Differential: Overhaul Mazda RX-8 I рестайлинг

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 27

Roll Pin Disassembly Note

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

Scheme 28

Locknut Disassembly Note

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

Scheme 29

Companion Flange Disassembly Note

1. Remove the companion flange using the SST.

Scheme 30

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 31

Rear Bearing Disassembly Note

Scheme 32

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

Scheme 33

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

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.

Scheme 34

1. Assemble in the order indicated in the table.

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.

Scheme 35

Backlash of pinion gear and side gear

0.1 mm {0.004 in} or less

See WASHER THICKNESS SPECIFICATION .

WASHER THICKNESS SPECIFICATION

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 36

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 kg.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 37

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

Oil Seal (Side Gear) Assembly Note

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

Scheme 38

Rear Bearing Outer Race Assembly Note

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

Scheme 39

Front Bearing Outer Race Assembly Note

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

Scheme 40

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.

Scheme 41

Drive Pinion Component Assembly Note

Drive pinion preload adjustment

Note. Perform preload adjustment with the oil seal un-installed.

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 kg.m, 95-209 ft.lb} Differential drive pinion preload 1.3-1.7 N.m {14-17 kg.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.

Scheme 42

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 43

Scheme 44

1. Apply differential oil to the thread of a new locknut.
2. Tighten a new locknut with the torque recorded at the drive pinion preload adjustment using the SST .
3. 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 kg.cm, 12-15 in.lb}

Scheme 45

1. Stack the side bearing race and differential gear case component on the surface plate as shown in the figure, and measure the height using a caliper and a ruler. This is value A. Standard Height A 158.1-159.5 mm {6.224-6.280 in}
2. Measure the width of the indicated area of the differential gear case component installed in the differential carrier. This is value B. Standard width B 170.9-171.1 mm {6.729-6.736 in}

Scheme 46

Scheme 47

Scheme 48

Scheme 49

1. The combined thickness of the left and right adjustment shims is obtained by the following formula. Shim thickness (mm {in}) =B-A+ (0.01-0.03 {0.0004-0.0118 in})
2. If the combined thickness of the previously assembled adjustment shims is equal to the calculated thickness, use the shims as they are.
3. If the combined thickness of the previously assembled adjustment shims is not equal to the calculated thickness, or if the adjustment shims have to be replaced, select two appropriate adjustment shims from «ADJUSTMENT SHIM THICKNESS SPECIFICATION»(ref-367659-S30340110672010072700000) table below. ADJUSTMENT SHIM THICKNESS SPECIFICATION Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in}) 550 5.50 {0.217} 605 6.05 {0.238} 560 5.60 {0.220} 610 6.10 {0.240} 565 5.65 {0.222} 615 6.15 {0.242} 570 5.70 {0.224} 620 6.20 {0.244} 575 5.75 {0.226} 625 6.25 {0.246} 580 5.80 {0.228} 630 6.30 {0.248} 585 5.85 {0.230} 635 6.35 {0.250} 590 5.90 {0.232} 640 6.40 {0.252} 595 5.95 {0.234} 650 6.50 {0.256} 600 6.00 {0.236} - - NOTE: If the adjustment shims are to be reused, assemble the left and right shims that were identified during disassembly. When assembling the side bearing races, do not mix the left and right side bearings that were identified during disassembly.
4. Assemble the differential gear case component and the side bearing race to the differential carrier.
5. Tap the selected adjustment shim between the differential carrier and the side bearing race with a plastic hammer as shown in the figure.
6. Align the bearing cap alignment marks, assemble the bearing cap, and then temporarily tighten the bolts.
7. Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of one of the ring gear teeth.
8. Secure the drive pinion and measure the backlash of the ring gear. Backlash of drive gear and ring gear Standard: 0.09-0.11 mm {0.0035-0.0043 in} Minimum value: 0.05 mm {0.0020 in} or more Variance: 0.07 mm {0.0028 in} or less NOTE: Measure the backlash at 4 locations around the ring gear. Make sure all of the 4 locations are within specification, and the minimum value for the 4 locations is 0.05 mm {0.0020 in} or more and the variance is 0.07 mm {0.0028 in} or less
9. If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
10. Measure the ring gear preload between the backlash. Ring gear preload 0.49-2.45 N.m {5.0-24.9 kg.cm, 4.4-21.6 in.lb} NOTE: When moving the gear case component in the axial direction, replace the adjustment shims. If the adjustment shim on the right side is replaced with one that is 0.05 mm {0.0020 in} thicker, replace the one on the left with one that is 0.05 mm {0.0020 in} thinner.

Bearing Cap Assembly Note

1. Align the bearing cap alignment marks and assemble the bearing cap with the arrow facing outward. See figure below. Tightening torque 72.6-106.9 N.m {7.41-10.91 kg.m, 53.5-78.84 ft.lb}
2. Perform the drive pinion and ring gear tooth contact inspection.

Scheme 50

Scheme 51

Scheme 52

Scheme 53

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. 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.
4. 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.