drive pinion depth, Remove fend yoke ond insert the bearing preload adjusting shim between pinion spacer and bearing, hen tighten end yoke fo 9-11 INCH Ibs, (10-13 emkg). In eddition to the preload ad- justine ims there are spocers available to provide proper fodjustment. After finishing adjustment of drive pinion bearing preload remove the end yoke and apply a thin coot of grease {o outer surface of oil sel, then drive seal into postion in gear carrier. After greasing il seal lip, insert end yoke ond fighten ‘ipo 200 Rapa ema Campa7 Drive Axles ARROW/COLT (Cont.) ide Bearing Preload - Fit each side bearing into differential core leaving shims out; ute suitable tool (CT-1102) {for this procedure. Ensure sida bearings are completely seated before proceeding. Install differential case assembly on gear carrier, then colculate the clearance between side bearing out- fer race and gear cartier as shown in illustration. After ob: taining clearance add .002" (.05 mm) preload figure to each fide. Insert shims equally on both sides. Align gear carrier ond bearing cap index marks, then tighten cop retaining bolts. Feeler Gauges ; Fig. 9 Measuring Clearance Between Side Bearing ‘and Geor Carrier Ring Gear Deflection — Attach o dial indicator to back side of ring gear and measure deflection, If ring gear has excessive Geflecion, correct position of the astembly in relation to differential case and again perform measurement. Replace ring gear or differential case os necessary. Drive Pinion Backlash ~ Measure backlash of drive pinion in at least four different spots on ring gear with drive pinion securely fixed in final position. Set up @ dial indicator on ring ring gear teeth edges. If measured backlash is greater than (005-007" (.13-18 mm), shift shims from ring gear side 10 back of the ring gear to obtain proper backlash. If the ‘measure valve is less than stondard value, reverse the moving Of shims as stated above. Side bearing shims are available in vorious thicknesses. — Check gear tooth contact using point impression ‘method described at beginning of ths section. Final Inspection & Assembly ~ lightly coot each gear ond bearing before and during reassembly with gear oil. Af stalling each component, ensure all rotating parts are free to move smoothly. Install diHerential gear assembly to axle hous- ing ofter applying sealing agent and tighten gear carrier ‘mounting nuts in diagonal sequence. TIGHTENING SPECIFICATIONS Application Fr Lbs. (mkg) ‘Outer Bearing Retainer Brake Bock Pate. Ale Housing Drain Plog Level Plog z Ring Geor-to Dillerentoi Case Final Drive End Yoke (Final Torque} Ditferetil Carrier Cop. Differential Gear Carrier Assembly to-Axle Housing Colt 22.25 (3.03.5) Arrow 18-22 (2.530) 25.29 (35-40) 25:29 (35-40) 25-29 (3.5-4.0) 317.1) 29149) - 97-54 (6.57.5) 170.160 (16.622.1) 25:29 (35-40) AXLE ASSEMBLY SPECIFICATIONS Specifications In. (mm) 0.01 (0.3) Application Bearing-to-Beoring Retainer. Differential Pinion-to- Pinion Shaft .001-.002 (.02-.08) Differential Pinion ond Side Gear Backlash... 0.003 (0-08) Drive Pinion Preload With Seal 9-11 INCH Ibs. (10-13 emkg) Without Seal 6:9 INCH Ibs. (7-10 emg) Drive Pinion and Ring Gear Backlash... 008.007 (.13-.18) ‘ipo 200 Rapa ema Campa