36S02T0 differential and drive line repair 2002

manual transmission and driveline differential and driveline repair student guide COURSE CODE: 36S02T0 ORDER NUMBER: FCS-13235-REF Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS WHEN WORKING ON BRAKE COMPONENTS, AVOID BREATHING THE DUST BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2002 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division February, 2002 CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of demonstrate a genuine concern for my service needs time after my service visit to ensure that I'm completely satisfied Fix it right the first time Complete servicing my vehicle in a Be responsive to questions or concerns I bring to your attention timely and professional manner Expectation “Fix It Right The First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix It Right The First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model – Self Study – Self Study – FordStar Broadcasts – FordStar Broadcasts – Ford Multimedia Training (FMT) – Instructor Led – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” TABLE OF CONTENTS DAY ONE INTRODUCTION INTRO-1 Student’s Introduction Intro-1 Day One Flowchart Morning Intro-5 Day One Flowchart Afternoon Intro-6 Day One Agenda Intro-7 Prerequisite Review Questions Intro-8 LESSON 1-1 Objectives 1-1 Contents 1-1 Worksheet A (At Workstation #5) Instructor-Led Demo – Total Axle Backlash 1-2 Student’s Answer Sheet 1-2 Worksheet B (At Workstation #5) Instructor Demo – Measuring Driveshaft Runout/Balance 1-4 Student’s Answer Sheet 1-4 Worksheet C (At Workstation #5) Instructor Demo – Companion Flange Runout 1-5 Student’s Answer Sheet 1-5 Operating Angles and Balance 1-6 Oscillation 1-7 Proper Angles 1-8 Worksheet D (At Workstation #5) Instructor Demo – Driveshaft Angle Measurement 1-9 Student’s Answer Sheet 1-9 Universal joints 1-10 LESSON 2-1 Objectives 2-1 Contents 2-1 Axle Assemblies 2-2 Pre-Disassembly Component Inspection 2-3 Worksheet E (On Bench) Activity #1 – Visual Inspection 2-4 Student’s Answer Sheet 2-4 Instructor Demo (Instructor Unit) Backlash Measurement 2-5 Student’s Information Sheet 2-5 Worksheet F (Bench) Activity #2 – Ring Gear Backlash Measurement 2-6 Student’s Answer Sheet 2-6 Instructor Demo (Instructor Unit) Backface Runout Measurement 2-7 Student’s Information Sheet 2-7 Worksheet G (On Bench) Activity #3 – Ring Gear Backface Runout Measurement 2-8 Student’s Answer Sheet 2-8 Instructor Demo (Instructor Unit) Checking Pinion Bearing Preload 2-9 Student’s Information Sheet 2-9 Pinion Bearing Preload 2-10 Worksheet H (On Bench) Activity #4 – Checking Pinion Bearing Preload 2-11 Student’s Answer Sheet 2-11 Differential and Driveline Repair February, 2002 i TABLE OF CONTENTS Tooth Contact Pattern Check 2-12 Instructor Demo (Instructor Unit) Running a Gear Pattern 2-15 Student’s Information Sheet 2-15 Worksheet I (Bench) Activity #5 – Running a Gear Pattern 2-16 Student’s Answer Sheet 2-16 LESSON 3-1 Objectives 3-1 Contents 3-1 Indexing Components 3-2 Instructor Demo Case Spreader Use 3-3 Student’s Information Sheet 3-3 Differential Removal 3-4 Pinion Removal 3-5 DAY TWO AND DAY THREE INTRODUCTION INTRO-1 Day Two and Day Three Flowchart Intro-1 Day Two Agenda Intro-2 Day Three Agenda Intro-2 LESSON 4-1 Objectives 4-1 Contents 4-1 Instructor Demo Differential Bearing Removal Tool 4-2 Student’s Information Sheet 4-2 Instructor Demo Pinion Depth Setting Tool 4-3 Student’s Information Sheet 4-3 Pinion Installation 4-4 Pinion Markings 4-6 Instructor Demo Differential Bearing Shim Selection 4-7 Student’s Information Sheet 4-7 Instructor Demo Differential Bearing Shim Selection 4-8 Student’s Information Sheet 4-8 Instructor Lecture Limited Slip Differential Service 4-9 Student’s Information Sheet 4-9 Limited Slip Differentials 4-10 Limited Slip Operation 4-11 Ford 7.5" and 8.8" Traction-Lok 4-12 Ford 9.75" and 10.25" Traction-Lok 4-13 Ford 10.5" Two-Piece Traction-Lok 4-14 General Rules of Limited Slip service Points 4-15 Worksheet J (At Workstation 1) 8.8" Rear Axle Disassembly and Assembly (Bench) 4-16 Student’s Information Sheet 4-16 Differential Carrier Installation 4-24 Worksheet K (At Workstation 2) 7.5" Rear Axle Disassembly and Assembly (Bench) 4-28 Student’s Information Sheet 4-28 ii February, 2002 Differential and Driveline Repair TABLE OF CONTENTS Pinion Installation 4-31 Worksheet L (At Workstation 5) Limited Slip Differential Disassembly and Assembly (Bench) 4-40 Student’s Answer Sheet 4-40 Worksheet M (Workstation 5) Driveshaft Angle Measurement (On-Vehicle) 4-42 Student’s Answer Sheet 4-42 LESSON 5-1 Objectives 5-1 Contents 5-1 Worksheet N (At Workstation 3) Aluminum 8.8" Front Axle Disassembly and Assembly (Bench) 5-2 Student’s Answer Sheet 5-2 Worksheet O (At Workstation 4) Dana 35 Axle Disassembly and Assembly (Bench) 5-18 Student’s Answer Sheet 5-18 FINAL EXAM EXAM-1 Contents Exam-1 Written Evaluation Exam-2 Student’s Answer Key Exam-3 Differential and Driveline Repair February, 2002 iii TABLE OF CONTENTS NOTES iv February, 2002 Differential and Driveline Repair INTRODUCTION ◆ STUDENT’S INTRODUCTION ◆ Manual Transmission and Drivetrain Curriculum The Manual Transmission and Drivetrain Curriculum Path consists of eight courses Each course is one of the following types: Self-Study – This type of course is a self-paced program The technician is responsible for learning the material on his or her own The training material consists of a reference book and accompanying videotape The videotape is designed to support the material in the reference book and should not be used on its own Ford Multimedia Training (FMT) – This type of course is also self-paced The multimedia course allows the technician to interact with the training materials The multimedia course allows the technician to utilize the knowledge attained in the self-study course The FMT concentrates on relationships, such as the cause- andeffect relationships between symptoms and components Distance Learning (FORDSTAR) – This type of course is an instructor-led, interactive type It is presented over the FORDSTAR Distance Learning Network The instructor can present information to, relate questions to, and interact with the technicians Demonstrations and video presentations are used to introduce material Classroom – The classroom course allows for practical, real-world application of skills and knowledge learned in the other courses The eight courses included in the Manual Transmission and Drivetrain Curriculum are as follows: Differential and Driveline Operation – Self-Study Course code: 36S01S0 Differential and Driveline Repair – Classroom Course code: 36S02T0 Manual Transmission/Transaxle Operation – Self-Study Course code: 36S03S0 Manual Transmission/Transaxle Diagnosis – FMT Course code: 36S04M0 Manual Transmission/Transaxle Repair – Classroom Course code: 36S05T0 Transfer Case and 4x4 System Operation – Self-Study Course code: 36S06S0 Transfer Case and 4x4 System Diagnosis – FORDSTAR Course code: 36S07F0 Transfer Case and 4x4 System Repair – Classroom Course code: 36S08T0 All students must have completed the Differential and Driveline Self-Study Course prior to enrolling in this course Students must pass the Differential and Driveline Operation Self-Study Post-Test, located in the Manual Transmission Transaxle Diagnosis FMT, before taking this class Students who have not completed the self-study course and pass the test should not be admitted to this class Their presence will slow down the course flow, as well as monopolize valuable instructor time Differential and Driveline Repair February, 2002 Intro-1 INTRODUCTION Curriculum Goals The goals of this curriculum are: To provide the necessary training to enable the technician to identify, diagnose, and perform timely “fix it right the first time – on time” repairs Increased customer satisfaction Increased technician productivity Fewer repeat repairs Course Objectives Upon completion of the Differential and Driveline Classroom Course, the technician will be able to: Perform rear axle and differential disassembly procedures (8.8" and 7.5" rear axles, 8.8" and DANA 35 front axles) – Perform pre-disassembly component inspection – Roll and interpret a gear contact pattern before disassembly – Perform ring gear backlash measurement – Determine ring gear backface runout measurement – Determine pinion bearing preload measurement – Set pinion bearing preload – Explain the importance of indexing components – Explain proper differential removal procedures – Explain proper pinion removal procedures – Perform component inspection procedures – Explain the use of the axle housing spreader – Use axle case housing spreader during disassembly and assembly Perform disassembly of the limited slip differential – Identify the different types of Traction-Lok differential carriers – Use the differential/pinion bearing removal tool – Perform disassembly of 8.8" differential – Perform disassembly of 9.75" differential – Perform disassembly of 10.5" differential Intro-2 February, 2002 Differential and Driveline Repair LESSON DAY TWO AND DAY THREE WORKSHEET O (AT WORKSTATION 4) DANA 35/30 AXLE DISASSEMBLY AND ASSEMBLY (BENCH) STUDENT’S ANSWER SHEET (Continued) Install and torque bearing caps (30 ft/lb) NOTE: Be sure the gauge tube remains stationary Select the proper pinion shim using provided pinion shims as gauge NOTE: The pinion shims must be flat and clean NOTE: A slight drag should be felt for correct shim selection Do not attempt to force the shim between the gauge block and the gauge tube This will minimize the selection of a shim thicker than required, which results in a deep tooth contact in final assembly STOP: CALL THE INSTRUCTOR OVER FOR THE PINION SHIM EVALUATION #1 Give the instructor the shim you selected and the shims that are 0.001" below it and 0.001" above it Record your results Pinion shim selection: Pinion Markings: ± Final Pinion Selection: _ Remove the gauge tube and pinion preload tools 5-24 February, 2002 Differential and Driveline Repair DAY TWO AND DAY THREE LESSON WORKSHEET O (AT WORKSTATION 4) DANA 35/30 AXLE DISASSEMBLY AND ASSEMBLY (BENCH) STUDENT’S ANSWER SHEET (Continued) Install the selected shim on the pinion and press bearing on pinion Install the differential dummy bearings (205-247) onto the differential carrier and install the differential carrier 10 With the pinion gear NOT installed, position the dial indicator with bracketry and measure total end play NOTE: Repeat this step until the readings are consistent Line A: Reading with ring gear NOT installed = NOTE: Also record this reading on the shim selection chart below 11 Place a NEW crush sleeve on the pinion 12 Install outer pinion bearing 13 Install oil slinger (if equipped) 14 Apply small amount of Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant or equivalent meeting Ford specs WSP-M2C197-A to the lip of the seal Position pinion seal on the tool 15 Use the pinion seal replacer [205-133] to install the pinion seal 16 Lubricate the pinion splines with Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant or equivalent meeting Ford specs WSP-M2C197-A 17 Place pinion assembly in differential housing CAUTION: Be careful not to damage the pinion seal while installing the pinion assembly 18 Install the companion flange aligning the index marks Differential and Driveline Repair February, 2002 5-25 LESSON DAY TWO AND DAY THREE WORKSHEET O (AT WORKSTATION 4) DANA 35/30 AXLE DISASSEMBLY AND ASSEMBLY (BENCH) STUDENT’S ANSWER SHEET (Continued) 19 Install the new pinion nut by hand 20 Rotate the differential so that the companion flange is up Hold the companion flange with the companion flange holding tool Tighten the pinion nut while rotating the pinion occasionally to ensure the cone and roller bearings are seating properly Take frequent cone and roller bearing torque preload readings with the in/lb torque wrench until the rotating torque specs are met Pinion rotational torque must be in/lb more than the original pinion reading What should your pinion rotational torque be? _ CAUTION: If the pinion nut is over-tightened and rotational torque is too high, the crush sleeve will be damaged and will be unusable When rotational torque gets close to reaching the proper torque, tighten the pinion nut in very small increments (5 degrees), until proper torque is met 5-26 February, 2002 Differential and Driveline Repair DAY TWO AND DAY THREE LESSON WORKSHEET O (AT WORKSTATION 4) DANA 35/30 AXLE DISASSEMBLY AND ASSEMBLY (BENCH) STUDENT’S ANSWER SHEET (Continued) STOP: CALL YOUR INSTRUCTOR OVER FOR THE EVALUATION #2 21 Rotate the differential so the companion flange is down Install the differential master bearings [205247] onto the differential carrier and install the differential carrier 22 Position the dial indicator with bracketry Force the ring gear into the pinion gear until no end play is felt and set the dial indicator to zero Force the ring gear away from the pinion gear as far as possible and check reading NOTE: Repeat this step until the readings are consistent Line D: Reading with pinion gear installed = NOTE: Also record this reading on the shim selection chart Differential and Driveline Repair February, 2002 5-27 LESSON DAY TWO AND DAY THREE WORKSHEET O (AT WORKSTATION 4) DANA 35/30 AXLE DISASSEMBLY AND ASSEMBLY (BENCH) STUDENT’S ANSWER SHEET (Continued) 23 Using the chart below figure the left and right shim sizes SHIM SELECTION CHART Actual Result in mm (inch) Line Example Result in mm (inch) A Total end play (without gears) B Add Preload C Total A & B 2.2352(0.088) D End Play (with gears) 1.0414(0.041) E Subtract from ring gear side (for backlash) F Total (subtract E from D) this in the shim size for the ring gear side G 2.032 (0.080) +0.2032(0.008) -0.0762(0.003) +0.2032(0.008) -0.0762(0.003) 0.9652(0.038) Total (subtract F from C) this is the shim size for the other side 1.27 (0.050) 24 Using the press install the differential shims and bearings CAUTION: Make sure the proper bearing cones stay with the proper bearings 25 Install the housing spreader [205-001] Install the dial indicator with bracketry, making sure to position the round tip in the housing spreader adapter hole 26 Zero out the dial indicator Spread the axle housing until the dial indicator reads 0.015 inch (0.381 mm) Remove the dial indicator with bracketry 5-28 February, 2002 Differential and Driveline Repair DAY TWO AND DAY THREE LESSON WORKSHEET O (AT WORKSTATION 4) DANA 35/30 AXLE DISASSEMBLY AND ASSEMBLY (BENCH) STUDENT’S ANSWER SHEET (Continued) 27 Install the left and right side bearing cones and install the carrier into the housing 28 Install the bearing caps and bolts hand tight CAUTION: Do not tighten bolts to spec at this time NOTE: Be sure bearing caps are installed on proper sides 29 Remove spreader tools 30 Tighten the bolts to 30 ft/lb 31 Verify that the differential rotates freely 32 Use the dial indicator with bracketry to measure the ring gear backlash 1st measurement 2nd measurement 3rd measurement 4th measurement Average measurement _ STOP: CALL YOUR INSTRUCTOR OVER FOR EVALUATION #3 33 If the backlash is not within specs, correct by increasing the thickness of one shim and decreasing the thickness of the other shim by the same amount Differential and Driveline Repair February, 2002 5-29 LESSON DAY TWO AND DAY THREE WORKSHEET O (AT WORKSTATION 4) DANA 35/30 AXLE DISASSEMBLY AND ASSEMBLY (BENCH) STUDENT’S ANSWER SHEET (Continued) 34 Apply gear marking compound 35 Turn one complete rotation of the ring gear in each direction Record results on your sheet STOP: CALL YOUR INSTRUCTOR OVER FOR EVALUATION #4 36 Install the axle shaft 37 Install the cover 5-30 February, 2002 Differential and Driveline Repair DAY THREE FINAL EXAM CONTENTS ! Differential and Driveline Repair Written Evaluation February, 2002 Exam-1 FINAL EXAM DAY THREE WRITTEN EVALUATION You will complete the written evaluations at your seat The questions focus on areas identified during the classroom session They require you to use critical thinking skills to solve problems To meet the requirements of this course, you must correctly answer 80% of the (21 of 27) questions to pass You may use all the reference material available to you in the classroom, including service publication CD ROM/DVDs and your student reference guide However, the sharing of answers with the other technicians will not be permitted Exam-2 February, 2002 Differential and Driveline Repair DAY THREE FINAL EXAM WRITTEN EVALUATION STUDENT’S ANSWER KEY NAME: DIRECTIONS: Use this sheet to mark the correct answers for the Written Evaluation Do this by circling the letter of the correct answer T F 14 A B C D T F 15 A B C D T F 16 A B C D T F 17 A B C D T F 18 A B C D T F 19 A B C D T F 20 A B C D T F 21 A B C D T F 22 A B C D 10 T F 23 A B C D 11 T F 24 A B C D 12 T F 25 A B C D 13 T F 26 A B C D 27 A B C D Differential and Driveline Repair February, 2002 Exam-3 FINAL EXAM DAY THREE NOTES Exam-4 February, 2002 Differential and Driveline Repair ROTUNDA TOOL LIST AND ORDER FORM The tools listed below were used during the presentation of this course It is essential that correct tools be used during transmission service and repair For your convenience, the tools are listed below and a Rotunda Order Form can be found on the following pages TOOLS • Housing Spreader Adapter T96T-4000-A (LH) [205-368] • Housing Spreader Adapters T93T-4000-A [205-335] • Housing Spreader Adapter Set T95T-4000-A [205-356] • Inner Drive Pinion Bearing Cone Replacer T53T-4621-C [205-005] • Limited Slip Differential Rotating Tool T97T-4205-C [205-378] • Limited Slip Differential Tool T97T-4205-D [205-386] • Magnetic Base Dial Indicator D78P-4201-B [100-D002] • Pinion Driver 205-460 • Pinion Flange Remover T65L-4851-B [205-018] • Pinion Seal Replacer T79P-4676-A [205-133] • Pinion Seal Replacer T83T-4676-A [205-208] • Pinion Thread Protector T85T-4209-AH [205-229] • Rear Output Bushing Adapter T90T-7127-H [308-190] • Rigid Bar or Pipe (do not use breaker bar) • Screw T76P-4020-A9 [205-109] • Shim Driver T85L-4067-AH [205-220] • Side Bearing Replacer T57L-4221-A2 [205-010] • Step Plate Adapter D80L-630-4 [205-D015] • Step Plate Adapter T81P-4220-A [205-165] • Traction Lok Clutch Gauge Excluding Mandrel T80P-4946-A [205-135] • Traction Lok Clutch Gauge Mandrel T97T-4946 A [205-389] • Traction Lok Torque Tool Set T59L-4204-A [205-013] (7.5" and 8.8" – 28 spline) • Traction Lok Torque Tool Set T66L-4204-A [205-022] (8.8" – 31 spline) • Traction Lok Torque Tool Set T97T-4205-A [205-384] (9.75") • Traction-Lok Clutch Gauge T87T-4946-A [205-270] • Spreader Adapter [205-001-01] Part of TKIT 2001-FLM Dana 30 only • Guage Disc D80T-4020-F44 (Dana 30 only) TOOLS (continued) • Jaw Puller D97L-4221-A [205-D072] • Aligning Adapter T76P-4020-A3 [205-105] • Bearing Preload Tool T93P-4220-AR [205-S337] • Bearing Removal Tool D81L-4220-A [205-D036] • Bench Mounted Holding Fixture 307-003 (T57L-500-B) • Bracketry for Dial Indicator 100-D004 (D78P-4201-F) • Clutch Housing Alignment Adapter 308-021 (T75L-4201-A) • Companion Flange Holding Tool T78P-4851-A [205-126] • Companion Flange Holding Tool T57T-4851-B [205-012] • Companion Flange Replacer TOOL-4858-E [205-002] • Companion Flange runout gauge T92L-4251-B [205-319] • Dial Indicator Set (TOOL-4201-C [100-002] • Differential Clutch Gauge 205-446 • Differential Clutch Gauge 205-447 • Differential Housing Spreader 205-001 (TOOL-4000-E) • Differential Carrier Bearing Installer T83P-4220-CH [205-187] • Drive Pinion Flang Installer T8ST-4851-AH [205-233] • Driver Handle T80T-4000-W [205-153] • Driveshaft Clamp Plate T92L-4251-C [205-320] • Dummy Bearing, Differential Bearing T86T-4222-AH [205-247] • Dummy Bearing LH T93P-4222-A [205-338] • Dummy Bearing RH T93P-4222-B [205-339] • Electronic Vibration Analyzer (EVA) or equivalent • Feeler Gauge Set D81L-4201-A • Gauge Block 205-110 (T76P-4020-A10) • Gauge Disc T76P-4020-ALL [205-111] • Gauge Disc T75P-4020-A2 [205-093] • Gauge Disc T79P-4020-A15 [205-125] • Gauge Disc T79P-4020-A18 [205-129] • Gauge Disc T90T-4020-B [205-303] • Gauge Tube 205-336 (T93P-4020-A) • Gauge Tube T79P-4020-A19 [205-130] • Gauge Tube T80P-4020-F49 [205-D034] • Gauge Tube T89P-4020-A [205-292] ORDER FORM ITEM NUMBER QTY PREFIX BAL OF NO PART I ADDITIONAL SPECIFICATIONS (if required) COL COL OPTIONAL: CATALOG PAGE NO FAX NUMBER 1-800-762-6181 DESCRIPTION EXTENDED TOTAL UNIT PRICE TOTAL PART II Buyer, having been quoted both an installment Price and a lesser Cash Price, hereby purchases from Seller on installment price basis, upon the terms and conditions set forth on the face hereof, the equipment to be delivered and installed at Buyer’s premises, as described above and agrees to pay Seller the Installment Price therefore as so set forth until paid in full Dealer Parts Code #: Dealer Name: Address: ❏ 30 Day Open Account City, State, Zip: Installment Plan (Fixed Rate) ❏ 12 Mo (Minimum $1,000) ❏ 24 Mo (Minimum $3,000) ❏ 48 Mo (Minimum $10,000) ❏ 60 Mo (Minimum $15,000) (Reverse side must be completed) Phone #: Fax #: PART III ❏ 36 Mo (Minimum $5,000) Attention: (ORDERS OVER $4,000) FCSD CREDIT MANAGER APPROVAL Notice To Buyer: Order Date: Ship to arrive by (Date or ASAP): Address: City, State, Zip: Do not sign this contract before you read it or if it contains any blank spaces You are entitled to an exact copy of the contract you sign Under the law you have the right to pay off in advance the full amount due and under certain circumstances to obtain partial refund of the time charge BUYER ACKNOWLEDGES RECEIPT OF A TRUE AND COMPLETELY FILLED IN COPY OF THIS CONTRACT AT THE TIME OF SIGNING May 2000 315-195 Prices subject to change without notice PRINT NAME AUTHORIZED DEALERSHIP SIGNATURE (BUYER) DEALER: Be sure you have completed Parts I and II for all orders, Part III for Installment Plan Orders 315-195 (Previous editions may not be used) FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632) TERMS & CONDITIONS Payment and Terms of Payment a If Buyer has requested the Dealer Open Account payment plan via the Ford Dealer Statement in Part II of the order form, and Seller agrees to sell pursuant to such plan, then Buyer shall pay the total purchase price shown on the invoice b If Buyer has requested the Installment Plan (Fixed Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Down Payment (if any), and the Time Balance in equal monthly installments in accordance with the terms set forth below c If Buyer has requested the Installment Plan (Variable Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Total Cash Price and any interest thereon in accordance with the Loan and Security Agreement to be executed by Buyer and Seller Title Title to Equipment purchased by Buyer from Seller shall pass to Buyer upon Seller’s receipt of all amounts owing by Buyer to Seller hereunder Risk of Loss Seller shall be responsible for risk of loss until Equipment is delivered to the location set forth herein, at which time risk of loss shall be the responsibility of Buyer Acceptance and Inspection Buyer shall be deemed to have accepted Equipment upon Seller’s delivery Equipment shall be deemed to have been delivered in good condition unless Buyer gives Seller notice to the contrary within 10 days after Seller’s delivery Delays Seller shall not be liable for any failure or delay in delivering Equipment, or for any failure to perform any provision hereof, resulting from fire, flood or other casualty, riot, strike or other labor difficulty, governmental regulation or other restriction, or any other cause beyond Seller’s control Unconditional Obligation Buyer’s obligation to make payments to Seller or its assignee shall be absolute and unconditional and shall continue unmodified despite any loss, damage or other interruption in the use of Equipment The obligation of Buyer to pay in full any amounts due under this contract shall not be subject to dispute, claim, counterclaim, defense or other right which Buyer may have to assert against Seller or the manufacturer of Equipment Buyer acknowledges that: (a) Buyer has selected Equipment and Manufacturer, and Buyer has determined Equipment’s suitability and fitness for the Buyer’s purpose, (b) Seller is not the manufacturer of Equipment, and (c) Manufacturer issues its own warranty and performs the obligations under such warranty Warranty THE MANUFACTURER’S WARRANTY SHALL BE BUYER’S EXCLUSIVE REMEDY, RECOURSE OR DAMAGE FOR ANY DEFECT IN WORKMANSHIP OR MATERIAL OR ANY FAILURE OF THE EQUIPMENT SELLER MAKES NO WARRANTIES, REPRESENTATIONS, INDEMNITIES OR GUARANTEES WHATSOEVER WITH RESPECT TO EQUIPMENT EITHER EXPRESS OR IMPLIED, ARISING BY LAW OR CUSTOM, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE LIABILITY OF THE SELLER SHALL BE LIMITED TO EXPRESS OBLIGATION TO DELIVER THE EQUIPMENT UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, WHETHER FORESEEABLE OR UNFORESEEABLE, WHICH BUYER MAY INCUR, EXPERIENCE OR CLAIM, INCLUDING, BUT NOT LIMITED TO, CLAIMS FOR LOSS OF PROFITS, INTERRUPTION IN BUSINESS, LOST OPPORTUNITY, WORK STOPPAGE OR OTHER IMPAIRMENT OF ASSETS, ARISING OUT OF MISREPRESENTATION, NEGLIGENCE, STRICT LIABILITY, IN TORT OR OTHERWISE, ON ACCOUNT OF ENTERING INTO OR RELYING ON THIS AGREEMENT, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Freight and Taxes Freight costs and applicable taxes will be added to the final invoice and will be borne by Buyer Security Interest Buyer hereby grants to Seller a continuing security interest in the Equipment, including all products and proceeds thereof, until all amounts due hereunder are paid Buyer agrees to execute, and pay filing fees for, any financing statement or other documents deemed necessary by Seller to maintain a valid security interest in the Equipment 10 Maintenance Buyer shall use the Equipment carefully and properly Buyer, at Buyer’s own expense, shall maintain and repair all items of the Equipment in order to keep them in good order and condition and, in particular, shall comply fully with the maintenance, operating, usage or other instructions provided by the manufacturer Buyer authorizes Seller, or any third party appointed by Seller, to inspect the Equipment when necessary Buyer shall at all times keep the Equipment free and clear of all liens, charges or encumbrances 11 Personal Property Ford proprietary diagnostic equipment (including the software, if applicable) shall be kept at Buyer’s premises as listed on the reverse side and shall remain personal property regardless of how and to what degree it may be affixed or attached to any building or structure or what may be the consequence of its removal from such building or structure Buyer shall not encumber the Equipment (including software, if applicable) until all amounts owing to Seller hereunder are paid In addition, Seller grants to Buyer, and Buyer accepts, a non-exclusive license to use the Equipment (including the software, if applicable) in accordance with the terms and conditions set forth herein The license (and Equipment) shall not be leased, sold, assigned or otherwise transferred, in whole or in part In the event, Buyer proposes to lease, sell assign or otherwise transfer the Equipment (and/or its software, if applicable), in whole or in part, to any person or entity, Ford Motor Company shall have a Right of First Refusal to purchase the Equipment (including all software, if applicable) for Ten and 00/100 Dollars ($10.00) in U.S currency 12 Insurance and Indemnification Buyer shall defend, indemnify and hold harmless Seller from and against, and at Buyer’s own expense provide insurance satisfactory to Seller covering any and all losses, damages, claims, expenses and other liabilities (including attorney’s fees,) relating to or arising out of: (I) damage, loss, theft, or destruction of the Equipment, or (ii) death, injury or property damage connected with the use, operation or condition (including without limitation, defects whether or not discoverable by any party) of the Equipment Buyer shall promptly notify Seller of any such claim Seller shall have the right to participate, at its own expense, in any proceeding for which Buyer has undertaken the defense of Seller, and in no event shall Buyer settle any claim against Seller without Seller’s prior written consent, Buyer shall provide evidence of such insurance to Seller upon demand Seller is under no obligation to examine any insurance certificate or advise Buyer that its insurance does not comply with the requirements set forth herein The losses covered by insurance shall in all cases be payable to Seller and Buyer as their interests may appear If Buyer fails to insure the Equipment as herein provided, Seller may, but is not obligated to, place such insurance upon the Equipment and the Buyer agrees to pay to Seller on demand the premiums for such insurance placed by Seller In no event shall any insurance coverage be deemed to limit or replace Buyer’s obligation to indemnify Seller as provided herein 13 Default In the event that Buyer: (a) fails to pay any amount due hereunder within ten (10) days of the due date, (b) fails to comply with any other provision hereof, (c) files, or if there is filed against Buyer, any petition under any bankruptcy or insolvency laws or suffers the appointment of any trustee or receiver for all or any part of Buyer’s business or assets, or (d) has any assignment (voluntarily or involuntarily), lien, attachment or levy issued against the Equipment (unless such petition, assignment or appointment, lien, attachment or levy is withdrawn or nullified within twenty (20) days) then Buyer shall be in default hereunder and all of Buyer’s indebtedness and obligations to Seller shall, at Seller’s option, become immediately due and payable, and Seller may, at its option, terminate this contract and repossess any and all items of Equipment with or without legal process and sell the same at private or public sale without prior notice to Buyer to the extent permitted by law Upon request, Buyer shall deliver the Equipment to Seller at a place designated by Seller Repossession and/or sales of the Equipment upon such default shall not affect the Seller’s right to retain all payments made prior to repossession or to recover the balance due hereunder for any deficiency Buyer shall reimburse Seller all costs of collection, repossession and resale (including reasonable attorneys’ fees, court costs and other expenses incurred by Seller.) Buyer hereby releases Seller from any liability for damages resulting from repossession hereunder The rights and remedies of Seller, in the event of default herein mentioned shall not be deemed exclusive but shall be cumulative and in addition to all other rights and remedies existing under law, and may be enforced successively or concurrently Waiver by Seller of any default shall not be deemed a waiver of any other default 14 General The waiver by either party of, or failure to claim, a breach of any provision of this contract shall not be deemed to be a waiver of any provision of this contract, shall not be deemed to be a waiver of any subsequent breach or to affect in any way the effectiveness of such provision This contract constitutes the entire agreement between the parties and may not be changed except by an instrument in writing signed by the party to be charged This contract may not be assigned by Buyer without the Seller’s prior written consent Seller may assign this contract at any time but shall not thereby be relieved from any liability hereunder In the event that one or more clauses of this contract are found to be unenforceable, illegal or contrary to public policy by court of competent jurisdiction, the remainder of this contract shall remain in full force and effect except for the unenforceable, illegal or other provisions This agreement is a Michigan agreement and shall be interpreted, construed and enforced in accordance with the laws of the State of Michigan, United States of America Each of the parties here to agrees that any legal or equitable action or proceeding with respect to this agreement shall be brought only in any court of the State of Michigan, or in any court of the United States of America sitting in Michigan, and each of the parties hereto submits to and accepts generally and unconditionally the jurisdiction of those courts with respect to such party’s person and property Each party hereby irrevocably waives any objection to the laying of venue of any such action or proceeding in the above described courts 15 Finance Charge Monthly portion of Finance Charge (Part III, Item 3) due is calculated each month by multiplying 1/12 of the annual finance charge rate times the remaining portion of the Unpaid Balance of Cash Price, and is added to the portion of the Unpaid Balance of Cash Price due each month PART III Installment Plan Agreement Cash Price $ Down Payment (if any) $ Unpaid Balance of Cash Price (Difference between and 2) $ Finance Charge (Finance charge will reduce each month) Call 1-800-768-8632 for the current finance charge rate $ Time Balance (3 + 4) $ Number of Installments ❏ 12 ❏ 24 ❏ 36 ❏ 48 ❏ 60 equal monthly installments Taxes and transportation (if any) will be billed separately Installment Payment Price (1 + 4) $ I agree to pay the time Balance set forth in accordance with the above schedule and the terms and conditions of this order form Dealer Signature: Date: MAIL COMPLETED ORDER FORM TO: ROTUNDA EQUIPMENT PROGRAM P.O Box 1450 Kenosha, WI 53141 September 1999 315-195 Prices subject to change without notice ... Exam-3 Differential and Driveline Repair February, 2002 iii TABLE OF CONTENTS NOTES iv February, 2002 Differential and Driveline Repair INTRODUCTION ◆ STUDENT’S INTRODUCTION ◆ Manual Transmission and. .. 27 questions) to pass Differential and Driveline Repair February, 2002 Intro-5 INTRODUCTION DAY ONE FLOWCHART MORNING Intro-6 February, 2002 Differential and Driveline Repair INTRODUCTION DAY... 1-2 February, 2002 Differential and Driveline Repair DAY ONE LESSON DRIVESHAFT RUNOUT AND BALANCE Driveshaft Marking Driveline balance or runout generally causes symptoms