
130 Chapte r  7 Pro pelle r sh aft 
14 
.  12 ~ 
"> ., I> 
"  10 11 
9 a
·6)6f 
. -r 3 
~I"")~ 2 
Fig. 7 .2 CCllIre bearing and CV joint cOIll I)onenls (Sec 3) 
1 FIO,,/  sll,1// 2 Inncr (/(IS/ cJ(cfudm 3 Cemrc bC.1riny 11 Rubber in$u/.l/(J' 
5 1f00wl/f/ 6 Du/!)( rlusl cXl;/mh'I 7 AIlYflml'lJ/ shim 8 flull 
FiU · 7.3  T ho  recess (;ufo\l\lcd) in the <:orllre bearing housing m ust la ce forw(.rd (Soc J) 
10 To lI~fll the bearing. first f,lI the 51)
alrgned.  Ihen refit and tighten  the constanillclocity joint  housing bolts. 14 Refit the propeUef shalt With ,efefcnce to Section 2. 
4 U nillorsal joints in sp ectio n 
)  Weaf  in the 
needle  rollef heafings is Ch,Uoclefi sed by  vibfalion in the tfan srnission.  'clonks' on takrng up the drille. and  in e~treme cases 01 tack 0 1 lubficat ion.  mOlalhc  squoaking.  and ultimately grating  and 
shrie king  sounds as the bOilflngs breiJk up. 
9 Fl.",!!.: /0 C('/IIf<.' 1",11 /1 Cllcllf'S 12 CV /01111 ilssl:mbly 
13 Sprillg c.lf' 14 Boll 
Fig.  7.4 Using.~ plillor  10 withdraw the centre bClI ring (Sec 3) 
Fig. 7.5 Bendi" g the metal tabs to secure the insulator (Sec 3) 
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1 
134 Chapte r  8  Rea r axl e 
FiO. 8.5 Discorlllccti!l9 the rcar sI"biliser Iwr (Sec 3) 
7 U~"'!I u"ps (FlU 8 5) I)UU rile  s1.1h,l,s(lI b.ll 10 lilt:!  lCol. while unstocwIIlIJ the mOlllllnlU I)oIIS from the Ie;)' ;l~II!. flcl110vc the C!JIllI'S 8 W,lh the rC:II Ildc sUlt,lbly  SUIlI>o.ICd. lIIlSCICW rhe nulS hom the hallom 01 the U-bolts i1rld reOlOlle rhe lowel S I)llrlU p l;lrcs .. ",t! 1115 .. 1<11015. 9 Wllh rhe help of an asslSlilnt. hft the rem a~lc over the "~
Chock Ihe front wheels then jack up the re,lr of the c~r ilnd support with onle stilnds. Remove the .ear wheel 2 Ilelea se the hilndb.nke and .emove Ihe brake drum. 
3 USIng a socket through the special holes in the drive lI.::tnge. unsc'ew the bollS secu.ing the b.::tckp late and bearing ,el.::tinor to tho a~le cilSln g (pholo). 11 Withdraw tho a~leshnft. together with the bearing. "  it is  tight due 10 tho oulor Ir
ig. 8
.6 RelHoving t h o Mdeshalt .e l'l ining hoits (Soc 4) 
If 
I 
/1 
II 
I 
\, 
Fig 8 .7  U sing long bolls to ""ithdra"" tho a~leshaft (Sec 4) 
cd 
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m 
) 
Chapter 8 Rear axle 135 
Fig 8 .8 Drilling the beMing rf!t
5 AxlcshiJft homing -renewal 
Noto: A SfJL'CI.1f 1001 IS "Hlliller! /0 n'III1:''''''[1 (,0111 lilt' axles/mIl (s,:c Fly 89) 1 Remove the ;,xlushalt as ,h:sG"hcd 1(' St;CIl0n 1 2 Usin\J all 8 mill (0.31 In) dldl, 1Il;,kc  a hole III the he,Hlnt!  ,etauun\1 119 . t
G Cleiln the  l1xlcshnf1.  be,non\) ,,,t;WlC'  ,Hld "xle C.,1511l\) 7 Locl1le the loe1ll1ll9  HIWlIlel 011 the l1xleshl1lt. followed uy tho new uoa,ing wIth the 001 sel1l [l1CIll\) l1WilY ['om the l1~leshaft Hallge. 8 Slide on the new hea'lIl\) rcta"lIn\) '1119 and pr ess J fully 11\l111l1st tile hearing inner IWck. uSIng  a slJItJIJle puller or J  ICWlth oftuue. 9 Re fIt Ihe l1xleshalt wllh refe'ence to S ectIon <1 
6 Axle reM cover relllov,,1 ilnd refitting 
Chock the  hont wheels then lilck up the re,l( o f the Cl1r il'l(l SOPPOI1 on axle stands. 
2 Cl em1 the reM cover .Jnd surroundIng  .Jre" (photo) 3 Remove the hllmlbr"ke relay  le ver lind seco nd.Jry  cable. or 
transverse ,od  (as  ;;Jpplicilblc) with reletCnce to Ch"pter 9. <1 Place a suitable container helle~th the reM "x Ie to c~tch the oil as the rear cover is removed. 
5 Undo and remove t he  ten IJOlt s and sprinU washers lhilt securo the reill cover to the llIl,l l drive housillg LIlt aWilY th e re"r cover and its 
\Jasko!. ~ Before refitting the ,oar cover Illilke sure thm the mating fJces  ilre free of th() old Uaskct or 10nlting compound. 
7 FIt  a new uasket Jnd then the lea, cover and secure wIth the ten bolts and spring washers. The cover bolts protrude IntO the fillal drive hOUSor1U so it is important that a  SUlwble  oll·resist.Jr1t scaling 
... __ ro* 
Fig. 8.9 Usill(J the special Ford tool to removc the axlesllilfl henring (Sec 5) 
r;olllpoulid IS SlIll:ilr() d onto lioe Ihro,'ds of each boll bef ore  it IS [,twd. 8 TIUhwll tllr: cover secu,,"!.! holls 10 lhe spec,[,ed torque Wfl:IICh 
se ttln\) 
9  ReCOlillect 
Iht! h,lndbr,l~e components with re ference to ChJp ter 9. 10 R efil l ti,e 1e;1I ,ule with the correct 9rJde 01 oil then lower the C,lr to 
the UIOUIl(i 
G 
2 Axle reM cover 
7 
Pinion oil seal -re"cw,,1 
This ope r,ltion may be performed WIth the rear axle in position or on 
the benc h 
2 Undo ~nd remove the two holts. sprinU Jlld plain washers that secure lhe centre bearing support to  the under51(fe of the body (reler to 
Chapter 7) 3 With a sc"ber 0' fde. Ill
propeller sha h to ttt() flool I I 
J m 
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Chapter 8 Rear axle 136 ) 
5 C~rellJlly cle~n Ihe Ir Oll 1 01 the Im,ll d"ve housinU ~s there will Ilroll
P ReM axle -o verh;;lul 
Note: Mosl ymilycs wtlf Ilft'h" 10 If.'IWW Iflt' comfllelC IC,ll ,Jxfc ,15 .1 111111 d II IS WOII! ,.II/IC' I/Ioll! 10 rf,SllliI",fc Ille UII/I 10 lel/t·w '''IV r/;/11I.Jycd 01 WOIII  poll Is ro do tlw ,ob correclly Icquires Ifle usc 01 spccial <111(1 cxpellsive loofs willch tin' "'",u/lly of y"WY"'S do 1/01 h,lVl' The P"n1
,' . 2 Remove the a xlesh;;lhs (Sec lIon 4) "nd the;lxle ,e". covel (Secllon 6) . If rleceSS;;Jry remove lire !H" ke !liIckpl;,ws 3 WOlk,n!) inside IIlI! axle  casUlU . undo .lnd .emove Ihe four bolts th" t hold Ihe  IWO U'Shill>cd dlllerentl,ll be"rmg CilPS III the Cilsing. 4 W,lh a sc.iber. m
15 Froni I'll Im
",.IY  I,,, ",move(1  Ih:xl uSlnU  " ulllvers,,1 two·leuged puliCI  and sui!
NOLI! : 1 hu h"le 11110 willch thc peu Irts  IS  shghlly "'I>c.ed. lind the I>pl''''.'I'! "",1 may he IrIJhLly  peelH)d over ;'Iml  should he r.:!e;rned with a ·.u,I.II,I" ,".11111;1". ,tr,ll 11 th'''!1 a ... "It IIlI;t.11 dllfl. "'i> out Ihe drllelenli"l p"uon Ue", slr"h. 1.011 .Iw.ly tlr" d,lh;u!Oltl;r1 pinian ue,us.  sido {leMS "lid IhruSI was hers; IA"'!l':,"" 10 ell::ure Ih"t the th,usl washe.s ",e lell wllh Ihe ir relative 
liP,"" 12 1'",1"~"If)f .. ,1 Il1te.s (It Ihe 
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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'
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
_ 
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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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
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

144 Chapter 9 Braking systom 
9 II there Dre no inspec tion  holes, remove the  wheels and drums In inspect  the linings . 10 Where any lining is less Ih,111 the nllnimufll thickness,  renew Ihp. complete SCI 01 re,ll b,~ke shoes. 11 Refi ' the drums  lind wheels as necessary then lowe. tho em \0  thl) 9lOund. 
Ch eck operation of servo lIoil 12 Visually  inspCCllhe  vaCUUll1 hose IClIding hom the inlet mlllllfolll Of air box 10 the servo unit fOf dc\c,iOf1l1lon  and security. 13 Wit h  the engine Slopped. dCI).es s the bra ke pedal several ,imes to dissipate t he VOC U\Ull  hoUl the sorvo Imit. 14 Depress the b'i1kc 11Cdll1 wilh moderate pressure then Sin' I the 
cnU illC . As the V
R/mew fhe /)rilke I/Ilid 21 lJIucd  Ihe  hyd.; ."loc sySle m as d"scllherl III Seelloll 15 ilUOwnl! II", 
Ihe new h ,,,k\) Ih"d to COnlph: lely 1,lIlhe C:"CUtt he"I!1 bled . 22 AI Ihe sanl\) I"ne rcn,uve  Ihe 'Ci" ",ake \I'lOn,s alld check tho  wlu,,,1 
cylonclers  10' leak"IJe. 
3  Front disc pl1ds - renewal 
Apply  t
he handbr
I . 
. ~ .. " ,)  •. :Y. 
2 RemOV(l Ihe hont wheels. 
3 It Ihe  fhnd  level in the maste' cylondel reservoir  is high. when the pistons l1re moved into  thei, respecI,ve bo,es to  accommodate new pi1ds. thO leyel could rise sulticienlly fo, Iho fluid 10 oyerflow. Place ilhsoruent clOlh .1round the reSe,yO". o. syphon a Imlo  Ituid oul. so 1)'Cven tUlg Pil"ltwOlk  
<1 F rollt brake caliper  _ rcmoy'll iltld refitting 
1 nemove the f,on! disc pads i1S tie sc"lJc(/ in Section 3. 2 1111 'S Itll,,,,d,,(1 10 lit ncw Ci1tiper pistoll s "nd/o, seals. dep,ess the tH.1k'J Iwel,,1 10 hlUlU the pistons i"to COI11i1ct with thO (fisc and 
'-.. ~ 
, . 
3 .9B  Fitting  the tenS ion springs 
.--.::.:.:; . 
....... . ~,' 
灲潣慲浡湵慬献捯m 

1 Chapter 9  Braki ng system 1 49 
,1  M aste r cylinder -overhaul 
With tho m
recuperating  valvo. Oepress Ihe primll'y piston  during Ihis procedure. 5 Exl.;'!ct  Ihe primary and secondary pistons. IOgether wi,h their associated components. noting Ihe  order of lemOlln l.  H nccessary top Ihe master cylinder on a block of wood or  use air pressure  from il foot pUIllP through the inlel porlS. G Separate  rhe primmy ,10d secondary l)is10 11S irani lha intermediilte 
sprinu . Uso  tho !inUe.s 10 remove tile  Ulilnd seDI from  the primil'Y 
r""' lon . 
The secondil'y piSlon  assembly should  ho sOfh"ated by lilting the u"mblo leaf ove , Ihe shouldered cnd 01 tho viston . Using the lingo,s. 
rr  'wo the se
9 Dotach lhe villve space ,. tilking c
master  cylinder on a block  of wood or  use  air pressure  from  a 1001 pump through tho inlet  ports. 12 Prise  the seals  from the pistons, nOling which way round  they are lilled. then il necessary  remove tho springs  and seals.  The prima ry 
pis ton  spring  is retained by a screw. 
Both types 13 Clean  all tho components  in  melhylated  spirits or brake fluid then 
inspec t them for  wear  and damage.  Check the cylinder bore and pistons  for scorinu and corrosion.  and if eviden t renew  the complete nI
1 
2~ 
3~ 
13 
1 
2 
3 
4 5  6 
7 8 
R 
22 
21 
Fig.  9
.8 Exploded view 01 the  Girlin g master cylinder (Sec 11) 
Filler cap 9 Seal 16 Secondary piston 
Seal 10 MaSler  cylinder body 17 Seal 
Seal  !Clainer 
11 WiJslrer 18 Rell11i1er 
Fluid reservoi r 12 Reservoir relaining screw 19 Spring 
Seal 
1 3 Seal 20 Spring  fl/Miner 
Relainer 
14 Primary piSlon 21 Valve 
Primary  fCCllpCfaling  valve 
15 Spring 22 Seal 
Circlip 
10 
! 
" 1 , 
1 
I 
! 
! 
I , 
J 
,[ 
1 
I 
I 
; . 
!I ' i ;. 
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