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Home >> Mazda >> 2001 >> B2500 SE, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 185 (Differentials & DRIVEAXLES) >> Differential >> Front Differential Case RUNOUT Check

Front Differential Case RUNOUT Check

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.
  1. Remove the front axle assembly. See FRONT AXLE ASSEMBLY REMOVAL/INSTALLATION .
  2. Install axle on bench.
    NOTE: Place a drain pan under the axle to catch fluid.
  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
    G01167289Courtesy of MAZDA MOTORS CORP.
  5. Install and position Dial Indicator with Bracketry.
    6. NOTE: If the ring gear runout exceeds specification, the cause may be a warped ring gear, a damaged differential case, loss of differential bearing preload or a damaged axle housing.
    Fig 2: Measuring Ring Gear Runout
    G01167290Courtesy of MAZDA MOTORS CORP.
  6. Check and record the ring gear runout.
    1. Rotate the differential case.
    2. Check and record the ring gear runout.
  7. Remove Dial Indicator with Bracketry.
    8. CAUTION: The matched numbers or letters stamped on both the differential bearing caps and axle housing must correspond upon assembly.
    Fig 3: Removing Differential Bearing Caps
    G01167291Courtesy of MAZDA MOTORS CORP.
  8. Remove the differential bearing caps.
    1. Remove the four bolts.
    2. Remove the differential bearing caps.
  9. Install Spreader Adapter ST 49 UN01 027  .
    NOTE: Make sure the indicator needle is in spreader adapter hole.
    Fig 4: Installing Spreader Adapter
    G01167292Courtesy of MAZDA MOTORS CORP.
    CAUTION: Spreader Adapter bolts have a minimum thread engagement.
  10. Install Differential Housing Spreader ST 49 UN01 026  and Dial Indicator with Bracketry.
    1. Install Differential Housing Spreader ST 49 UN01 026  .
    2. Install Dial Indicator with Bracketry.
    Fig 5: Installing Differential Housing Spreader & Dial Indicator With Bracketry
    G01167293Courtesy of MAZDA MOTORS CORP.
    11. CAUTION: Over-spreading can cause damage to the axle housing.
    Fig 6: Spreading Axle Housing
    G01167294Courtesy of MAZDA MOTORS CORP.
  11. Spread the axle housing.
    1. Adjust the Dial Indicator to zero.
    2. Tighten the spreader screw until the axle housing is spread.
    3. Remove the Dial Indicator with Bracketry.
    12. CAUTION: Wood blocks must be used to avoid axle housing damage.
    NOTE: Keep the shims and bearing cups in order.
    Fig 7: Removing Differential Case
    G01167295Courtesy of MAZDA MOTORS CORP.
  12. Remove the differential case from the axle housing.
    1. Position the wood blocks.
    2. Use two pry bars and push down on the pry bars.
    3. Remove the differential case.
    4. Remove Differential Housing Spreader ST 49 UN01 026  and Spreader Adapter ST 49 UN01 027  .
  13. Measure the pinion bearing preload.
    • Use a N.m (lb/in) beam type torque wrench to measure the torque required to maintain rotation of the pinion and record the measurement for reference during assembly.
  14. Index mark the companion flange to the pinion stem.
    Fig 8: Marking Companion Flange To Pinion Stem
    G01167296Courtesy of MAZDA MOTORS CORP.
  15. Use Coupling Holder ST 49 S120 710  to remove the pinion nut.
    Fig 9: Removing Pinion Nut
    G01167297Courtesy of MAZDA MOTORS CORP.
  16. Use a 2-jaw puller to remove the companion flange.
    17. 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.
    Fig 10: Removing Pinion
    G01167298Courtesy of MAZDA MOTORS CORP.
  17. 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.
  18. Install the differential bearing caps and tighten the four bolts.
    Fig 11: Installing Differential Bearing Caps
    G01167299Courtesy of MAZDA MOTORS CORP.
  19. Rotate the differential case to ensure free rotation.
    Fig 12: Rotating Differential Case
    G01167300Courtesy of MAZDA MOTORS CORP.
  20. Install and position the Dial Indicator with Bracketry.
    21. NOTE: If the ring gear runout is within specification, the original out-of-specification runout was caused by insufficient differential bearing preload.
    Fig 13: Checking Ring Gear Runout
    G01167301Courtesy of MAZDA MOTORS CORP.
  21. Check and record the ring gear runout.
    1. Rotate the differential case.
    2. Check and record the ring gear runout.
  22. Position the differential case with the differential bearing cups in the axle housing.
  23. Install the differential bearing shim on the LH side.
    Fig 14: Installing Differential Bearing Shim
    G01167302Courtesy of MAZDA MOTORS CORP.
  24. Install the LH differential bearing cap.
    1. Position the LH differential bearing cap.
    2. Install the two bolts finger tight.
    Fig 15: Installing LH Differential Bearing Cap
    G01167303Courtesy of MAZDA MOTORS CORP.
  25. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim can be assembled with a slight drag feel.
    Fig 16: Installing Progressively Larger Differential Bearing Shim
    G01167304Courtesy of MAZDA MOTORS CORP.
  26. Remove the Dial Indicator with Bracketry.
  27. Remove the differential bearing caps.
    1. Remove the four bolts.
    2. Remove the differential bearing caps.
    Fig 17: Removing Differential Bearing Caps
    G01167305Courtesy of MAZDA MOTORS CORP.
  28. Remove the differential case from the axle housing.
    Fig 18: Removing Differential Case
    G01167306Courtesy of MAZDA MOTORS CORP.
  29. Remove the ring gear.
    1. Remove the eight ring gear bolts.
    2. Use a drift punch to separate the ring gear from the differential case.
    30. NOTE: Use of proper shims is necessary for this step.
    Fig 19: Installing Differential Case
    G01167307Courtesy of MAZDA MOTORS CORP.
  30. Install the differential case in the axle housing without the ring gear.
    1. Position the differential case.
    2. Position the differential bearing caps.
    3. Install the four bolts.
  31. Install and position the Dial Indicator with Bracketry.
    1. Rotate the differential case to ensure the differential bearings are properly seated.
    2. Install and position the dial indicator with bracketry.
    32. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings.
  32. Measure the differential case runout without the ring gear.
    1. Rotate the differential case.
    2. Check and note the differential case runout.
      Fig 20: Measuring Differential Case Runout Without Ring Gear
      G01167308Courtesy of MAZDA MOTORS CORP.
    33. NOTE: If runout is now within specification, use new differential bearings for assembly. If runout is still excessive, the axle housing is damaged and must be replaced.
  33. Recheck runout with the new differential case and differential bearings.
    1. Rotate the differential case.
    2. Recheck and note the differential case runout.
  34. Assemble the axle. See FRONT AXLE AND DIFFERENTIAL DISASSEMBLY/ASSEMBLY  .
  35. Install the front axle assembly. See REAR DIFFERENTIAL CASE (STANDARD & LIMITED SLIP) REMOVAL/INSTALLATION  .
  36. Fill the axle assembly with axle lubricant meeting specification API Service GL-5.
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