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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 › Disassembly Note

Disassembly Note

  1. Remove the front axle assembly. See AXLE ASSEMBLY FRONT REMOVAL / INSTALLATION .
  2. Install the axle on bench.
    NOTE:
    • Place a suitable drain pan under the axle.
  3. Drain the axle fluid.
    1. Remove the ten differential cover bolts.
    2. Remove the differential cover.
  4. Remove the axle shaft using a jerking motion.
    Fig 1: Removing Axle Shaft Using Jerking Motion
    G04308864Courtesy of MAZDA MOTORS CORP.
  5. Use Converter Seal Remover SST  49 UN01 0870 or equivalent and Impact Slide Hammer SST  49 0223 630B and Adapter SST  49 UN11 101 to remove the LH axle seal.
    Fig 2: Removing LH Axle Seal
    G04308865Courtesy of MAZDA MOTORS CORP.
  6. Use Bearing Cup Puller SST, impact Slide Hammer SST  and Adapter SST  to remove the LH axle bearing.
    Fig 3: Removing Axle Bearing
    G04308866Courtesy of MAZDA MOTORS CORP.
  7. Use Converter Seal Remover SST  49 UN01 0870 or equivalent and Impact Slide Hammer SST  49 0223 630B and Adapter SST  49 UN11 101 to remove the RH axle shaft seal.
    Fig 4: Removing RH Axle Shaft Seal
    G04308867Courtesy of MAZDA MOTORS CORP.
  8. Use Bearing Remover SST  and Impact Slide Hammer SST  49 0223 630B and Adapter SST  to remove the RH axle bearing.
    Fig 5: Removing RH Axle Bearing
    G04308868Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The matched numbers or letters stamped on both of the differential bearing caps and the axle housing must correspond upon assembly.
  9. Remove the differential bearing caps.
    1. Remove the four bolts.
    2. Remove the two differential bearing caps.
    Fig 6: Matched Numbers Or Letters Stamped
    G04308869Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The SST  bolts have a minimum thread engagement.
  10. Install Spreader Adapters SST  .
    Fig 7: Installing Spreader Adapters
    G04308870Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Make sure the indicator needle is in the spreader adapter hole.
  11. Install Differential Housing Spreader SST  and Dial Indicator with Bracketry.
    1. Install SST.
    2. Install Dial Indicator with Bracketry and Clutch Housing Alignment Adapter SST  308-021.
    Fig 8: Installing Dial Indicator With Bracketry
    G04308871Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Over-spreading may cause damage to the axle housing.
  12. Spread the axle housing.
    1. Adjust the Dial Indicator to zero.
    2. Tighten screw from Differential Housing Spreader SST49 UN01 026 until the axle housing is spread.
    3. Remove Dial Indicator with Bracketry.
    Fig 9: Dial Indicator With Bracketry
    G04308872Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Wood blocks must be used to avoid axle housing damage.
  13. Remove the differential case from the axle housing.
    1. Position the wood blocks.
    2. Use two pry bars; push down on the pry bars.
    3. Remove the differential case.
    4. Remove Differential Housing Spreader SST  .
    Fig 10: Removing Differential Housing Spreader
    G04308873Courtesy of MAZDA MOTORS CORP.
  14. Measure the pinion bearing preload.
    • Use a beam type torque wrench to measure the torque required to maintain rotation of the pinion and record the measure for reference during assembly.
  15. Index mark the companion flange to the pinion stem.
    Fig 11: Marking Companion Flange To Pinion Stem
    G04308874Courtesy of MAZDA MOTORS CORP.
  16. Use Coupling Holder SST  to hold the companion flange while removing the pinion nut.
    Fig 12: Holding Pinion Coupling Using SST
    G04308875Courtesy of MAZDA MOTORS CORP.
  17. Use a 2-jaw puller to remove the companion flange.
    WARNING:
    • Gear teeth may have sharp edges. When handling gear, use care to avoid personal injury.
    CAUTION:
    • Use a soft mallet to drive the pinion out of the axle housing.
  18. Remove the pinion from the axle housing.
    1. Hold the pinion inside the axle housing.
    2. Use a soft face hammer to remove the pinion from the axle housing.
    Fig 13: Removing Pinion From Axle Housing
    G04308876Courtesy of MAZDA MOTORS CORP.
  19. Use Converter Seal Remover SST  49 UN01 0870 or equivalent and Impact Slide Hammer SST  49 0223 630B and Adapter SST  49 UN11 101 to remove the pinion seal.
    Fig 14: Removing Pinion Seal
    G04308877Courtesy of MAZDA MOTORS CORP.
  20. Remove the oil slinger (1) and the differential pinion bearing (2).
    Fig 15: Differential Pinion Bearing
    G04308878Courtesy of MAZDA MOTORS CORP.
  21. Remove the outer differential pinion bearing cup by tapping alternately on each side to prevent it from cocking in the bore.
    Fig 16: Outer Differential Pinion Bearing Cup
    G04308879Courtesy of MAZDA MOTORS CORP.
  22. Remove the inner differential pinion bearing cup by tapping alternately on each side to prevent it from cocking in the bore.
    Fig 17: Inner Differential Pinion Bearing Cup
    G04308880Courtesy of MAZDA MOTORS CORP.
  23. Remove the differential pinion bearing.
    1. Install the Pinion Bearing Cone Remover SST  205-055 or equivalent on the differential pinion bearing assembly.
    2. Position the Pinion Bearing Cone Remover SST  205-055 or equivalent and the differential pinion bearing assembly in a press.
    3. Press the differential pinion bearing off.
    Fig 18: Removing Differential Pinion Bearing
    G04308881Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Measure the pinion position shim with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the differential pinion bearing).
  24. Remove the pinion position shim from the differential pinion gear.
    Fig 19: Removing Pinion Position Shim
    G04308882Courtesy of MAZDA MOTORS CORP.
  25. Remove the ring gear.
    1. Remove the eight bolts.
    2. Use a drift punch to separate the ring gear from the differential case.
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