Drive Gear Case Component Assembly Procedure

Install the drive gear case to the SST .

Fig 1: Installing Drive Gear Case To SST
Courtesy of MAZDA MOTORS CORP.
Install the baffle plate.
Tightening torque

6.9-9.8 N.m {70-99 kgf.cm, 61-86 In.lbf}

Fig 2: Installing Baffle Plate
Courtesy of MAZDA MOTORS CORP.
Using a press, assemble the bearing (RH).

Fig 3: Assembling Bearing (RH) Using Press
Courtesy of MAZDA MOTORS CORP.
Using a press, assemble the bearing (LH).
Temporarily assemble the bearing outer race (RH) and spacer to the drive gear.

Fig 4: Assembling Bearing (LH) Using Press
Courtesy of MAZDA MOTORS CORP.
Place the drive gear component on the surface plate as shown in the figure, and measure the height using a vernier caliper or height gauge. This is dimension A.

Fig 5: Identifying Dimension A
Courtesy of MAZDA MOTORS CORP.
Measure the width of the drive gear installation area in the drive gear case. This is dimension B.
The maximum and minimum thickness C of the adjustment shim can be expressed by the following formula:
C = B - A - (0.01-0.03 mm {0.00039-0.00118 in})
If the thickness of the installed adjustment shim is within the C range, use the shim as it is.

If the thickness of the installed adjustment shim is not within the C range, select the appropriate adjustment shim from the table below and use it.

Fig 6: Identifying Dimension B

Courtesy of MAZDA MOTORS CORP.

Adjustment shim

ADJUSTMENT SHIM REFERENCE

Identification mark	Thickness (mm {in})	Identification mark	Thickness (mm {in})
350	3.50 {0.1378}	420	4.20 {0.1654}
355	3.55 {0.1398}	425	4.25 {0.1673}
360	3.60 {0.1417}	430	4.30 {0.1693}
365	3.65 {0.1437}	435	4.35 {0.1713}
370	3.70 {0.1457}	440	4.40 {0.1732}
375	3.75 {0.1476}	445	4.45 {0.1752}
380	3.80 {0.1496}	450	4.50 {0.1772}
385	3.85 {0.1516}	455	4.55 {0.1791}
390	3.90 {0.1535}	460	4.60 {0.1811}
395	3.95 {0.1555}	-	-
400	4.00 {0.1575}	-	-
405	4.05 {0.1594}	-	-
410	4.10 {0.1614}	-	-
415	4.15 {0.1634}	-	-

Using the plastic hammer, install the bearing outer race (LH).

Fig 7: Installing Bearing Outer Race (LH)
Courtesy of MAZDA MOTORS CORP.
Install the drive gear component.

Fig 8: Installing Drive Gear Component
Courtesy of MAZDA MOTORS CORP.
Install the spacer with its notch facing the bearing, and also facing upward, as shown in the figure.

Fig 9: Installing Spacer
Courtesy of MAZDA MOTORS CORP.
Using a plastic hammer, assemble the adjustment shim.

Fig 10: Assembling Adjustment Shim
Courtesy of MAZDA MOTORS CORP.
Align the bearing cap alignment marks, assemble the bearing cap.
Tightening torque

37-51 N.m {3.8-5.2 kgf.m, 27.3-37.6 ft.lbf}

Fig 11: Aligning Bearing Cap Alignment Marks
Courtesy of MAZDA MOTORS CORP.
Assemble the SST to the drive gear shaft, and hand-tighten the nut.
SST tightening torque

2.1 N.m {21 kgf.cm, 19 in.lbf}

Fig 12: Assembling SST To Drive Gear Shaft
Courtesy of MAZDA MOTORS CORP.
Install the drive gear shaft with the SST assembled and verify that the preload is within the specification using the torque wrench as shown in the figure.
Standard drive gear bearing preload

0.6-2.1 N.m {6.2-21.4 kgf.cm, 5.4-18.5 in.lbf}
- If the drive gear rotational torque is not within the specification, adjust it by selecting the proper spacer.
  
  Fig 13: Checking Preload
  Courtesy of MAZDA MOTORS CORP.
Remove the drive gear shaft.
Using a press, install the oil seals.
NOTE:
- Mark the press-in depth of each oil seal to the SST and press fit oil seals to the specified position.
Oil seal installation lengths

Fig 14: Oil Seal Installation Lengths
Courtesy of MAZDA MOTORS CORP.

LH

Fig 15: Installing Oil Seal (LH)
Courtesy of MAZDA MOTORS CORP.

RH inner

Fig 16: Installing Oil Seal (RH Inner)
Courtesy of MAZDA MOTORS CORP.

RH outer

Fig 17: Installing Oil Seal (RH Outer)
Courtesy of MAZDA MOTORS CORP.
Install the C-ring to the drive gear shaft and insert the drive gear shaft until it is secured by the C-ring.
CAUTION:
- Be careful not to damage the oil seal when installing the drive gear shaft.
Fig 18: Inserting Drive Gear Shaft
Courtesy of MAZDA MOTORS CORP.
Pull the drive gear shaft by hand and verify that the drive gear shaft is secured by the C-ring at the specified position.

Fig 19: Pulling Drive Gear Shaft
Courtesy of MAZDA MOTORS CORP.