Differential: Overhaul Mazda RX-8 I

Bearing Cap Disassembly Note

1. Mark the bearing cap and differential carrier for proper installation.

Scheme 18

Scheme 19

Scheme 20

1. Remove the adjustment shim using a flathead screwdriver.
2. Put left and right identification marks on the removed adjustment shims and side bearing outer races.

Side Bearing Disassembly Note

1. Remove the side bearing using the SST.
2. Put left and right identification marks on the removed side bearings.

Scheme 21

Roll Pin Disassembly Note

1. Tap the roll pin out from the direction shown in the figure using a pin punch.

Scheme 22

Locknut Disassembly Note

1. Remove the locknut while fixing the companion flange using the SST.

Scheme 23

Companion Flange Disassembly Note

1. Remove the companion flange using the SST.

Scheme 24

Drive Pinion Component Disassembly Note

1. Install the removed locknut to the drive pinion top to prevent damage to the thread.
2. Remove the drive pinion component by tapping the locknut lightly using a plastic hammer.
3. Remove the locknut installed in Step 1 .

Scheme 25

Rear Bearing Disassembly Note

1. Remove the rear bearing using the SST and a press.

Scheme 26

Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note

1. Remove the bearing outer race by lightly tapping the edge of the bearing outer race using a flathead screwdriver.

Scheme 27

Note. Clean away the old silicone sealant before applying the new silicone sealant. Install the rear cover within 10 min after applying the silicone sealant. Allow the sealant to set at least 30 min or more after installation before filling the differential with differential oil.

1. Assemble in the order indicated. (Scheme 28)

Scheme 28

Washer Assembly Note

1. Assemble the side gear, thrust washer, pinion gear, and the pinion shaft to the gear case.
2. Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of one of the pinion gear teeth.
3. Fix either one of the side gears.
4. Move the pinion gear and measure the backlash at the pinion gear top. If it is not within the specification, adjust by choosing the proper washer.

Standard

0.03-0.15 mm (0.001-0.005 in) (MT)

0.1 mm (0.004 in) or less (AT)

Washers (MT)

Washers (AT)

Scheme 29

Scheme 30

Roll Pin Assembly Note

1. Align the differential gear case and pinion shaft pin holes.
2. Tap the roll pin in using a pin punch.

Ring Gear Assembly Note

Scheme 31

1. Apply a small amount of thread-locking compound to each of points A on the back of the ring gear, and bolt thread areas B (around the entire ring). Application thickness Back of ring gear points A: Approx. 0.4 cm 3 (0.4 cc, 0.024 cu in) (1 location approx. 0.04 cm 3 (0.04 cc, 0.0024 cu in) Ring gear bolt thread points B: Approx. 0.4 cm 3 (0.4 cc, 0.024 cu in) (1 location approx. 0.04 cm 3 (0.04 cc, 0.0024 cu in)
2. Install the ring gear to the differential gear case and tighten the bolts in a criss-cross pattern.

Tightening torque

68.6-83.3 N.m

(7.00-8.49 kgf.m, 50.6-61.4 ft.lb)

Side Bearing Assembly Note

Note. When assembling the side bearings, do not mix the left and right side bearings that were identified during disassembly.

Scheme 32

1. Press the side bearing in using the SST and a press.

Scheme 33

1. Apply differential oil to the lip of a new oil seal.
2. Assemble the oil seal using the SSTs.

Rear Bearing Outer Race Assembly Note

1. Press the rear bearing outer race into the differential carrier using the SST and a press.

Scheme 34

Front Bearing Outer Race Assembly Note

1. Press the front bearing outer race into the differential carrier using the SST and a press.

Spacer Assembly Note

Pinion height adjustment

Note. Use the installed spacer when adjusting. Install the spacer with the chamfer on the SST side.

Scheme 35

Scheme 36

Scheme 37

1. Assemble the spacer, bearing inner race (rear side), and the SST (O-ring) to the SST (49 8531565) as shown in the figure.
2. Insert the set assembled in Step 1 from the rear side of the differential carrier.
3. Assemble the SST (49 8531 567), front bearing, companion flange, and a washer from the front side of the differential carrier.
4. Tighten the locknut to the extent that the SST (49 8531 565) can be turned by hand.
5. Place the SST (49 8531 565) on top of the SST (49 0660 555).
6. Place the SST on the surface plate and set the dial gauge to zero.
7. Set the SSTs as shown in the figure.
8. Place the measuring probe of the dial gauge at the point where the side bearing is installed in the differential carrier and measure at the lowest position. Measure the left and right sides.
9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total by 2. From this sum, subtract the sum of the number inscribed on the end of the drive pinion divided by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value.

Pinion height standard

0.038 mm (0.0015 in) or less

Note. When the values obtained by the measurements taken in Step 8 , 9 are 0.06 mm (0.0024 in), 0.04 mm (0.0016 in) and the tip surface of the drive pinion value is 2, the formula is ((0.06+0.04)/2) - (2/100) = 0.03. Therefore, assemble a spacer 0.03 mm (0.0012) thicker than the currently assembled one. The thickness settings are in increments of 0.015 mm (0.0006), so choose one closest in thickness and install.

Scheme 38

Scheme 39

Rear Bearing Assembly Note

Note. Install the spacer with the chamfer on the gear side.

1. Assemble the spacer selected in the pinion height adjustment to the drive pinion.
2. Press the drive pinion into the rear bearing using the SSTs and a press.

Drive Pinion Component Assembly Note

Drive pinion preload adjustment

Note. Perform preload adjustment with the oil seal uninstalled.

1. Assemble the following parts to the drive pinion. New collapsible spacer Front bearing New spacer Companion flange New washer New locknut
2. Turn the serrated part of the drive pinion by hand to seat the bearing.
3. Tighten the locknut temporarily tightened in Step 1 from the lower limit of the specified tightening torque using the SST, and obtain the specified preload. Record the tightening torque at this time. Tightening torque 128-284 N.m (13-29 kgf.m, 95-209 ft.lb) Drive pinion preload 1.3-1.7 N.m (14-17 kgf.cm, 12-15 in.lb) If the specified preload cannot be obtained within the specified tightening torque, replace with a new collapsible spacer and adjust again.
4. Remove the locknut, washer, and companion flange.

Oil Seal (Companion Flange) Assembly Note

1. Apply differential oil to the lip of a new oil seal.
2. Assemble the oil seal using the SST.

Scheme 40

Scheme 41

Scheme 42

1. Tighten a new locknut with the torque recorded at the drive pinion preload adjustment using the SST.
2. Verify that the drive pinion preload is within the specification. If not within the specification, perform the preload adjustment again.

Drive pinion preload

1.3-1.7 N.m (14-17 kgf.cm, 12-15 in.lb)

Bearing Cap Assembly Note

1. Align the bearing cap alignment marks and assemble the bearing cap with the arrow facing outward. Tightening torque 72.6-106.9 N.m (7.41-10.91 kgf.m, 53.5-78.84 ft.lb)
2. Perform the drive pinion and ring gear tooth connect inspection.

Scheme 43

Scheme 44

Scheme 45

1. Apply tooth marking compound evenly to both surfaces of the ring gear.
2. Rotate the ring gear back and forth for several times.
3. Inspect the tooth contact pattern in 4 locations around the ring gear, and verify that the tooth contact points exhibit the pattern shown in the figure. If the tooth contact points are normal, wipe off the marking compound. If the tooth contact points are not normal, adjust the pinion height, then adjust the backlash.
4. If the toe and flank contact points appear as shown in the figure after the drive pinion and ring gear teeth contact inspection, replace the spacer with a thinner one, and move the drive pinion outward.
5. If the heel and face contact points appear as shown in the figure after the drive pinion and ring gear teeth contact inspection, replace the spacer with a thicker one, and move the drive pinion inward.

Scheme 46