Drive Gear Case Component Assembly Procedure

Install the drive gear case to the SST.

Fig 1: Identifying SST (49 M005 561)
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: Locating Baffle Plate
Courtesy of MAZDA MOTORS CORP.
Using a press, assemble the bearing (RH).
Substitution SST
- 49 H028 202
  Outer diameter: 58-61 mm {2.29-2.40 in}
  
  Inner diameter: 56 mm {2.20 in} or more
  
  Plate thickness: 1 mm {0.04 in} or more
  
  Fig 3: Assembling Bearing Using SST (49 H028 202)
  Courtesy of MAZDA MOTORS CORP.
Using a press, assemble the bearing (LH).
- 49 H028 202
  Outer diameter: 58-61 mm {2.29-2.40 in}
  
  Inner diameter: 56 mm {2.20 in} or more
  
  Plate thickness: 1 mm {0.04 in} or more
Temporarily assemble the bearing outer race (RH) and spacer to the drive gear.

Fig 4: Assembling Bearing Using SST (49 H028 202)
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})

Fig 6: Identifying Dimension B
Courtesy of MAZDA MOTORS CORP.
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.

ADJUSTMENT SHIM

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 Using Plastic Hammer
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 Using Plastic Hammer
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: Identifying 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: Identifying SST (49 L011 201)
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 SSTs , 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.
LH inner

Substitution SST
- 49 S019 006
  Outer diameter: 61-66 mm {2.41-2.59 in}
  
  Plate thickness: 2 mm {0.08 in} or more
  
  Fig 14: Identifying SST (49 G030 797, 49 S019 006)
  Courtesy of MAZDA MOTORS CORP.
LH outer

Fig 15: Identifying SST (49 G030 797, 49 L019 301)
Courtesy of MAZDA MOTORS CORP.

RH inner

Substitution SST
- 49 B025 001
  Outer diameter: 57-64 mm {2.25-2.51 in}
  
  Plate thickness: 2 mm {0.08 in} or more
  
  Fig 16: Identifying SST (49 G030 797, 49 B025 001)
  Courtesy of MAZDA MOTORS CORP.
RH outer

Substitution SST
- 49 T034 201A
  Outer diameter: 59-64 mm {2.33-2.51 in}
  
  Inner diameter: 55 mm {2.17 in} or more
  
  Length: 5 mm {0.20 in} or more
  
  Plate thickness: 2 mm {0.08 in} or more
  
  Fig 17: Identifying SST (49 T034 201A)
  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: Installing 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.