1974 FORD CAPRI Workshop Manual

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4 5 6
2 3
14
1 3 @~~-@
9 10
Fig . 8.1 0 ElIl>loded view o f the reM C1Kle {Sec 8)
I Axle housing 2 Diffcrcnlilll case (lJper lolle/ belJriJlg 3 DiffcIClltiDl r;ase Sillill 4 Crowflwhccl 5 GoskCI 6 COVCI 1 Drive (Jillion flange
8 Od seal 9 Drive pinion Ii/per follt·, bemiflg 10 Drive 11111;0'1 SIJaCCf _fixcd Icoglll 01 CQfl.1psllJlc II VI.IIIl Vilfve 12 O,ive {limon
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CIt I
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13 PmiOIl yea! 5".111 14 DlflClenliM C(lSf! 15 Sil/C yellr 16 O,flCfCIJ/ii!l pillion 17 Rctllininy filly 18 Axfcsh,1!1
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r'9' 8.11 Differential ClOsing and bCiHillU C Fig. 8 .1 3 Removing tholockinu pin IrOtlllh c pinion goar shaft (Sec 8)
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~i9. 8.1 5 Checking tho d iff erential sid e gear ontilioal (Sec 8)
Fig. 8.12 RClll ovin!J the differential assemhlv (Sec 8)
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fig . 8 .1 4 Oiffercntiill cOIllI)oncnlS (Sec 8)
Fig. 8.1 6 Chocking the crownwheel and pinion backlash (Sec 8)
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Chapter 8 Rear axle 139
ci,cumS«"Ulces mny only one pmt of the two be renewed. fnspect the dllfe,enti,ll pinions nnd side gems for signs of pitting. score mMks. Chipping nnd general wem. Obtain new gears as necessa,y . Inspect the th,ust washers lor signs of weM or deep sco,ing. Obwin new thrust wnshe,s as necessary. Once the pinion o il senl has been disturbed it must be discMded and a new one obtained. 20 When new pnrts have been obwined ns required. reassembly cnn begin. First lit the thrust washers to the side gems and place them in position in the differential housing. The ground side of the thrust washers IllUSt lace the side gC.Jrs. 21 Place tile thrust wilshers behind the dillelentini pinion genrs i1nd mesh these twO Oems with the Side gears through the tWI) ilpertores in the lilllerentlill housing. Milke sure they ilre diametlicilily opposite 10 each other. RO«l!e the clillerent'i11 pinion gears through 90' so brinUlI1\j them into line with the pinion genr shnlt bore 111 the housinlt 22 Insert the pinion genr shnft with the lock In!) p'n hole III line with the pill hole. 23 Usinu leeler 1),IU!Jcs. measure the en{lll(",t 01 ench s,de Be,,,. II the speclficd h\Jure IS excecrt"d. IU!W tl"u~t washlllS mu"t he olJt,uned
-omnlllie the a~~el)lhly ,lg,llll ,trld ht new thll,st wa:,lu' suilahle dinmetci tul!c . cmclully lit the larg"r ti!per rollI)' benllll\) onto Ihe pillion shafl. The lar\ler dlilllleter 01 the be,lllllU !\lust be nex110 the pInion head
28 Using soitable diameter tubes. fit the two Wper roller bearing cones into the finnl dlive housing. making sure that they ale litted the correct way round. 29 Slide the shim and spncer onlO the pinion shalt and insert inlo t he final drive housing. 30 Relit the second and smaller diameter wper loller bea,ino onto the end of the pinion shaft lind 101i0w Ihis Wilh a new oil seal. Sefore Ihe senl is nctually fitted. apply some grense to the inner Ince between the two lips of the seal. 31 Apply n little jOinting compoond to the outer Ince of the seD I. 32 Using n tuhulilr dllft 01 suitable dinmeter, carefully drive the oil seal into the fillal (hive housinlJ. Make quite sore thnt it is lilted squarely and flush with the housinU. 33 Refn the drive pinion IInnge nnd hold securely in n bench vice. It II fixed lenIJth spncCl is Itlted. fit ilnd tighten the pinion nut 10 the spec ,lied lorque. If a collapsihle spnce r is f,tte d. follow the prOCedlHe
g iven in Section 7 paragraph 14. setting the pinion turning to'que to hetween 25 nnd 2.7 Nnt (1.810 2 0 Ihf It) which includes 0.2 to 0.<1 Nm (0.15 10 0.30 Ibl It) lor the ndriitional friction of the new oil senl II new hea,inns h~ve heen filted. logether With n li~e(l len(Jth SP,lCer. check thm the tOrlllllg torque is bel ween the limits just stmed. If not. a longer or shorter spilcer must he I,tted until the setting IS correct 34 Fit the healing cones to the cf,fierenllal houslIlg heallll(Js and carefully ease the housing Into posilion in the finill drive housmg 35 Relit the be,IIII'!J CilpS in thell originnl pOSitions. Srnc,ll n httle JOlntmg compound on the threilcfs 01 each cnp secuIII'O bolt nnd fit 11110 position. When ,111 low halts have bcen rein ted tiUhten these up in a (h"IJonal and progresSive milnne, to the speCi fied torque. 36 I I pOSSIble. 1Il00nt n dlnl in(licntor onu(Je so thnt the probe IS resting on one of the teeth of the crownwheel and determine the backlash hetween the clownwheel and pillion. The bileklash may be vMicd by elecreasll'\) the thickness of the shims bellind one beilling nnd incrensing the thickness of shirns behind the othcr. thus moving the crownwheel ;nlO or out ofmcsh as requi,ed. The tOt.llthlckness 01 the shims must not be chnn\)ed. 37 The hesl check the do·it·yourself owner cnn make to aSCerta", the correct meshinu of the crownwheel ilnd pinion is to smear ,I htt le engineer's blue onto the crownwheel and pinion iJnd then lot"te the pinion. The con1 COlleCI 100110 CO"t.1ct
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t Heavy conWCl 0" huel. at 100lh !,leu Move p'",on lowa,ds crownwhcd u:.!:.crt:1 3nd c,ownwhuel towards p,n,on
.~\;!~" •. ,;.';,;,"",.,=,"--
l ' Fig. 8.17 CrownwheeJ and pinion setting chart (Sec 8)
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·0 ) Chapter 8 Rear axle
crowllwh(lcl teeth. Refer to Fig 8.' 7 where the corrcCl100l h paltcrn is shown, Also shown arc incorrec t loorh patterns ilnd the method of oi11 9 Wheel stud -renewal
Chock the IrOllt wheels then lilck up the ,eaf of the Cill ilnd sUPPor! will> ilxlc S1 ,I PU.lSS Or dllvc the wheel SlUt! through t he axlestwft /I;)n9c. 5 Clc " 1',,11 tho slUd lully "'to Ihe lIan!)c "s"'\.1 ~ wheel nut ~nd wilsho,s as ,own III Fill . 818 ., neht the IHilke (hum ,11ld ,e~, wheel then lowel the eM 10 the
IUlld
10 lillli ted-slip diffc ronli"l-\.Ien er,,1
The IIllllwd·shp (I,fle,ent,,,1 's f,tled to 2 8 Spec,,,1 modl:ls ""d Its "';1111 purpose is to il,event wheef SPIll 01 the IIlsule ,ea, wheel when dnvin(l round bends or oul of l>emls w ith lull enOl/Ie powe, applied.
F i
ll. 8.19 Cutaway view o f the limited·slip differential (Sec 10 )
A Crowf!whecl /J fJ'{""I!/IIi,,/ carrier r: PIllIOII ue .. " /J $h .. ,{1 r fhlll.I'IIIII!llill",,,,II/,1C<.'S r Uukr IJ{;,I<.-((III """Ht'nll,,1 ,;,/1 IIf,'1 ) (; 1"111:1 I"a/(: ((III axle . K Suit.' !I''""'' I. /lIIIHI IIII!/-I" 1M S,IIIIIII woIsl".:,s
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F ig . 8.18 U sinll 11 wheel nut 10 pull il slud in to lhe ilJ(le
flonge (Sec 8)
Under these cond,tlons thNe I S il weiohttriln~IN 1 0 lilo oulslde wheel. ,111d lho deS'Bn of the standJIl1 (hlf(:relll,al is such Ihal all ,1dvmse I(uque con 110 ajlpl".:d 10 l11e Ills, de wheel ca"slIlII wheel ~pln, The l,lll ,W procarmanuals.com

Chapter 8 Rear axle 141
lings apm! and compress the clutch plntes. The nction is varinble. depending on the power npplied. so tlMt under full power the dIfferential will lock completely nlld full torque will be appl;ed to both
11 Fa ult diagnosis -rear axlo
Symptom
NOIse
"Clonk· Oil nccelera tlon nnd deceh:ontlun
,... Ilenka\Je
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renr wheels . Under coasting or overrun conditions the differential will operate as a normal stnndard unit. The unit incorpora tes four different;nl pinions Roason(s)
Worn axleshaft bearing Insufficient luhricant
Worn dlfferentinl houSIng bearings Worn crown wheel and pinion Incorrect crown wheel nnd pinion mush
Worn 1I. leshalt splrnes Excessive crownwheel nluJ pinIon bncklnsh
Pm ion oil senl Icnkrng ReM cove r gasket leaklllg 011 seal on , , ,
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Chapter 9 Braking system
Fault rflnunosis -hrnking sys tem Foothrnk.c I)(!dnl -removal .1nd refluing From m ake caliper -overhau l .. Front blake cillipCf -removal ;1nd 'Cl,UUl\1 .... ______ ._ .................... . Front brake discs -inspection, ,enlov,,1 and rcl,!\in(J Front disc pilds -renewal , ....... _ ...... .. General description ..... .... ........ . ............ . H andb Spcci/ic:ltions
Syste m type
I=rOl1t brakes ~c tt,ickncss :
Now ....................................... .
Min rmum.
Oisc fun ·out (ma~inlum including hub).
Mini'l1ulll disc pad lining Ihickness
Re ar brakes MInimum bfake shoe lining thickness.
Torque w re nch settings Caliper ....... ................. ................................... . Brake disc .................... . Backpl"te ........................... .................... .......... ................ .... .. .. .......... . Hydraulic unions. Bleed screw (ma~) .... Aecuf>Cfaling valve 'Clainel (Gi,ling)
Gonoral description
23
16
5 ,
G 3 1 18 20 19 14 15
Oisc brakes aro f;tted 10 Iho front wheels and drum brakes to the lea. wheels. Tho cable or cablo and rod opelilled handbrake oper:11es independently on the real wheels. A vacuum sorvo unit is fiued
" "tween the mastel cytinde. and loolbrake pedal to provide assistance 'en the pedal is depressed.
T he hy,aulic circui t is split frOnt and rear. Undel normal conditions
M,lSIC' cylinder -ove.hilul Milsle. cylinder -removill ilnd .e liuing . P.eSStue d,ffcrenliill swit c h -desoiplion .• e m ov,,1 and .el,ning P,essure ,educing valve · description. relllovill ilnd .er,llonu
Reil' i),lGkplilte · ,emov"r ilnu refining Hei!( i)r"ke shoes -renewal ....... .................. .............. . . Routine m"intenance ........ . ................. .
SlOp·lilmp switch - removal. re/rUlng and ildJustmcflI . Vilcuum servo unil _ description . Vncuum servo unil -rcrnovnl nod rcfiUing Wheel cylindcr -rcmovnl. ove.haul and ref'lIing
11 10 12 13 ,
7 2 17 21 22 8
Dlml hyd'i1ulic cif cuit. snlol Ironl i1nd rCilr WIth IlreSSU,e reducing v:llve in reil r ci.cui t on Iiller models. DISC I,onl brilkes i1nd self·ndjust illu rca .
(!rum brilkes. all wilh servo aSSIstance. Calrle or c.,blc .1nd rod operated handbrake on rear l)f"k es
12 .7 mm (0.5 in) 11.4 rnm (0.45 in) 009 nlln (0.0035 in) 3 .0 mm (0.118 in)
1.5 mm (0.059 in)
Nm 471068 41 1046 271031 71010 10 491062
Ibl It 351050 301034 20 to 23 5 to 7 7 36 to 46
both ci.cuilS operale in unison. howeve •. in the event of faIlure o f one circui t Ihe lemaining ci.cui l will p procarmanuals.com

) Chapter 9 Braking syste m 143
2
Fig. 9.1 DU