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Adjusting Shim Assembly Note

  1. Assemble the differential carrier to the SSTs.
  2. Assemble the spacer to the differential carrier.
  3. Using a vernier caliper and straight edge, measure the height of the rear differential component. This is dimension A.
    G13558052Courtesy of MAZDA MOTORS CORP.
  4. Measure the width of the installed differential in the differential carrier with the spacer installed. This is value B.
    G13558053Courtesy of MAZDA MOTORS CORP.
  5. The combined thickness of the left and right adjusting shims is obtained by the following formula.

    C1 = B - A + 0.110 mm {0.00433 in}C2 = B - A + 0.200 mm {0.00787 in}

  6. If the combined thickness of the previously installed adjusting shims is between C1 and C2, use the shims as they are.
  7. If the combined thickness of the previously installed adjusting shims is not between C1 and C2, or if the adjusting shims have to be replaced, select two appropriate adjusting shims from the table below.
    ADJUSTING SHIM THICKNESS SPECIFICATION

    Identification mark Thickness (mm {IN}) Identification mark Thickness (mm {IN})
    339 3.39 {0.133} 393 3.93 {0.155}
    342 3.42 {0.135} 396 3.96 {0.156}
    345 3.45 {0.136} 399 3.99 {0.157}
    348 3.48 {0.13} 402 4.02 {0.158}
    351 3.51 {0.138} 405 4.05 {0.159}
    354 3.54 {0.139} 408 4.08 {0.161}
    357 3.57 {0.141} 411 4.11 {0.162}
    360 3.60 {0.142} 414 4.14 {0.163}
    363 3.63 {0.143} 417 4.17 {0.164}
    366 3.66 {0.144} 420 4.20 {0.165}
    369 3.69 {0.145} 423 4.23 {0.167}
    372 3.72 {0.146} 426 4.26 {0.168}
    375 3.75 {0.148} 429 4.29 {0.169}
    378 3.78 {0.149} 432 4.32 {0.170}
    381 3.81 {0.150} 435 4.35 {0.171}
    384 3.84 {0.151} 438 4.38 {0.172}
    387 3.87 {0.152} 441 4.41 {0.174}
    390 3.90 {0.154} - -
    CAUTION:
    • If adjusting shims are to be reused, do not mix up the left and right shims.
    • Do not mix up the left and right side bearing outer races and spacers.
  8. Assemble the rear differential component to the differential carrier.
  9. Tap the selected adjusting shim between the spacer and the bearing race with a plastic hammer.
  10. Perform the ring gear and drive pinion backlash adjustment.
    NOTE:
    • Install the SST so that it does not contact the ring gear.
    G11427079Courtesy of MAZDA MOTORS CORP.
    1. Install the SST and dial gauge to the differential carrier using a vise as shown in the figure.
      G11427080Courtesy of MAZDA MOTORS CORP.

      SST tightening torque 

      5.0 N.m {51 kgf.cm, 44 in.lbf}

      NOTE:
      • Measure the backlash at 4 locations around the ring gear. Make sure that 1 of the 4 locations is within the standard, and the minimum value for the 4 locations is 0.05 mm {0.002 in}in or more and the variance is 0.07 mm {0.003 in} or less.
      G13558056Courtesy of MAZDA MOTORS CORP.
    2. Secure the drive pinion and measure the backlash from when the ring gear is moved.

      Drive pinion and ring gear backlash 

      Standard: 0.09-0.14 mm {0.004-0.005 in}

      Minimum: 0.05 mm {0.002 in} or more

      Variance: 0.07 mm {0.003 in} or less

      • If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
    NOTE:
    • When moving the gear case component in the axial direction, replace the adjusting shims. If the adjusting shim on the right side is replaced with one that is 0.03 mm {0.001 in} thicker, replace the one on the left with one that is 0.03 mm {0.001 in} thinner.
    ADJUSTING SHIM THICKNESS SPECIFICATION

    Identification mark Thickness (mm {IN}) Identification mark Thickness (mm {IN})
    339 3.39 {0.133} 393 3.93 {0.155}
    342 3.42 {0.135} 396 3.96 {0.156}
    345 3.45 {0.136} 399 3.99 {0.157}
    348 3.48 {0.13} 402 4.02 {0.158}
    351 3.51 {0.138} 405 4.05 {0.159}
    354 3.54 {0.139} 408 4.08 {0.161}
    357 3.57 {0.141} 411 4.11 {0.162}
    360 3.60 {0.142} 414 4.14 {0.163}
    363 3.63 {0.143} 417 4.17 {0.164}
    366 3.66 {0.144} 420 4.20 {0.165}
    369 3.69 {0.145} 423 4.23 {0.167}
    372 3.72 {0.146} 426 4.26 {0.168}
    375 3.75 {0.148} 429 4.29 {0.169}
    378 3.78 {0.149} 432 4.32 {0.170}
    381 3.81 {0.150} 435 4.35 {0.171}
    384 3.84 {0.151} 438 4.38 {0.172}
    387 3.87 {0.152} 441 4.41 {0.174}
    390 3.90 {0.154} - -
  11. Inspect the drive pinion and ring gear teeth contact points.
    1. Coat both surfaces of the ring gear uniformly with a thin red lead coating.
    2. While rotating the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact.
    3. Inspect the tooth contacts in four locations around the ring gear, and check that the tooth contacts showing the red lead coating are the same as the pattern indicated in the figure.
    • If the tooth contact is good, wipe off the red lead coating.
    • If it is not good, adjust the pinion height, then adjust the backlash.
    G13558057Courtesy of MAZDA MOTORS CORP.
    • If toe and flank contact appears as shown in the figure, replace the spacer with a thinner one, and move the drive pinion outward.
    G13558058Courtesy of MAZDA MOTORS CORP.
    • If heel and face contact appears as indicated in the figure, replace the spacer with a thicker one and move the drive the pinion inward.
    G13558059Courtesy of MAZDA MOTORS CORP.
    SPACER THICKNESS SPECIFICATION

    Identification mark Thickness (mm {IN}) Identification mark Thickness (mm {IN})
    08 3.08 {0.1213} 29 3.29 {0.1295}
    09 3.095 {0.1219} 30 3.305 {0.1301}
    11 3.11 {0.1224} 32 3.32 {0.1307}
    12 3.125 {0.1230} 33 3.335 {0.1313}
    14 3.14 {0.1236} 35 3.35 {0.1319}
    15 3.155 {0.1242} 36 3.365 {0.1325}
    17 3.17 {0.1248} 38 3.38 {0.1331}
    18 3.185 {0.1254} 39 3.395 {0.1337}
    20 3.20 {0.1260} 41 3.41 {0.1343}
    21 3.215 {0.1266} 42 3.425 {0.1348}
    23 3.23 {0.1272} 44 3.44 {0.1354}
    24 3.245 {0.1278} 45 3.455 {0.1360}
    26 3.26 {0.1283} 47 3.47 {0.1366}
    27 3.275 {0.1289} - -
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