Differential Assembly Mazda 3 BM

Differential Assembly

1. Assemble in the reverse order of disassembly.

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

1. Install the ring gear to the gear case.
2. Tighten the bolts evenly and gradually in the order shown, (bolt fixed type) Tightening torque 152-176.4 N.m {15.5-17.9 kgf.m, 112-130 ft.lbf} NOTE: If the gear case has been newly replaced perform Step (3).
3. Install the sensor rotor to the gear case using the SST and suitable plate.
4. Install a new bearing. Press the new bearing (sensor rotor side) onto the gear case using the SST. Press on the other new bearing (ring gear side) in the same manner.
5. Apply ATF to the thrust washers and pinion shaft.
6. Install the pinion gear and thrust washers into the gear case.
7. Install the pinion shaft.
8. Install the roll pin, and crimp it to prevent it from coming out of the gear case.
9. Apply ATF to the thrust washers.
10. Install the thrust washers and side gears into the gear case, then turn the side gears and align them with the drive shaft holes.
11. Measure the backlash of the side gears as follows: Install the left and right drive shafts in the differential Support the drive shafts on V-blocks. Measure the backlash of both side gears. Differential backlash Standard: 0.05-0.15 mm {0.002-0.005 in} Maximum: 0.5 mm {0.020 in} If not as specified, replace the differential.

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

1. Remove the bearing race and adjustment shim from the converter housing using the SST .
2. Install the bearing race into the transaxle case.
3. Set the differential on the transaxle case.
4. Install the bearing race removed in Step 1 into the SST .
5. Set the differential on the SST (selector).
6. Turn the selector to eliminate the gap between its two halves.
7. Set the six SSTs (collars) on the transaxle case in the position shown.
8. Set the converter housing on the transaxle case and tighten the SSTs (bolts) to the specified torque. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
9. Turn the SST (selector) to increase the clearance (arrow) using the SSTs (bars), until it no longer turns. This is to seat the bearing race.
10. Turn the selector in the opposite direction until the preload is eliminated (gap is reduced).
11. Insert the SST through the converter housing and attach it to the pinion shaft.
12. Install the SST and a pull scale or torque wrench. NOTE: Read the preload when the differential starts to turn. Measure several times and calculate the average value.
13. Adjust the clearance of the SST (selector) to obtain the specified preload/pull scale reading. Differential bearing Preload Preload: 1.4-2.3 N.m {14-24 kgf.cm, 12-20 in lbf} Reading on pull scale: 14-23 N {1.4-2.4 kgf, 3.1-5.3 lbf} NOTE: Measure the clearance around the entire circumference, and select a shim based on the maximum clearance. The maximum allowable number of adjustment shim is one.
14. Measure the clearance as shown.
15. Take the maximum reading and determine the shim to be used. Differential preload adjust shims (mm {in}) DIFFERENTIAL PRELOAD SPECIFICATIONS 0.50 {0.020} 0.55 {0.022} 0.60 {0.024} 0.65 {0.026} 0.70 {0.028} 0.75 {0.030} 0.80 {0.031} 0.85 {0.033} 0.90 {0.035} 0.95 {0.037} 1.00 {0.039} 1.05 {0.041} 1.10 {0.043} 1.15 {0.045} 1.20 {0.047} 1.25 {0.049} 1.30 {0.051} 1.35 {0.053} 1.40 {0.055} 1.45 {0.057} 1.50 {0.059} 1.55 {0.061}
16. Remove the converter housing and SST (selector).
17. Install the required adjustment shim and tap the bearing race into the converter housing.
18. Install the converter housing. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
19. Install the SST to the pinion shaft through the converter housing. NOTE: Measure several times and calculate the average value.
20. Verify that the preload is within the specification. If not, return to Step 1. Differential bearing Preload Preload: 1.4-2.3 N.m {14-24 kgf.cm, 12-20 in.lbf} Reading on pull scale: 14-23 N {1.4-2.4 kgf, 3.1-5.3 lbf}
21. Remove the converter housing.