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Home >> Mazda >> 2005 >> B3000 Base, Automatic >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Differential >> Drive Pinion Rear Removal/Installation >> Installation Note

Installation Note

  1. Position Pinion Bearing Cup Replacer ST  49 UN01 035 and the inner and outer bearing cups in their respective bores.
    1. After placing the inner and outer bearing cups in their bores, place ST  49 UN01 035 (inner) on the inner pinion bearing cup.
    2. Place ST  49 UN01 035 (outer) on the outer pinion bearing cup.
    3. Install ST  49 UN01 035.
      Fig 1: Positioning Pinion Bearing Cup Replacer & Inner & Outer Bearing Cups
      G03729714Courtesy of MAZDA MOTORS CORP.
  2. Tighten ST  49 UN01 035 to seat the pinion bearing cups into their bores.
    Fig 2: Seating Pinion Bearing Cups Into Their Bores
    G03729715Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Steps 3 and 4 are an alternate method of performing Steps 1 and 2.
  3. Drive the outer pinion bearing cup into the axle housing using Driver Handle ST  49 F027 003 and Pinion Bearing Cup Replacer ST  49 UN01 035.
    Fig 3: Driving Outer Pinion Bearing Cup Into Axle Housing
    G03729716Courtesy of MAZDA MOTORS CORP.
  4. Drive the inner pinion bearing cup into the axle housing using Driver Handle ST  49 F027 003 and Pinion Bearing Cup Replacer ST  49 UN01 035.
    Fig 4: Driving Inner Pinion Bearing Cup Into Axle Housing
    G03729717Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Whenever the cups are replaced, the pinion bearings must also be replaced.
    NOTE:
    • If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not properly seated.
  5. Make sure the cups are properly seated in their bores.
    Fig 5: Identifying Properly Seated Cups
    G03729718Courtesy of MAZDA MOTORS CORP.
  6. Install the original oil slinger and rear bearing onto Middle Pinion ST  49 8531 565.
    Fig 6: Installing Original Oil Slinger And Rear Bearing Onto Middle Pinion
    G03729719Courtesy of MAZDA MOTORS CORP.
  7. Install Collar B ST  49 UN27 004 and o-ring to Middle Pinion ST  49 8531 565 and install them into the rear axle casing.
  8. Install Collar A ST  49 UN27 003, yoke and washer.
  9. Tighten the nut on Middle Pinion ST  49 8531 565 making sure the yoke can be turned by hand.
  10. Tighten the nut on Middle Pinion ST  49 8531 565 making sure the yoke can be turned by hand.
  11. If 7.5 inch differential, install Gauge Block (Front) 205-129 onto Middle Pinion ST  49 8531 565.
    Fig 7: Installing Special Tools To Yoke
    G03729720Courtesy of MAZDA MOTORS CORP.
  12. If 8.8 inch differential, install Gauge Block (Front) ST  49 UN27 001 and Gauge Block (Rear) ST  49 UN27 002 onto Middle Pinion ST  49 8531 565.
    Fig 8: Installing Special Tools
    G03729721Courtesy of MAZDA MOTORS CORP.
  13. Place ST  assembly on a surface plate and set the dial indicator to zero.
  14. Place Gauge Set ST  49 0727 570 on top of Gauge Block (Front) ST  49 UN27 001.
    Fig 9: Placing Gauge Set Top Of Gauge Block (Front)
    G03729722Courtesy of MAZDA MOTORS CORP.
  15. Place the pointer of the dial indicator so that it contacts where the side bearing is installed in the housing. Measure the lowest position on the left and right sides of the casing.
  16. Add the right and left side measurements and divide by two to get the thickness dimension.

    Specification: 

    0 mm { 0 in } 

  17. If not within specification, adjust the pinion height by selecting a shim which will bring the reading within specification.
    NOTE:
    • If the drive pinion is marked with a plus (+) reading, this amount must be added to 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.

  18. Measure the oil slinger/selective shim with a micrometer to verify the oil slinger/selective shim thickness.
  19. Use a press and Pinion Bearing Cone Replacer ST  49 UN01 036 to press the pinion bearing until it is firmly seated on the pinion and pinion shim.
    Fig 10: Seating Pinion Bearing
    G03729723Courtesy of MAZDA MOTORS CORP.
  20. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 11: Placing New Drive Pinion Collapsible Spacer On Pinion Shaft
    G03729724Courtesy of MAZDA MOTORS CORP.
  21. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, inner pinion bearing, and drive pinion collapsible spacer) into the rear axle housing bore.
    Fig 12: Installing Drive Pinion Assembly
    G03729725Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.
  22. Install a new rear axle drive pinion seal.
    1. Install the outer pinion bearing.
    2. Install the rear axle drive pinion shaft oil slinger in the rear axle housing.
    3. Install the rear axle drive pinion seal on Pinion Seal Replacer ST  49 UN01 031.
      Fig 13: Installing Rear Axle Drive Pinion Seal
      G03729726Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Coat the lips of the seal with appropriate grease.
  23. Place Pinion Seal Replacer ST  49 M005 796 in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place.
    Fig 14: Installing Rear Axle Drive Pinion Seal
    G03729727Courtesy of MAZDA MOTORS CORP.
  24. Lubricate the rear companion flange splines with lubricant.
    NOTE:
    • Disregard the scribe marks if a new rear companion flange is being installed.
  25. Align the rear companion flange with the drive pinion shaft.
    Fig 15: Aligning Rear Companion Flange With Drive Pinion Shaft
    G03729728Courtesy of MAZDA MOTORS CORP.
  26. Install the rear companion flange using ST  205-002 or equivalent.
    Fig 16: Installing Rear Companion Flange
    G03729729Courtesy of MAZDA MOTORS CORP.
  27. Position the new pinion nut.
    Fig 17: Positioning New Pinion Nut
    G03729730Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.
  28. Use Coupling Holder ST  205-126 to hold the companion flange while tightening the pinion nut.
    Fig 18: Tightening Pinion Nut
    G03729731Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded.

    Pinion bearing preload (new pinion bearings)

    Tightening torque 

    1.8-3.3 N.m {18.4-34 kgf.cm, 16-29 in.lbf} 

    Pinion bearing preload (used pinion bearings)

    Tightening torque 

    0.9-1.5 N.m {9.1-15.3 kgf.cm, 8-14 in.lbf} 

  29. Install the differential case in the rear axle housing; See DIFFERENTIAL CASE REAR (STANDARD AND LIMITED SLIP) REMOVAL/INSTALLATION .
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