Axle And Differential Front Disassembly/Assembly: Disassembly

Remove the front axle assembly; see AXLE ASSEMBLY FRONT REMOVAL/INSTALLATION .
Install the axle on bench
NOTE:
- Place a suitable drain pan under the axle.
Drain the axle fluid
1. Remove the ten differential cover bolts
2. Remove the differential cover
Remove the axle shaft using a jerking motion

Fig 1: Removing Axle Shaft
Courtesy of MAZDA MOTORS CORP.
Use Converter Seal Remover ST 49 UN01 0870 or equivalent and Impact Slide Hammer ST 49 0223 630B and Adapter ST 49 UN 11 101 to remove the LH axle seal

Fig 2: Removing LH Axle Seal
Courtesy of MAZDA MOTORS CORP.
Use Bearing Cup Puller ST 308-047 or equivalent and Impact Slide Hammer ST 49 0223 630B and Adapter ST 49 UN11 101 to remove the LH axle bearing

Fig 3: Removing LH Axle Bearing
Courtesy of MAZDA MOTORS CORP.
Use Converter Seal Remover ST 49 UN01 0870 or equivalent and Impact Slide Hammer ST 49 0223 630B and Adapter ST 49 UN11 101 to remove the RH axle shaft seal

Fig 4: Removing RH Axle Shaft Seal
Courtesy of MAZDA MOTORS CORP.
Use Bearing Remover ST 307-318 or equivalent and Impact Slide Hammer ST 49 0223 630B and Adapter ST 49 UN11 101 to remove the RH axle bearing

Fig 5: Removing RH Axle Bearing
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- The matched numbers or letters stamped on both of the differential bearing caps and the axle housing must correspond upon assembly.
Remove the differential bearing caps
1. Remove the four bolts
2. Remove the two differential bearing caps
  
  Fig 6: Removing Differential Bearing Caps
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - The ST bolts have a minimum thread engagement.
Install Spreader Adapters ST 49 UN01 027

Fig 7: Installing Spreader Adapters
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Make sure the indicator needle is in the spreader adapter hole.
Install Differential Housing Spreader ST 49 UN01 026 and Dial Indicator with Bracketry
1. Install ST 49 UN01 026
2. Install Dial Indicator with Bracketry and Clutch Housing Alignment Adapter ST 308-021
  
  Fig 8: Installing Differential Housing Spreader
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - Over-spreading may cause damage to the axle housing.
Spread the axle housing
1. Adjust the Dial Indicator to zero
2. Tighten screw from Differential Housing Spreader ST 49 UN01 026 until the axle housing is spread
3. Remove Dial Indicator with Bracketry
  
  Fig 9: Spreading Axle Housing
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - Wood blocks must be used to avoid axle housing damage.
Remove the differential case from the axle housing
1. Position the wood blocks
2. Use two pry bars; push down on the pry bars
3. Remove the differential case
4. Remove Differential Housing Spreader ST 49 UN01 026
  
  Fig 10: Removing Differential Case From Axle Housing
  Courtesy of MAZDA MOTORS CORP.
Measure the pinion bearing preload
- Use a beam type torque wrench to measure the torque required to maintain rotation of the pinion and record the measure for reference during assembly.
Index mark the companion flange to the pinion stem

Fig 11: Marking Companion Flange To Pinion Stem
Courtesy of MAZDA MOTORS CORP.
Use Coupling Holder ST 205-126 to hold the companion flange while removing the pinion nut

Fig 12: Removing Pinion Nut
Courtesy of MAZDA MOTORS CORP.
Use a 2-jaw puller to remove the companion flange
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.
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
  
  Fig 13: Removing Pinion From Axle Housing
  Courtesy of MAZDA MOTORS CORP.
Use Converter Seal Remover ST 49 UN01 0870 or equivalent and Impact Slide Hammer ST 49 0223 630B and Adapter ST 49 UN 11 101 to remove the pinion seal

Fig 14: Removing Pinion Seal
Courtesy of MAZDA MOTORS CORP.
Remove the oil slinger (1) and the differential pinion bearing (2)

Fig 15: Removing Oil Slinger And Differential Pinion Bearing
Courtesy of MAZDA MOTORS CORP.
Remove the outer differential pinion bearing cup by tapping alternately on each side to prevent it from cocking in the bore

Fig 16: Removing Outer Differential Pinion Bearing Cup
Courtesy of MAZDA MOTORS CORP.
Remove the inner differential pinion bearing cup by tapping alternately on each side to prevent it from cocking in the bore

Fig 17: Removing Inner Differential Pinion Bearing Cup
Courtesy of MAZDA MOTORS CORP.
Remove the differential pinion bearing
1. Install the Pinion Bearing Cone Remover 205-055 or equivalent on the differential pinion bearing assembly
2. Position the Pinion Bearing Cone Remover 205-055 or equivalent and the differential pinion bearing assembly in a press
3. Press the differential pinion bearing off
  
  Fig 18: Removing Differential Pinion Bearing
  Courtesy of MAZDA MOTORS CORP.
  NOTE:
  - Measure the pinion position shim with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the differential pinion bearing).
Remove the pinion position shim from the differential pinion gear

Fig 19: Removing Pinion Position Shim From Differential Pinion Gear
Courtesy of MAZDA MOTORS CORP.
Remove the ring gear
1. Remove the eight bolts
2. Use a drift punch to separate the ring gear from the differential case