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Assembly Note

WARNING: This page is about a different car, the 2002 Mazda B4000, 2002 Mazda B3000, and 2002 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
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 ST 49 UN01 035  to install the differential pinion bearing cups.
    Fig 1: Installing Differential Pinion Bearing Cups
    G01167233Courtesy of MAZDA MOTORS CORP.
  2. Install the original oil slinger and rear bearing onto the Middle Pinion ST 49 8531 565  .
    Fig 2: Installing Oil Slinger & Rear Bearing
    G01167234Courtesy of MAZDA MOTORS CORP.
  3. Install Collar Tool ST 49 8531 568  and O-ring to Middle Pinion ST 49 8531 565  and install them into the differential casing.
  4. Install Collar ST 49 8531 567  , yoke and washer.
  5. Tighten the nut in Middle Pinion ST 49 8531 565  making sure the yoke can still be turned by hand.
  6. Install Gauge Block (Front) ST 49 UN27 001  onto Middle Pinion ST 49 8531 565  .
    Fig 3: Installing Gauge Block (Front)
    G01167235Courtesy of MAZDA MOTORS CORP.
  7. Place ST  on a surface plate and set the dial indicator to zero.
  8. Place Gauge Set ST 49 0727 570  on top of Gauge Block ST 49 UN27 001  .
    Fig 4: Installing Gauge Set On Gauge Block
    G01167236Courtesy 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 slinger/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.
    Fig 5: New Pinion Marking (Metric) Chart
    G01167237Courtesy of MAZDA MOTORS CORP.
    Fig 6: New Pinion Marking Chart
    G01167238Courtesy of MAZDA MOTORS CORP.
    13. CAUTION: The same pinion bearing used in this procedure must be used in final assembly.
    Fig 7: Installing Pinion Bearing
    G01167239Courtesy of MAZDA MOTORS CORP.
  13. Install the pinion bearing.
    1. Place the pinion position shim on the pinion.
    2. Use Bearing Installer Set ST 49 F401 331  and Attachment C ST 49 F401 337A  to press the differential pinion bearing until it is firmly seated on the pinion and pinion position shim.
  14. Replace the collapsible spacer on the pinion stem.
    15. CAUTION: Installation without the proper tool can result in early seal failure. If the pinion becomes cocked during installation, remove it and install a new one.
    Fig 8: Installing Differential Pinion Bearing & Pinion Seal
    G01167240Courtesy of MAZDA MOTORS CORP.
  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 ST 205-133  to install the pinion seal.
  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 9: Installing Pinion Gear In Axle Housing
    G01167241Courtesy of MAZDA MOTORS CORP.
    17. CAUTION: The companion flange must never be hammered on or installed with power tools.
    Fig 10: Aligning Index Marks
    G01167242Courtesy of MAZDA MOTORS CORP.
  17. Align the index marks and position the companion flange.
  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 ST 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 11: Tightening Pinion Nut
      G01167243Courtesy of MAZDA MOTORS CORP.
    20. CAUTION: Master bearings are marked LH and RH and must be installed accordingly.
    Fig 12: Installing Master Bearings
    G01167244Courtesy of MAZDA MOTORS CORP.
  20. Remove the differential bearings and install the Master Bearing (LH) and the Master Bearing (RH) on the differential case.
  21. Install the differential case with master bearings into the axle housing.
    Fig 13: Installing Differential Case
    G01167245Courtesy of MAZDA MOTORS CORP.
    22. NOTE: Repeat this step until a consistent reading is obtained.
    Fig 14: Measuring Total End Play
    G01167246Courtesy of MAZDA MOTORS CORP.
  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 section.
  23. Remove the differential case.
    1. Remove the Dial Indicator with Bracketry.
    2. Remove the differential case.
    Fig 15: Removing differential case
    G01167247Courtesy 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.
    25. NOTE: Do not reuse ring gear bolts.
    Fig 16: Installing Ring Gear
    G01167248Courtesy of MAZDA MOTORS CORP.
  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.
  26. Install the remaining ring gear bolts.
    Fig 17: Installing Ring Gear Bolts
    G01167249Courtesy 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 18: Installing Differential Case
    G01167250Courtesy of MAZDA MOTORS CORP.
  28. Position the Dial Indicator with Bracketry.
    Fig 19: Positioning Dial Indicator With Bracketry
    G01167251Courtesy 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 20: Zeroing Dial Indicator
    G01167252Courtesy 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 21: Measuring For Differential Bearing Shim Thickness
    G01167253Courtesy 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 22: Removing Differential Case & Master Bearings
    G01167254Courtesy of MAZDA MOTORS CORP.
    33. 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.
    Fig 23: Clamp Bearing Preload Tool In A Soft-Jawed Vise
    G01167256Courtesy of MAZDA MOTORS CORP.
  33. Clamp Bearing Preload Tool ST 205S-337  base or equivalent in a soft-jawed vise with the bearing mounting surface above the surface of the vise.
  34. Position the differential bearing assembly in Bearing Preload Tool ST 205S-337  or equivalent and tighten the tool.
    Fig 24: Installing Differential Bearing Assembly In Bearing Preload Tool
    G01167258Courtesy of MAZDA MOTORS CORP.
  35. Measure the differential bearing stand height.
    1. Invert Bearing Preload Tool ST 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 25: Measuring Differential Bearing Stand Height
    G01167260Courtesy of MAZDA MOTORS CORP.
  36. Select the appropriate differential bearing shims.
    Fig 26: Differential Bearing Shim Selection Chart (1 Of 4)
    G01167255Courtesy of MAZDA MOTORS CORP.
    Fig 27: Differential Bearing Shim Selection Chart (2 Of 4)
    G01167257Courtesy of MAZDA MOTORS CORP.
    Fig 28: Differential Bearing Shim Selection Chart (3 Of 4)
    G01167259Courtesy of MAZDA MOTORS CORP.
    Fig 29: Differential Bearing Shim Selection Chart (4 Of 4)
    G01167261Courtesy of MAZDA MOTORS CORP.

    Round off initial thickness to the nearest shim thickness as in the example for final shim thickness.

    Fig 30: Number Of Stripes & Color Code Dimension Chart
    G01167262Courtesy of MAZDA MOTORS CORP.
  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 31: Installing Differential Bearing
    G01167263Courtesy of MAZDA MOTORS CORP.
    38. NOTE: Make sure the indicator needle is in the spreader adapter hole.
    Fig 32: Installing Dial Indicator With Bracketry
    G01167264Courtesy of MAZDA MOTORS CORP.
  38. Install the dial indicator with bracketry.
    1. Install Spreader Adapter ST 49 UN01 026  .
    2. Install the Dial Indicator with Bracketry.
    39. CAUTION: Over-spreading can cause damage to the axle housing.
  39. Spread the axle housing.
  40. Remove the Dial Indicator with Bracketry.
    Fig 33: Removing Dial Indicator With Bracketry
    G01167265Courtesy of MAZDA MOTORS CORP.
    41. CAUTION: Never attempt to drive the differential bearing shims in place. The axle housing machined surfaces can be permanently damaged.
    Fig 34: Positioning Differential Bearing Shims
    G01167266Courtesy of MAZDA MOTORS CORP.
  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.
    42. NOTE: Push the differential case down to fully seat the differential bearing cups in the axle housing.
    Fig 35: Installing Differential Case
    G01167267Courtesy of MAZDA MOTORS CORP.
  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.
  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 36: Installing Bearing Caps
    G01167268Courtesy of MAZDA MOTORS CORP.
  44. Remove Spreader Adapter ST 49 UN01 026  and Differential Housing Spreader ST 49 UN01 027  .
    45. NOTE: Measure the ring gear backlash at four places to obtain a consistent reading.
    Fig 37: Measuring Ring Gear Backlash
    G01167269Courtesy of MAZDA MOTORS CORP.
    Fig 38: Ring Gear Backlash Shim Thickness Chart (1 Of 2)
    G01167270Courtesy of MAZDA MOTORS CORP.
    Fig 39: Ring Gear Backlash Shim Thickness Chart (2 Of 2)
    G01167271Courtesy of MAZDA MOTORS CORP.
  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 TECHNICAL DATA .
      • 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.
  46. Remove the Dial Indicator with Bracketry.
  47. Rotate the differential case to ensure free rotation.
    Fig 40: Rotating Differential Case
    G01167272Courtesy of MAZDA MOTORS CORP.
  48. Use Axle Bearing Seal Installer ST 49 UN01 028  and Driver Handle ST 49 F027 003  to install the RH axle shaft bearing.
  49. Use the Axle Seal Replacer ST 205-350  or equivalent and Driver Handle ST 49 F027 003  to install the RH axle shaft seal.
  50. Use the Axle Bushing Replacer 205-347 or equivalent and Driver Handle ST 49 F027 003  to install the LH axle bearing.
  51. Use the Axle Seal Replacer ST 205-350  or equivalent and Driver Handle ST 49 F027 003  to install the LH axle seal.
  52. Install the axle shaft. See FRONT AXLE ASSEMBLY REMOVAL/INSTALLATION .
    53. 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 41: Installing Axle Housing Cover
    G01167273Courtesy of MAZDA MOTORS CORP.
  55. Install the front axle assembly. See FRONT AXLE ASSEMBLY REMOVAL/INSTALLATION .
  56. Fill the axle to specification with axle lubricant meeting specification API Service GL-5.
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