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Home >> Mazda >> 2005 >> B3000 Base, Automatic >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Differential >> Axle And Differential Front Disassembly/Assembly >> Assembly

Axle And Differential Front Disassembly/Assembly: Assembly

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 Pinion Bearing Cup
      G03729819Courtesy of MAZDA MOTORS CORP.
  2. Install the original oil slinger and rear bearing onto the Middle Pinion ST  49 8531 565
    Fig 2: Installing Original Oil Slinger And Rear Bearing Onto Middle Pinion
    G03729820Courtesy 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 Special Tools
    G03729821Courtesy 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: Placing Gauge Set On Top Of Gauge Block
    G03729822Courtesy 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
    OLD PINION SPECIFICATION

    Old Pinion Marking New Pinion Marking (Metric)
    -10 -8 -5 -3 0 +3 +5 +8 +10
    +10 +0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.003 0
    +8 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.03 0 -0.03
    +5 +0.15 +0.13 +0.10 +0.08 +0.05 +0.03 0 -0.03 -0.05
    +3 +0.13 +0.10 +0.08 +0.05 +0.03 0 -0.03 -0.05 -0.08
    0 +0.10 +0.08 +0.05 +0.03 0 -0.03 -0.05 -0.08 -0.10
    -3 +0.08 +0.05 +0.03 0 -0.03 -0.05 -0.08 -0.10 -0.13
    -5 +0.05 +0.03 0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15
    -8 +0.03 0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18
    -10 0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20
    OLD PINION SPECIFICATION

    Old Pinion Marking New Pinion Marking
    -4 -3 -2 -1 0 +1 +2 +3 +4
    +4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
    +3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
    +2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
    +1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
    0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
    -1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
    -2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
    -3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
    -4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
    CAUTION:
    • The same pinion bearing used in this procedure must be used in final assembly.
  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
      Fig 5: Installing Pinion Bearing
      G03729823Courtesy of MAZDA MOTORS CORP.
  14. Replace the collapsible spacer on the pinion stem
    CAUTION:
    • Installation without the proper tool can result in early seal failure. If the pinion seal becomes cocked during installation, remove it and install a new one.
    NOTE:
    • The pinion seal must be fully seated all the way around or pinion seal damage can occur.
  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
      Fig 6: Installing Differential Pinion Bearing And Pinion Seal
      G03729824Courtesy of MAZDA MOTORS CORP.
  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 7: Positioning Pinion Gear In Axle Housing
      G03729825Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • The companion flange must never be hammered on or installed with power tools.
  17. Align the index marks and position the companion flange
    Fig 8: Aligning Index Marks
    G03729826Courtesy of MAZDA MOTORS CORP.
  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 Nm (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 9: Tightening Pinion Nut - With Torque Specification
      G03729827Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • Master bearings are marked LH and RH and must be installed accordingly.
  20. Remove the differential bearings and install the Master Bearing (LH) and the Master Bearing (RH) on the differential case
    Fig 10: Removing Differential Bearings
    G03729828Courtesy of MAZDA MOTORS CORP.
  21. Install the differential case with master bearings into the axle housing
    Fig 11: Installing Differential Case With Master Bearings Into Axle Housing
    G03729829Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Repeat this step until a consistent reading is obtained.
  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
      Fig 12: Measuring Total End Play
      G03729830Courtesy of MAZDA MOTORS CORP.
  23. Remove the differential case
    1. Remove the Dial Indicator with Bracketry
    2. Remove the differential case
      Fig 13: Removing Differential Case
      G03729831Courtesy 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
    NOTE:
    • Do not reuse ring gear bolts.
  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
      Fig 14: Installing Ring Gear
      G03729832Courtesy of MAZDA MOTORS CORP.
  26. Install the remaining ring gear bolts
    Fig 15: Installing Remaining Ring Gear Bolts - With Torque Specification
    G03729833Courtesy 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 16: Positioning Differential Case In Axle Housing
      G03729834Courtesy of MAZDA MOTORS CORP.
  28. Position the Dial Indicator with Bracketry
    Fig 17: Positioning Dial Indicator With Bracketry
    G03729835Courtesy 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 18: Pushing And Rocking Ring Gear Into Mesh With Pinion Gear
    G03729836Courtesy 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 19: Moving Ring Gear Away From Pinion Gear
    G03729837Courtesy 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 20: Removing Master Bearings
    G03729838Courtesy of MAZDA MOTORS CORP.
    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.
  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
    Fig 21: Clamping Bearing Preload Tool
    G03729839Courtesy of MAZDA MOTORS CORP.
  34. Position the differential bearing assembly in Bearing Preload Tool ST  205S-337 or equivalent and tighten the tool
    Fig 22: Tightening Bearing Preload Tool - With Torque Specification
    G03729840Courtesy 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 23: Measuring Differential Bearing Stand Height
      G03729841Courtesy of MAZDA MOTORS CORP.
  36. Select the appropriate differential bearing shims
    Dana 35 Axle Actual Example
    Line-A End play without ring gear   0.498
    Line-B End play with ring gear   -0.245
    Line-C Subtract Line-B from Line-A, also record on Line-C, below   0.253
    Dana 35 Axle Left Differential Bearing Height Right Differential Bearing Height
    Actual Example Actual Example
    Master Bearing Height 0.8695 0.8695 0.8695 0.8695
    Line-D Actual Bearing Height   -0.8478   -0.8491
    Line-E Difference   0.0217   0.0204
    Dana 35 Axle Left Side Dana 35 Axle Right Side
    Actual Example Actual Example
    Line-B End Play With Ring Gear Line-E Bearing Height + 0.2450 +0.0217 Line-C End Play Line-E Bearing Height + 0.2530 +0.0204
    TOTAL Lines B and E Backlash (Subtract) -0.006 0.2667 -0.0060 TOTAL Lines C and E Backlash/preload (Add) +0.0200 0.2734 +0.0200
    Initial Thickness(1)   0.2607 Initial Thickness 0.2934  
    Final Shim Thickness-Left   0.261 Final Shim Thickness Right   0.293
    (1) Round off initial thickness to the nearest shim thickness as in the example for final shim thickness.
    Numbers of Stripes and Color Code Dimension A
    mm Inch
    2-C-COAL 7.7978-7.8105 0.3070-0.3075
    1-C-COAL 7.7470-7.7597 0.3050-0.3055
    5-BLU 7.6962-7.7089 0.3030-0.3035
    4-BLU 7.6454-7.6581 0.3010-0.3015
    3-BLU 7.5946-7.6073 0.2990-0.2995
    2-BLU 7.5458-7.5565 0.2970-0.2975
    5-PINK 7.4422-7.4549 0.2930-0.2935
    4-PINK 7.3914-7.4041 0.2910-0.2915
    3-PINK 7.3406-7.3533 0.2890-0.2895
    2-PINK 7.2898-7.3025 0.2870-0.2875
    1-PINK 7.2390-7.2517 0.2850-0.2855
    5-GRN 7.1882-7.2009 0.2830-0.2835
    4-GRN 7.1374-7.1501 0.2810-0.2815
    3-GRN 7.0866-7.0993 0.2790-0.2795
    2-GRN 7.0358-7.0485 0.2770-0.2775
    1-GRN 6.9850-6.9977 0.2750-0.2755
    5-WH 6.9342-6.9469 0.2730-0.2735
    4-WH 6.8834-6.8961 0.2710-0.2715
    3-WH 6.8326-6.8453 0.2690-0.2695
    2-WH 6.7818-6.7945 0.2670-0.2675
    1-WH 6.7310-6.7437 0.2650-0.2655
    5-YEL 6.6802-6.6929 0.2630-0.2635
    4-YEL 6.6294-6.6421 0.2610-0.2615
    3-YEL 6.5786-6.5913 0.2590-0.2595
    2-YEL 6.5278-6.5405 0.2570-0.2575
    1-YEL 6.4770-6.4897 0.2550-0.2555
    5-ORNG 6.4262-6.4389 0.2530-0.2535
    4-ORNG 6.3754-6.3881 0.2510-0.2515
    3-ORNG 6.3246-6.3373 0.2490-0.2495
    2-ORNG 6.2738-6.2865 0.2470-0.2475
    1-ORNG 6.2223-6.2357 0.2450-0.2455
    2-RED 6.1722-6.1849 0.2430-0.2335
    1-RED 6.1214-6.1341 0.2410-0.2415
  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 24: Installing Differential Bearings
      G03729842Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • Make sure the indicator needle is in the spreader adapter hole.
  38. Install the dial indicator with bracketry
    1. Install Spreader Adapter ST  49 UN01 026
    2. Install the Dial Indicator with Bracketry
      Fig 25: Installing Dial Indicator With Bracketry
      G03729843Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • Over-spreading can cause damage to the axle housing.
  39. Spread the axle housing
  40. Remove the Dial Indicator with Bracketry
    Fig 26: Spreading Axle Housing
    G03729844Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Never attempt to drive the differential bearing shims in place. The axle housing machined surfaces can be permanently damaged.
  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
      Fig 27: Positioning Differential Bearing Shims
      G03729845Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • Push the differential case down to fully seat the differential bearing cups in the axle housing.
  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
      Fig 28: Positioning Differential Case
      G03729846Courtesy of MAZDA MOTORS CORP.
  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 29: Installing Bearing Caps - With Torque Specification
      G03729847Courtesy of MAZDA MOTORS CORP.
  44. Remove Spreader Adapter ST  49 UN01 026 and Differential Housing Spreader ST  49 UN01 027
    NOTE:
    • Measure the ring gear backlash at four places to obtain a consistent reading.
  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 DRIVELINE/AXLE SPECIFICATIONS .
      • 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.
        Fig 30: Measuring Ring Gear Backlash
        G03729848Courtesy of MAZDA MOTORS CORP.
        BACKLASH SPECIFICATION

        Backlash Change Required Thickness Change Required
        MM Inch MM Inch
        0.025 0.001 0.050 0.002
        0.050 0.002 0.050 0.002
        0.076 0.003 0.101 0.004
        0.101 0.004 0.152 0.006
        0.127 0.005 0.152 0.006
        0.152 0.006 0.203 0.008
        0.177 0.007 0.254 0.010
        0.203 0.008 0.254 0.010
        0.228 0.009 0.304 0.012
        0.254 0.010 0.355 0.014
        0.279 0.011 0.355 0.014
        0.304 0.012 0.406 0.016
        0.330 0.013 0.457 0.018
        0.335 0.014 0.457 0.018
        0.381 0.015 0.508 0.020
  46. Remove the Dial Indicator with Bracketry
  47. Rotate the differential case to ensure free rotation
    Fig 31: Rotating Differential Case To Ensure Free Rotation
    G03729849Courtesy 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 205-350 ST  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 205-350 ST  or equivalent and Driver Handle ST  49 F027 003 to install the LH axle seal
  52. Install the axle shaft; see AXLE ASSEMBLY FRONT REMOVAL/INSTALLATION .
    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 32: Installing Axle Housing Cover - With Torque Specification
      G03729850Courtesy of MAZDA MOTORS CORP.
  55. Install the front axle assembly; see AXLE ASSEMBLY FRONT REMOVAL/INSTALLATION .
  56. Fill the axle to specification with axle lubricant meeting specification API Service GL-5
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