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Section 321 (Differential): Axle: Disassembly

WARNING: This page is about a different car, the 2003 Mazda Tribute. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Mounting Axle Housing To Bench Using Special Tool
G01900451Courtesy of MAZDA MOTORS CORP.
CAUTION:
  • Extreme care must be taken not to damage aluminum axle housing while carrying out these procedures. 
  1. Using the special tool or equivalent, mount the axle housing to a bench.
    Fig 2: Removing Halfshaft Seals Using Special Tool
    G01900452Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • RH shown, LH similar.
  2. Using the special tools or equivalent, remove the two halfshaft seals.
    Fig 3: Removing Halfshaft Bearing Assemblies Using Special Tool
    G01900453Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • RH shown, LH similar.
  3. Using the special tools, remove the two halfshaft bearing assemblies.
    Fig 4: Removing Bolts & Bearing Caps
    G01900454Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The letters or numbers stamped on the cap and carrier must be matched upon assembly. 
  4. Remove the bearing caps.
    1. Remove the bolts.
    2. Remove the bearing caps.
      Fig 5: Removing Differential Case Using Special Tool
      G01900455Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • Overspreading can damage the axle housing. 
  5. Using the special tools, remove the differential case.
    1. Spread the axle housing.
    2. Remove the differential case and tag the bearing cups to indicate which side of the carrier they were removed from.
      Fig 6: Removing Special Tools
      G01900456Courtesy of MAZDA MOTORS CORP.
  6. Remove the special tools.
    Fig 7: Removing Drive Pinion Nut Using Special Tool
    G01900457Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Make sure the drive pinion does not fall out of the axle case when the drive pinion nut is removed. 
    NOTE:
    • The drive pinion nut is staked  in the groove of the drive pinion shaft. There may be metal left in the groove that must  be removed.
  7. Using the special tools, remove the drive pinion nut.
    Fig 8: Removing Drive Pinion, Collapsible Spacer And Drive Pinion Bearings
    G01900458Courtesy of MAZDA MOTORS CORP.
    WARNING:
    • Gear teeth have sharp edges. Use care when handling the drive pinion. Failure to follow these instructions may result in personal injury. Failure to follow these instructions may result in personal injury. 
  8. Remove the drive pinion, collapsible spacer and drive pinion bearings.
    1. Remove the drive pinion, collapsible spacer and inner drive pinion bearing.
    2. Remove the outer drive pinion bearing.
    3. Discard the collapsible spacer.
      Fig 9: Removing Outer Drive Pinion Bearing Cup Using Special Tool
      G01900459Courtesy of MAZDA MOTORS CORP.
  9. Using the special tools, remove the outer drive pinion bearing cup.
    Fig 10: Removing Inner Drive Pinion Bearing Cup Using Special Tool
    G01900460Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Make sure not to damage the axle housing when removing the inner drive pinion bearing cup. 
    CAUTION:
    • A new oil baffle located between the inner drive pinion bearing cup and the axle housing bore must be installed at the time of assembly. 
  10. Using the special tools or equivalent, remove the inner drive pinion bearing cup and oil baffle.
    Fig 11: Removing Differential Case Bearings And Shims Using Special Tools
    G01900461Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • LH side shown, RH side similar.
  11. Using the special tools, remove the differential case bearings and shims.
    1. Tag the bearing cups and cones together to indicate which side of the carrier they were removed from.
    2. Discard any damaged shims.
      Fig 12: Removing Ring Gear
      G01900462Courtesy of MAZDA MOTORS CORP.
      WARNING:
      • Gear teeth have sharp edges. Use care when handling the drive pinion. Failure to follow these instructions may result in personal injury. 
  12. Remove the ring gear.
    1. Remove and discard the bolts.
    2. Remove the ring gear.
      Fig 13: Removing Differential Pinion Shaft
      G01900463Courtesy of MAZDA MOTORS CORP.
  13. Remove the differential pinion shaft.
    1. Remove the differential pinion shaft lock pin.
    2. Remove the differential pinion shaft.
      Fig 14: Removing Two Pinion Gears, Two Side Gears And Four Thrust Washers
      G01900464Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • Make sure to note the location of the pinion gears, side gears and thrust washers to assemble in the same locations. 
  14. Remove the two pinion gears, two side gears and four thrust washers.
    1. Rotate the pinion gears and pinion gear thrust washers to the window and remove.
    2. Remove the side gears and side gear thrust washers.
      Fig 15: Removing Pinion Gears, Side Gears And Thrust Washers
      G01900465Courtesy of MAZDA MOTORS CORP.
  15. Using the special tool or equivalent, remove the drive pinion bearing and drive pinion position shim.
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