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Home › Mazda › 2007 › B3000 Base, Standard › Repair and Diagnosis › Drivelines & Axles › Differentials & Drive Axles › Differential › Axle And Differential Front Disassembly / Assembly › Assembly Note

Assembly Note

CAUTION:
  • Before beginning assembly, perform/inspect the following: When assembling the axle, ALWAYS use new gaskets and seals.
  • All fasteners must be tightened to the torque specification indicated.
  • When building up the subassembly, lubricate each component with API Service GL-5. Also, lubricate the subassembly as it is installed into the axle housing.
  • Many components and surfaces in the axle are precision machined. Careful handling during disassembly, cleaning, inspection, and assembly can prevent unnecessary damage to machined surfaces.
  • Whenever the differential pinion bearing cups are replaced, the differential pinion bearing must be replaced.
  1. Oil the new differential pinion bearing cups with axle lubricant meeting specification API Service GL-5 and install.
    • Use the Pinion Bearing Cup Replacer SST  49 UN01 035 to install the differential pinion bearing cups.
    Fig 1: Differential Pinion Bearing Cup
    G04308883Courtesy of MAZDA MOTORS CORP.
  2. Install the original oil slinger and rear bearing onto the Middle Pinion SST.
    Fig 2: Installing Original Oil Slinger And Rear Bearing
    G04308884Courtesy of MAZDA MOTORS CORP.
  3. Install Collar Tool SST  and O-ring to Middle Pinion SST  and install them into the differential casing.
  4. Install Collar SST, yoke and washer.
  5. Tighten the nut in Middle Pinion SST  making sure the yoke can still be turned by hand.
  6. Install Gauge Block (Front) SST  onto Middle Pinion SST  .
    Fig 3: Installing Gauge Block
    G04308885Courtesy of MAZDA MOTORS CORP.
  7. Place assembly on a surface plate and set the dial indicator to zero.
  8. Place Gauge Set SST  on top of Gauge Block SST  .
    Fig 4: Placing Gauge Set
    G04308886Courtesy of MAZDA MOTORS CORP.
  9. Place the pointer of the dial indicator so that it contacts where the side bearing is installed in the casing. Measure the lowest position on the left and right sides of the casing.
  10. Add the right and left side measurements and divide by two to get the thickness dimension.
  11. If not within specification, adjust the pinion height by selecting an oil stinger/selective shim which will bring the reading within specification.
    NOTE:
    • If the drive pinion is marked with a plus (+) reading, this amount must be subtracted from the thickness dimension.

      If the drive pinion is marked with a minus (-) reading, this amount must be added to the thickness dimension.

      The rear bearing must be the exact same as the one used in the previous steps.

  12. Measure the oil slinger/selective shim with a micrometer to verify the oil slinger/selective shim thickness.
    PINION MARKING SPECIFICATION

    Old Pinion Marking New Pinion Marking (Metric)
    -10 -8 -5 -3 0 +3 +5 +8 +10
    +10 +0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.003 0
    +8 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.03 0 -0.03
    +5 +0.15 +0.13 +0.10 +0.08 +0.05 +0.03 0 -0.03 -0.05
    +3 +0.13 +0.10 +0.08 +0.05 +0.03 0 -0.03 -0.05 -0.08
    0 +0.10 +0.08 +0.05 +0.03 0 -0.03 -0.05 -0.08 -0.10
    -3 +0.08 +0.05 +0.03 0 -0.03 -0.05 -0.08 -0.10 -0.13
    -5 +0.05 +0.03 0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15
    -8 +0.03 0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18
    -10 0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20
    PINION MARKING SPECIFICATION

    Old Pinion Marking New Pinion Marking
    -4 -3 -2 -1 0 +1 +2 +3 +4
    +4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
    +3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
    +2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
    +1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
    0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
    -1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
    -2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
    -3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
    -4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
    CAUTION:
    • The same pinion bearing used in this procedure must be used in final assembly.
  13. Install the pinion bearing.
    1. Place the pinion position shim on the pinion.
    2. Use Bearing Installer Set SST  and Attachment C SST  to press the differential pinion bearing until it is firmly seated on the pinion and pinion position shim.
    Fig 5: Installing Pinion Bearing
    G04308887Courtesy of MAZDA MOTORS CORP.
  14. Replace the collapsible spacer on the pinion stem.
    CAUTION:
    • Installation without the proper tool can result in early seal failure. If the pinion seal becomes cocked during installation, remove it and install a new one.
    NOTE:
    • The pinion seal must be fully seated all the way around or pinion seal damage can occur.
  15. Install the differential pinion bearing and pinion seal.
    1. Position the differential pinion bearing.
    2. Position the oil slinger.
    3. Position the pinion seal.
    4. Use Pinion Seal Replacer SST  to install the pinion seal.
    Fig 6: Installing Differential Pinion Bearing And Pinion Seal
    G04308888Courtesy of MAZDA MOTORS CORP.
  16. Position the pinion gear in the axle housing.
    1. Apply a small amount of axle lubricant meeting specification API Service GL-5 to the pinion gear splines.
    2. Position the pinion gear in the axle housing.
    Fig 7: Positioning Pinion Gear In Axle Housing
    G04308889Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The companion flange must never be hammered on or installed with power tools.
  17. Align the index marks and position the companion flange.
    Fig 8: Positioning Companion Flange
    G04308890Courtesy of MAZDA MOTORS CORP.
  18. Apply a small amount of lubricant to the washer side of the new pinion nut and install hand-tight.
    CAUTION:
    • Never back off the pinion nut to reduce preload. If reduced preload is required, install a new collapsible spacer and pinion nut.
    NOTE:
    • Pinion bearing preload is set by tightening the pinion nut.
  19. Use Coupling Holder SST  205-126 to hold the companion flange while tightening the pinion nut to set preload.
    1. Tighten the pinion nut, rotating the pinion occasionally to ensure the differential pinion bearings are seating properly. Take frequent preload readings until the desired reading is obtained by rotating the pinion with a N.m (inch-pound) torque wrench.
    2. If the original recorded preload is lower than specification, tighten to specification. If the original recorded preload is higher than specification, tighten to original reading as recorded.
    Fig 9: Rotating Pinion with Torque Specifications
    G04308891Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Master bearings are marked LH and RH and must be installed accordingly.
  20. Remove the differential bearings and install the Master Bearing (LH) and the Master Bearing (RH) on the differential case.
    Fig 10: Master Bearings
    G04308892Courtesy of MAZDA MOTORS CORP.
  21. Install the differential case with master bearings into the axle housing.
    Fig 11: Differential Case With Master Bearings In Axle Housing
    G04308893Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Repeat this step until a consistent reading is obtained.
  22. Measure the total end play.
    1. Position the Dial Indicator with Bracketry.
    2. Position the indicator tip on the machined surface and adjust to measure full travel.
    3. Push the differential case left and right (as far as possible).
    4. Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A in this article.
    Fig 12: Measuring Total End Play
    G04308894Courtesy of MAZDA MOTORS CORP.
  23. Remove the differential case.
    1. Remove the Dial Indicator with Bracketry.
    2. Remove the differential case.
    Fig 13: Dial Indicator And Differential Case
    G04308895Courtesy of MAZDA MOTORS CORP.
  24. If burrs or nicks are detected on the ring gear mounting surface, use a fine flat file to remove them.
    NOTE:
    • Do not reuse ring gear bolts.
  25. Install the ring gear.
    1. Position the ring gear and then start two or three ring gear bolts to align the holes in the ring gear and the differential case.
    2. Use an appropriate press to install the ring gear.
    Fig 14: Installing Ring Gear
    G04308896Courtesy of MAZDA MOTORS CORP.
  26. Install the remaining ring gear bolts.
    Fig 15: Installing Remaining Ring Gear Bolts with Torque Specifications
    G04308897Courtesy of MAZDA MOTORS CORP.
  27. Position the differential case.
    1. Install the Master Bearing (LH) and the Master Bearing (RH) on the differential case.
    2. Position the differential case in the axle housing with the three missing bolts positioned down.
    Fig 16: Master Bearing (LH), Master Bearing (RH), And Differential Case
    G04308898Courtesy of MAZDA MOTORS CORP.
  28. Position the Dial Indicator with Bracketry.
    Fig 17: Positioning Dial Indicator With Bracketry
    G04308899Courtesy of MAZDA MOTORS CORP.
  29. Push and rock the ring gear into mesh with the pinion gear (zero backlash) and set dial indicator to zero.
    Fig 18: Pushing And Rocking Ring Gear Into Mesh With Pinion Gear
    G04308900Courtesy of MAZDA MOTORS CORP.
  30. Move the ring gear away from the pinion gear as far as possible and record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line B in Step  34 of this procedure.
    Fig 19: Ring Gear Away From Pinion Gear
    G04308901Courtesy of MAZDA MOTORS CORP.
  31. Remove the Dial Indicator with Bracketry.
  32. Remove the differential case, the Master Bearing (LH), and the Master Bearing (RH).
    Fig 20: Master Bearing (LH) And Master Bearing (RH)
    G04308902Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Both of the differential bearing stand heights must be measured prior to installation on the differential case.
    NOTE:
    • Mark the left and right differential bearings before measuring.
  33. Clamp Bearing Preload Tool SST  205S-337 base or equivalent in a soft-jawed vise with the bearing mounting surface above the surface of the vise.
    Fig 21: Bearing Preload Tool Base In A Soft-Jawed Vise
    G04308903Courtesy of MAZDA MOTORS CORP.
  34. Position the differential bearing assembly in Bearing Preload Tool SST  205S-337 or equivalent and tighten the tool.
    Fig 22: Positioning Differential Bearing Assembly with Torque Specifications
    G04308904Courtesy of MAZDA MOTORS CORP.
  35. Measure the differential bearing stand height.
    1. Invert Bearing Preload Tool SST  205S-337 or equivalent and the bearing assembly in the vise.
    2. Use a depth micrometer to measure and record the differential bearing stand, height on the Differential Bearing Shim Selection Procedure Worksheet, Line D.
    3. Repeat for the other bearing.
    Fig 23: Using A Depth Micrometer
    G04308905Courtesy of MAZDA MOTORS CORP.
  36. Select the appropriate differential bearing shims.
    DANA 35 AXLE ACTUAL REFERENCE

    Dana 35 Axle Actual Example
    Line-A End play without ring gear   0.498
    Line-B End play with ring gear   -0.245
    Line-C Subtract Line-B from Line-A, also record on Line-C, below   0.253
    DANA 35 AXLE ACTUAL REFERENCE

    Dana 35 Axle Left Differential Bearing Height Right Differential Bearing Height
    Actual Example Actual Example
    Master Bearing Height 0.8695 0.8695 0.8695 0.8695
    Line-D Actual Bearing Height   -0.8478   -0.8491
    Line-E Difference   0.0217   0.0204
    DANA 35 AXLE ACTUAL REFERENCE

    Dana 35 Axle Left Side Dana 35 Axle Right Side
    Actual Example Actual Example
    Line-B End Play With Ring Gear Line-E Bearing Height + 0.2450 +0.0217 Line-C End Play Line-E Bearing Height + 0.2530 +0.0204
    TOTAL Lines B and E Backlash (Subtract) -0.006 0.2667 -0.0060 TOTAL Lines C and E Backlash/preload (Add) +0.0200 0.2734 +0.0200
    Initial Thickness*   0.2607 Initial Thickness 0.2934  
    Final Shim Thickness Left   0.261 Final Shim Thickness Right   0.293
    *Round off initial thickness to the nearest shim thickness as in the example for final shim thickness.
    NUMBER OF STRIPES AND COLOR CODE SPECIFICATION

    Numbers of Stripes and Color Code Dimension A
    mm Inch
    2- C-COAL 7.7978- 7.8105 0.3070- 0.3075
    1-C-COAL 7.7470- 7.7597 0.3050- 0.3055
    5-BLU 7.6962- 7.7089 0.3030- 0.3035
    4-BLU 7.6454- 7.6581 0.3010-0.3015
    3-BLU 7.5946- 7.6073 0.2990- 0.2995
    2-BLU 7.5458- 7.5565 0.2970- 0.2975
    5-PINK 7.4422- 7.4549 0.2930- 0.2935
    4- PINK 7.3914- 7.4041 0.2910-0.2915
    3- PINK 7.3406- 7.3533 0.2890- 0.2895
    2- PINK 7.2898- 7.3025 0.2870- 0.2875
    1-PINK 7.2390- 7.2517 0.2850- 0.2855
    5-GRN 7.1882-7.2009 0.2830- 0.2835
    4-GRN 7.1374- 7.1501 0.2810-0.2815
    3-GRN 7.0866- 7.0993 0.2790- 0.2795
    2-GRN 7.0358- 7.0485 0.2770- 0.2775
    1-GRN 6.9850- 6.9977 0.2750- 0.2755
    5-WH 6.9342- 6.9469 0.2730- 0.2735
    4-WH 6.8834- 6.8961 0.2710-0.2715
    3-WH 6.8326- 6.8453 0.2690- 0.2695
    2-WH 6.7818- 6.7945 0.2670- 0.2675
    1-WH 6.7310- 6.7437 0.2650- 0.2655
    5-YEL 6.6802- 6.6929 0.2630- 0.2635
    4-YEL 6.6294- 6.6421 0.2610-0.2615
    3-YEL 6.5786-6.5913 0.2590- 0.2595
    2-YEL 6.5278- 6.5405 0.2570- 0.2575
    1-YEL 6.4770- 6.4897 0.2550- 0.2555
    5- ORNG 6.4262- 6.4389 0.2530- 0.2535
    4- ORNG 6.3754- 6.3881 0.2510-0.2515
    3- ORNG 6.3246- 6.3373 0.2490- 0.2495
    2- ORNG 6.2738- 6.2865 0.2470- 0.2475
    1-ORNG 6.2223- 6.2357 0.2450- 0.2455
    2-RED 6.1722- 6.1849 0.2430- 0.2335
    1-RED 6.1214- 6.1341 0.2410-0.2415
  37. Install the differential bearings.
    1. Position the appropriate differential bearing (RH or LH).
    2. Use an appropriate press to install the differential bearing.
    3. Repeat for the other differential bearing.
    Fig 24: Installing Differential Bearing
    G04308906Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Make sure the indicator needle is in the spreader adapter hole.
  38. Install the dial indicator with bracketry.
    1. Install Spreader Adapter SST  .
    2. Install the Dial Indicator with Bracketry.
      Fig 25: Installing Dial Indicator With Bracketry
      G04308907Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Over-spreading can cause damage to the axle housing.
  39. Spread the axle housing.
  40. Remove the Dial Indicator with Bracketry.
    Fig 26: Removing Dial Indicator With Bracketry
    G04308908Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Never attempt to drive the differential bearing shims in place. The axle housing machined surfaces can be permanently damaged.
  41. Position the differential bearing shims.
    1. If removed, apply a light coating of axle lubricant meeting specification API Service GL-5 to one side of the differential bearing shims to help hold them in place.
    2. Position the differential bearing shims.
    Fig 27: Positioning Differential Bearing Shims
    G04308909Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Push the differential case down to fully seat the differential bearing cups in the axle housing.
  42. Position the differential case.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential case in place between the differential bearing shims.
    Fig 28: Positioning Differential Case
    G04308910Courtesy of MAZDA MOTORS CORP.
  43. Install the bearing caps in their original positions and tighten with the axle housing still spread.
    1. Position the differential bearing caps.
    2. Install the four bolts.
    Fig 29: Installing Differential Bearing Cap Bolts With Torque Specifications
    G04308911Courtesy of MAZDA MOTORS CORP.
  44. Remove Spreader Adapter SST  and Differential Housing Spreader SST  .
    NOTE:
    • Measure the ring gear backlash at four places to obtain a consistent reading.
  45. Measure the ring gear backlash.
    1. Mount the dial indicator
    2. Position the indicator needle and zero the indicator.
    3. Turn the ring gear without turning the pinion gear and record the measurement.
    • See DRIVELINE / AXLE SPECIFICATIONS .
    • If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
    Fig 30: Measuring Backlash
    G04308912Courtesy of MAZDA MOTORS CORP.
    BACKLASH SPECIFICATION

    Backlash Change Required Thickness Change Required
    MM Inch MM Inch
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
  46. Remove the Dial Indicator with Bracketry.
  47. Rotate the differential case to ensure free rotation.
    Fig 31: Rotating Differential Case
    G04308913Courtesy of MAZDA MOTORS CORP.
  48. Use Axle Bearing Seal Installer SST  49 UN01 028 and Driver Handle SST  49 F027 003 to install the RH axle shaft bearing.
  49. Use the Axle Seal Replacer 205-350 SST  or equivalent and Driver Handle SST  49 F027 003 to install the RH axle shaft seal.
  50. Use the Axle Bushing Replacer 205-347 or equivalent and Driver Handle SST  49 F027 003 to install the LH axle bearing.
  51. Use the Axle Seal Replacer 205-350 SST  or equivalent and Driver Handle SST  49 F027 003 to install the LH axle seal.
  52. Install the axle shaft; see AXLE ASSEMBLY FRONT REMOVAL / INSTALLATION .
    CAUTION:
    • Make sure the machined surfaces on both the axle housing and the differential cover are clean and free of lubricant before installing the new silicone sealant. The inside of the axle housing must be covered when cleaning the machined surface to prevent contamination.
  53. Clean the gasket mating surface of the axle housing and the differential cover.
    • Use silicone sealant.
    CAUTION:
    • The differential cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured.
  54. Install the axle housing cover.
    1. Position the axle housing cover.
    2. Install the ten bolts.
    Fig 32: Installing Axle Housing Cover Bolts
    G04308914Courtesy of MAZDA MOTORS CORP.
  55. Install the front axle assembly. See AXLE ASSEMBLY FRONT REMOVAL / INSTALLATION .
  56. Fill the axle to specification with axle lubricant meeting specification API Service GL-5.
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