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Section 248 (Differential): Axle: Assembly

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: Installing New Oil Baffle, Inner And Outer Drive Pinion Bearing Cups
G01900466Courtesy of MAZDA MOTORS CORP.
CAUTION:
  • A new oil baffle must be installed located between the inner drive pinion bearing cup and the axle housing bore. 
  1. Using the special tool or equivalent, install a new oil baffle, inner and the outer drive pinion bearing cups.
    1. Apply a light coat of rear axle lubricant to the drive pinion bearing cup bore.
      Fig 2: Assembling Drive Pinion Position Shim & Rear Bearing Inner Race
      G01900467Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • Use the same drive pinion position and nut.
  2. Using the special tool or equivalent, assemble the drive pinion position shim, rear bearing inner race. Secure the special tool with the O-ring. Then install this to the carrier.
    1. Using the special tool or equivalent, assemble the front bearing inner race, washer and nut to the special tool.
    2. Tighten the nut to the extent that the special tool can be turned by hand.
      Fig 3: Placing Special Tool On Surface Plate
      G01900468Courtesy of MAZDA MOTORS CORP.
  3. Place the special tool on the surface plate and set the dial indicator to zero.
    Fig 4: Placing Special Tool As Shown
    G01900469Courtesy of MAZDA MOTORS CORP.
  4. Place the special tool as shown.
    Fig 5: Placing Measuring Probe Of Dial Indicator
    G01900470Courtesy of MAZDA MOTORS CORP.
  5. Place the measuring probe of the dial indicator so that it contacts the place where the side bearing is installed in the carrier. Then measure left and right side of the lowest position.
  6. Add the two (left and right) values obtained by the measurements in the step 5 and then divide the total by 2. From this result, subtract the number inscribed on the drive pinion, and add 0.3435 to it. (If the number on the drive pinion is marked with + (plus), subtract the number. If the number on the drive pinion is marked with - (minus), add the number.) This is the pinion height adjustment value.
    NOTE:
    • Example: The measured results obtained at step 5 are - 0.2 mm and -0.3 mm, and the figure inscribed on the drive pinion is +0.02:
      Fig 6: Measurement Specifications
      G01900471Courtesy of MAZDA MOTORS CORP.

      Therefore, replace it with a drive pinion position shim 0.0735 mm thicker than currently used one. Replace with a drive pinion position shim of the nearest thickness of desired.

  7. Replace the drive pinion position shim as necessary.
    CAUTION:
    • If the drive pinion is marked with a plus (+) reading, this amount must be subtracted from the thickness measured. If the drive pinion is marked with a minus (-) reading, this amount must be added to the thickness measured. 
  8. Measure and record the clearance between the gauge tube and the gauge block.
    1. Select and check the correct drive pinion position shim as necessary.
      Fig 7: Installing Drive Pinion Position Shim And Bearing Onto Drive Pinion
      G01900472Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • The same drive pinion bearings and drive pinion bearing cups used in the drive pinion position shim selection procedure must be used in the final axle assembly. 
  9. Using the special tools or equivalent, install the drive pinion position shim and the bearing onto the drive pinion.
    1. Position the drive pinion position shim.
    2. Position the drive pinion bearing.
    3. Position the special tools.
    4. Using a press, firmly seat the drive pinion bearing on the drive pinion.
      Fig 8: Installing New Collapsible Spacer
      G01900473Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • Do not reuse the old collapsible spacer. 
  10. Install a new collapsible spacer.
    Fig 9: Installing Drive Pinion And New Drive Pinion Nut
    G01900474Courtesy of MAZDA MOTORS CORP.
  11. Using the special tools or equivalent, install the drive pinion and a new drive pinion nut.
    1. Rotate the drive pinion counterclockwise until all end play is removed then tighten the drive pinion nut.
      Fig 10: Checking Drive Pinion Rotational Torque
      G01900475Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • If the rotational torque is less than specification, tighten the drive pinion nut in small increments until it is within specification. Do not tighten the drive pinion nut more than 678 Nm (500 lb-ft) or the collapsible spacer will be damaged. If the rotation torque is higher than specification, the collapsible spacer has been compressed too far and a new collapsible spacer must be installed. 
      NOTE:
      • When tightening the drive pinion nut to remove initial end play, torque may exceed the maximum specification. Once end play is removed and the collapsible spacer has started to collapse, the torque should drop into the specified range.
      NOTE:
      • Rotate the drive pinion 10 revolutions before taking the reading.
  12. Check the drive pinion rotational torque and adjust as necessary.
    Fig 11: Installing Differential Case Into Axle Housing
    G01900476Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The differential case should move freely in the axle housing.
  13. Using the special tools, install the differential case into the axle housing.
    Fig 12: Seating Differential Case From Drive Pinion
    G01900477Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Repeat this step until a same reading is obtained twice.
  14. Seat the differential case away from the drive pinion then push the differential case toward the drive pinion while measuring and recording the differential case total end play.
    Fig 13: Removing Differential Case And Special Tools
    G01900478Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Take note which side each special tool was removed from so they can be installed on the same side of differential case for the next measurement with the ring gear installed.
  15. Remove the differential case and the special tools.
    Fig 14: Installing Two Pinion Gears, Side Gears And Thrust Washers
    G01900479Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • If reusing original pinion gears, side gears or thrust washers, install in the same locations that they were removed. 
  16. Install the two pinion gears, two side gears and four thrust washers.
    1. Position the side gears and side gear thrust washers.
    2. Rotate the pinion gears and pinion gear thrust washers to the differential pinion shaft hole in the differential case.
    3. Apply SAE 80W-90 rear axle lubricant to the pinion gears, side gears and thrust washers.
      Fig 15: Installing Differential Pinion Shaft
      G01900480Courtesy of MAZDA MOTORS CORP.
  17. Install the differential pinion shaft.
    1. Install the differential pinion shaft.
    2. Install the differential pinion shaft lock pin.
      Fig 16: Installing Ring Gear
      G01900481Courtesy 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. 
  18. Install the ring gear.
    1. Position the ring gear.
    2. Install new ring gear bolts in an alternately and evenly pattern.
      Fig 17: Installing Differential Case Into Axle Housing Using Special Tool
      G01900482Courtesy of MAZDA MOTORS CORP.
  19. Using the special tools, install the differential case into the axle housing.
    1. Install the special tools on the same ends of the differential case as they were previously installed.
    2. Locate the tip of the dial indicator on the flat surface of one of the ring gear bolts.
      Fig 18: Seating Differential Case Away From Drive Pinion
      G01900483Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • Repeat this step until a same reading is obtained twice.
  20. Seat the differential case away from the drive pinion then push the differential case toward the drive pinion while measuring and recording the differential case total end play.
    Fig 19: Removing Differential Case And Special Tools
    G01900484Courtesy of MAZDA MOTORS CORP.
  21. Remove the differential case and special tools.
  22. Calculate for the differential case bearing shims as follows:
    Fig 20: Differential Case Bearing Shims Selection Chart (1 Of 2)
    G01900485Courtesy of MAZDA MOTORS CORP.
    Fig 21: Differential Case Bearing Shims Selection Chart (2 Of 2)
    G01900486Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • If the special tools do not measure 18.136 mm (0.714 in) + or - 0.025 mm (0.001 in), the numbers in Step One will be overstated by the difference measured on each special tool. The number in Step Two will be overstated by the difference measured on special tool. Adjustments to the shim pack will have to be made in order to prevent bearing pre-loads from becoming excessive.
  23. Measure the width of the special tools used on the ends of the differential case and select the differential case bearing shims as necessary.
    Fig 22: Installing Differential Case Bearings And Correct Shims
    G01900487Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • RH shown, LH similar.
  24. Using the special tools, install the differential case bearings and correct shims.
    Fig 23: Installing Differential Case
    G01900488Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Overspreading can damage the axle housing. 
  25. Using the special tools, install the differential case.
    1. Spread the axle housing.
    2. Install the differential case.
      Fig 24: Removing Special Tools
      G01900489Courtesy of MAZDA MOTORS CORP.
  26. Remove the special tools.
    Fig 25: Installing Bearing Caps
    G01900490Courtesy of MAZDA MOTORS CORP.
  27. Install the bearing caps.
    1. Position the bearing caps in the position they were removed.
    2. Install the bolts.
      Fig 26: Measuring Ring Gear Backlash
      G01900491Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • The ring gear backlash should be measured at three equally spaced points on the ring gear. If the reading is high, the ring gear must be moved closer to the drive pinion by moving shims to the ring gear side from the opposite side. If the readings are low, the ring gear must be moved away from the drive pinion by moving shims from the ring gear side to the opposite side.
  28. Measure and adjust the ring gear backlash as necessary.
  29. Position the axle assembly with the drive pinion stem facing upward.
    Fig 27: Rotating Drive Pinion
    G01900492Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The total turning torque should be the drive pinion rotational torque plus 0.68 - 1.13 Nm (6 - 10 in-lb). If the total turning torque is too high, subtract an equal amount of shims from each side of the differential case. If the total turning torque is too low, add an equal amount of shims to both sides of the differential case.
  30. Measure and record the total turning torque to rotate the drive pinion and adjust as necessary.
    Fig 28: Installing Halfshaft Bearings Using Special Tool
    G01900493Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Lubricate the needle bearings with long life grease prior to installation. 
    NOTE:
    • RH shown, LH similar.
  31. Using the special tools, install the halfshaft bearings.
    32. Fig 29: Installing Halfshaft Seals Using Special Tool
    G01900494Courtesy of MAZDA MOTORS CORP.
  32. Using the special tools, install the halfshaft seals.
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