Peugeot 404 1968 70 Drive Axles Repair Guide

DESCRIPTION

Peugeot split housing rear axle uses a steel worm drive pinion against a bronze ring gear. The axle housing is aluminum allow. The gear reduction is 4.2:1 (5X21). Both axle shaft tubes are bolted to rear axle housing. Removal of right axle tube provides "side cover" access to axle housing internal parts. Propeller shaft is enclosed and splined onto steel drive pinion of rear carrier.

AXLE RATIO & IDENTIFICATION

REMOVING REAR AXLES

Peugeot uses only one ratio rear axle which is identified by counting the teeth of the ring gear and dividing by the number of teeth on the pinion gear. The ring should have 21 teeth and the pinion should have 5 teeth, therefore the axle ratio is described as 5X21 or 4.2:1.

REMOVAL & INSTALLATION

AXLE SHAFTS & BEARINGS

Removal - 1) Lift vehicle from rear and place stands under axle shaft housings. Remove wheel and brake drum. Remove nuts securing flange (backing plate) to axle housing. Attach axle shaft sliding hammer (special tool 8.0601) to axle with lug nuts. Slide block outward against shoulder of tool to release axle shaft complete with flange and bearing.

SPECIAL TOOL FOR REMOVING
REAR AXLE BEARING

2) In order to facilitate removal of bearing collar, tap lightly on outside of collar before placing axle assembly in bearing press. Place axle shaft in press, splined end up and install press adaptor under flange. Apply sufficient pressure to end of axle shaft to remove both collar and bearing. NOTE - A special axle shaft bearing puller (special tool 8.0507) may be obtained from Peugeot distributor.

Installation - To install, reverse procedure using adaptor press on bearing and then press on new collar. When installing bearing and collar, observe the following precautions:

SEPARATING REAR AXLE HOUSING
FROM REAR CARRIER HOUSING

Always use new collar. Press bearing and collar on separately. Pressure required to press on new collar should be between 6½ and 8 tons. If pressure is not at least 6½ tons, that collar should not be used. Make certain that bearing and collar are both seated. Before installing axle into axle housing, coat axle bearing flange and axle housing with Permatex number 3. torque axle flange nuts and wheel lug nuts to specifications.

DIFFERENTIAL CARRIER

Removal - 1) With vehicle raised and supported, disconnect shock absorbers, stabilizer bar, parking brake cables and hydraulic brake hose (plug end of brake hose). Lift rear of body or lower rear end to remove coil springs. Remove exhaust pipe flange from exhaust manifold and exhaust pipe clamp from transmission housing.

DISASSEMBLING DIFFERENTIAL ASSEMBLY

2) Support transmission with jack. Remove upper bolt and two lower nuts of rear engine mount. Lower transmission small amount. NOTE - Do not allow engine oil pan to rest on steering housing. Using suitable socket wrench (special tool 8.0406), remove propeller tube ball joint cover attaching bolts. Separate tube from transmission.

3) Lift rear of vehicle enough to allow removal of rear axle and wheel assembly. Remove propeller tube from rear carrier housing. Remove wheels and axle shafts (as previously out-line). Disconnect brake backing plates and unbolt axle shaft tubes from rear carrier housing. Separate axle tubes from rear carrier by tapping gently on each tube flange with mallet.

REMOVING STEEL WORM GEAR
FROM CARRIER HOUSING

Installation - To install, reverse removal procedure and note the following: Rear engine mount must be free of grease, oil and paint. NOTE - Never use trichlorethylene to clean mount. Coat each side of mount with Permatex number 3. When installing coil springs, first coil should face to rear. NOTE - Coil springs are interchangeable. Bleed brakes after connecting brake lines.

OVERHAUL

DISASSEMBLY

1) With carrier housing removed and placed on its left side, remove differential from carrier housing. Place differential in soft jawed vise and remove bolts from side of ring gear (differential) assembly. Discard bolts, as new ones must be used on reassembly.

2) With differential removed from carrier housing, remove front oil seal, spacer and rear cap. To remove steel worm gear, dip housing in boiling water until housing is at temperature of water. Place housing in soft jawed vise with spline of worm gear facing downward through vise. Drive worm gear and bearing assembly downward and out of case. Use drift (special tool 8.0505) to remove outer races of differential bearings. NOTE - Do not interchange races.

REASSEMBLY AND ADJUSTMENT

1) On the steel drive pinion, coat both bearing seats with lubriplate and press on both front and rear bearings. NOTE - When pressing bearings, only apply pressure to inner race of bearings.

2) Place carrier housing in hot water until temperature reaches 190°F (88.0°C). With housing pre-heated, place housing in soft jawed vise with filing hole facing downward. Install pinion worm gear in housing. Hold pinion and install front spacer without its rubber ring. Hold assembly in place by means of cast iron plate, placed over spline end of pinion. Tighten plate with two diagonally opposed nuts.

PRESSING BEARINGS ONTO WORM
GEAR SHAFT

INSTALLING WORM GEAR
INTO CARRIER HOUSING

SEATING WORM GEAR

3) Turn housing upside down. Use drift to gently top bearing outer race (rear bearing), which will drive pinion toward front of case and ensure proper seating of pinion. Use depth measuring tool (special tool N), at rear of case, to determine depth of outer race. Use some tool to determine depth of rear cover. Difference between two measurements is amount of shims to install between two measurements is amount of shims to install between rear cover and housing. Install shims and rear cover, with groove facing either side. NOTE - Coat mating surfaces with Permatex number 3, but do not install gasket. After installing rear cover, worm gear should rotate freely. Remove front cast iron cover, installed over splined end of pinion worm gear. Install oil seal, rubber ring and front spacer; with groove facing either side.

PROCEDURE FOR DETERMINING THICKNESS OF
SHIMS FOR REAR WORM GEAR BEARING COVER

INSTALLING SIDE BEARING OUTER RACE

REASSEMBLING DIFFERENTIAL

4) Use drift (special tool l) to install side bearing outer races (one in housing and one in side cover) to depth of .040" (1.0 mm).

5) If pinion gears were removed from bronze ring gear, reinstall. Install differential side gears into ring gear side plate, using new composition thrust washers. Install ring gear side plates on to bronze gear with 5/16" (7.9 mm) holes aligned with end of pinion grearshaft. Bolt side plates together using six new bolts. NOTE - Bolt heads must be on side of ring gear marked with gear ratio. Torque bolts to specifications and stake bolts by punching metal into one castellation of each nut.

6) With side plates bolted onto bronze ring gear, install assembly into carrier housing (ratio marking should face upward). Differential is properly seated on lower side bearing if it turns freely by rotating worm gear (pinion). Install housing side cover with paper gasket coated with Permatex number 3. NOTE - Make sure locating boss is next to drain plug and hole of side cover, install spacers (see illustration).

INSTALLING SPECIAL TOOL ON LEFT SIDE COVER

7) Turn housing over (so housing is sitting on side cover) and align two 5/16" (7.9 mm) holes in side plate with corresponding holes in housing. Install special tool (K) in illustrated position with both fingers fitted through 5/16" (7.9 mm) holes of side plate. Secure clamp (special tool L) to press tool "K" correctly onto housing.

INSTALLING SPECIAL TOOLS & MEASURING  DEPTH OF LEFT SIDE BEARING

8) Turn assembly over, using special tool (K) as a support. Install special clamp (tool M) and apply slight pressure on outer race of side bearing. Hold depth gauge (tool N) against housing side and push plunger to touch outer race of side bearing. Lock  plunger and use gauge "N" to check bearing plate "A" to determine shim thickness. Remove clamp "M" and install shims. bearing plate and both locking straps. Tighten bolts (of locking straps) to specifications.

PREPARING DIFFERENTIAL FOR ADJUSTMENT

9) Turn assembly over so that it sits on side cover. Remove clamp "L" and tool "K". Install clamp "M" and apply slight pressure on outer race of side bearing. Use depth gauge (tool N) to determine shim thickness, as outlined in step 8). Remove clamp "M" and install shims. Install bearing plate and both locking straps. Tighten bolts, of locking straps, to specifications.

10) Remove spacers installed on side cover and install right hand axle housing.

INSTALLING SHIMS & LOCKING PLATES

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Austin Healey Sprite MG Midget 1968 74 Drive Axles Repair Guide

Models Covered:

• Austin Healey Sprite (1968-70)
• MG Midget (1968-74)

DESCRIPTION

Rear axles are hypoid design with center line of pinion set below centerline of ring gear. The axle shafts, pinion and differential assemblies can be serviced without removing axle from vehicle. All differential adjustments are performed using shims. No adjustment for axle shaft end play is necessary.

AXLE RATIO AND IDENTIFICATION

Only one basic axle design is used on these models. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth.

REMOVAL AND INSTALLATION

AXLE SHAFT AND BEARINGS

1) With rear of vehicle raised and wheels removed, release handbrake and back off brake shoe adjusters. On models with disc wheels, remove brake drum locating screws and tap drums off hubs. Remove axle shaft retaining screw and withdraw shaft from hub assembly. On models with wire wheels, remove nuts securing drum to hub and tap brake drums off hub. Remove retaining screws securing hub extension flanges to hubs. Withdraw hub extensions and axle shafts.

2) Using suitable tool, remove hub nut and lock washer. Withdraw hub complete with bearing and seal. To install, repack hub bearings with grease and press hub into position. If paper washer or "O" ring was damaged on disassembly, they must be replaced. If seal was removed, drift it into position using suitable tool. Drift hub into axle housing using suitable tools and reinstall remainder of components in reverse of disassembly procedure.

PINION FLANGE AND SEAL

1) Mark propeller shaft and pinion flange for proper realignment and disconnect propeller shaft.Unscrew nut in center of flange, using suitable tool to prevent flange from rotating. Remove nut and washer and withdraw flange and pressed end cover from pinion shaft. Extract oil seal from axle housing.

2) Press new seal into axle housing with edge of sealing ring facing inwards. Replace flange and end cover, taking care not to damage edge of oil seal. Tighten pinion flange nut and reconnect propeller shaft, ensuring that index marks are lined up.

DIFFERENTIAL CARRIER

Drain rear axle and remove axle shafts. Mark propeller shaft and pinion shaft for correct reassembly and disconnect shaft. Remove nuts securing differential carrier to axle housing and withdraw complete carrier. To install, reverse removal procedure.

OVERHAUL

DISASSEMBLY

1) Check to ensure that differential bearing caps are marked to ensure correct replacement, then remove bearing cap nuts, washers and caps. Remove differential cage. Remove differential bearings from cage, using suitable tools and note that the thrust face of each bearing is marked "THRUST" and that shims are installed between inner ring of each bearing and differential cage. Knock back tabs of locking washers and unscrew bolts securing ring gear to differential cage, remove ring gear.

2) Tap out pin locating differential pinion shaft from ring gear side of cage as tapered pins are used. Drive out differential pinion shaft and remove pinions and thrust washers from cage. Remove pinion nut, flange and pressed end cover. Drive pinion shaft towards rear through carrier. Pinion shaft will come out with inner race and rollers for rear bearing, leaving outer race and complete front bearing in position.

3) Tap out inner race of front bearing and oil seal. Withdraw outer races using suitable tools. Slide off pinion sleeve and shims. Withdraw rear bearing inner race from pinion shaft using suitable tools. Note spacing washer against pinion head. Remove rear bearing outer race using suitable tools.

INSPECTION

Clean and inspect all components for worn or damaged parts. The ring and pinion gear must be replaced as a matched set if replacement of either is necessary.

REASSEMBLY AND ADJUSTMENT

CALIBRATING DIAL INDICATOR
(TOOL 18G-191)

Drive Pinion Depth - 1) Install outer bearing races in carrier using suitable tools. Smooth off pinion head with an oil-stone, taking care not to remove any markings etched on head. Assemble pinion and rear bearing with a washer of known thickness behind pinion head. Position pinion in carrier without bearing spacer and oil seal.

2) Install inner ring of front bearing and pinion flange and tighten nut slowly until a bearing preload of 8-10 INCH lbs. (9-12 kgcm) is obtained. Using tool 18G-191, adjust dial indicator to zero on machined step "A" of setting block (see illustration). Place dial indicator and base of tool on head of pinion and position tool so dial indicator feeler rests on center of differential bearing bore. Note any variation from zero. Now swing indicator to other bearing bore and again note variation from zero. Average the two variation together.

3) Take into consideration any variation in pinion head thickness. This will be shown as an unbracketed figure etched on pinion head and will always be minus. If no unbracketed figure is shown, pinion head is of nominal thickness. Using average dial indicator reading just obtained and the unbracketed figure from pinion head, perform the following calculation: If indicator reading is minus, add indicator reading to pinion head reading and REDUCE known washer thickness by this amount.

EXAMPLE

   Indicator Reading..................................  -.002"

   Pinion Marking.....................................  -.005"

   Variation from Nominal.........................  -.007"

Reduce known washer thickness by this amount.

4) If indicator reading is plus and numerically LESS than pinion marking, REDUCE the known washer thickness by the difference.

EXAMPLE:

   Pinion Marking.....................................  -.005"

   Indicator Reading.................................  +.003"

   Variation From Nominal.......................  -.002"

Reduce known washer thickness by this amount.

5) If indicator reading is plus and numerically GREATER than pinion marking. INCREASE the known washer thickness by the difference.

EXAMPLE:

   Indicator Reading.................................  +.008"

   Pinion Marking.....................................  -.003"

   Variation from Nominal........................  +.005"

Increase known washer thickness by this amount.

SIDE BEARING PRELOAD DIMENSIONS

6) The only cases where no changes are required to washer thickness are when indicator reading is PLUS and NUMERICALLY EQUAL to unbracketed pinion marking, or indicator reading is zero and there is no unbracketed marking on pinion head. Allowance should now be made as follows for mounting distance marked on pinion head in a rectangular bracket as follows:

7) If marking is a PLUS figure, REDUCE washer thickness by on equal amount. If marking is a MINUS figure, INCREASE washer thickness by on equal amount. A tolerance of .001" (.03 mm) is allowed in thickness of washer finally installed.

Pinion Bearing Preload - Install washer of thickness just calculated under pinion head and assemble pinion with bearings, pinion sleeve, oil seal, flange and nut. Pinion sleeve is of collapsible design and can only be used once. Therefore, the following procedure should be done with care or new sleeve will be required. Slowly tighten flange nut to specifications while holding flange to prevent rotation. During tightening process, occasionally check pinion bearing preload. When nut is tightened to specifications, preload should be to specifications. Installation of pinion is now complete.

CHECKING BEARING THICKNESS VARIATION
(TOOL 18G-191)

Side Bearing Preload - 1) This method of setting position of ring gear assembly depends on marking given on differential gear carrier and case. The dimension to be considered are (see illustration): "A" - The dimension from center line to bearing on right side. Variation in dimension "A" is stamped on carrier adjacent to right side bearing bore. "B" - The dimension from center line to bearing on left side. Variation is stamped on left side bearing bore. "C" - Dimension from bearing on one side of cage to bearing on other side and "D" - Dimension from rear face of ring gear to bearing on opposite side. Variation on "C" & "D" dimension are stamped on machined face of differential cage.

2) It is possible to calculate shim thickness required on left side by use of follwoing formula

                                            A+D-C+.002"

Substituting the actual variations shown, this formula gives shim thickness required to compensate for variation in machining plus the extra .002" (.05 mm) to give necessary bearing preload. In addition, allowance must be made for variations in bearing thickness in the following manner:

CHECKING BACKLASH
(TOOL 18G-191)

3) Rest bearing with inner race over recess and thrust face downwards on surface plate of tool 18G-191. Place dial indicator on surface plate and zero indicator on step "A" of gauge block of tool 18G-191. Swing indicator over until it rests on plain surface of inner bearing race. Hold inner race down against balls and note indicator reading. Indicator will normally indicate a negative reading. This negative variation should be ADDED to the shim pack previously calculated for that side of the differential.

4) To calculate shim thickness for the right side, use the following formula:

                                           B-D+.006"

substituting the actual values for "B" and "D" as described in 1). Again, final allowance must be made for variation in bearing thickness as described in 3) above.

5) When a framed number is marked on back of ring gear, e.g. +2, it must be taken into account before assembling shims and bearings to differential cage. If, for example, the mark +2, then shims of .002" must be transferred from left (ring gear) side to right side. If marking is -2, shims of .002" must be moved from right to left side.

Backlash Adjustment - 1) Assemble bearings (thrust faces outwards) and shims as calculated to differential cage. Bolt ring gear to differential cage. Bolt ring gear to differential cage but do not knock over locking tabs. Mount assembly on two "V" blocks and check runout by means of dial indicator. If runout  exceeds specifications, remove ring gear and check joint faces on cage ring gear for any particles of dirt. If parts are thoroughly cleaned it is unlikely that ring gear will not run true. Tighten bolts and knock over locking washers.

2) Install differential to carrier. Replace bearing caps and tighten nuts. Bolt surface plate of tool 18G-191 to carrier flange and mount a dial indicator in such way that an accurate backlash figure may be obtained. Correct figure for backlash to be used with any particular gear and pinion is etched on rear face of ring gear. A movement of .002" (.05 mm) shim thickness from one side of differential cage to the other will produce a variation  in backlash of about .002" (.06 mm). Use care to ensure absolute cleanliness during the operation as dirt can result in inaccurate readings and poor settings. Carrier may now be installed in rear axle housing.

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