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Differential Assembly: Assembly

WARNING: This page is about a different car, the 2001 Mazda Tribute. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: A new oil baffle must be installed located between inner drive pinion bearing cup and axle housing bore.
  1. Apply dry film lubricant to drive pinion bearing cup bore. Using a Cup Replacer (205-054), install a new oil baffle, inner and outer drive pinion bearing cups. Install Gauge Block (205-110), Gauge Disc (205-204), Aligning Adapter (205-104), Screw (205-109), Handle (205-111) and inner and outer drive pinion bearings. Preload drive pinion bearings to 27 INCH lbs. (3 N.m).
  2. Gauge block must be offset to obtain an accurate reading. Rotate gauge several half turns to correctly seat drive pinion bearing. Position gauge 45 degrees. SeeFig 1 .
    NOTE: If drive pinion is marked with a plus (+) reading, this amount must be subtracted from thickness measured. If drive pinion is marked with a minus (-) reading, this amount must be added to thickness measured.
  3. Position Gauge Tube (205-108), bearing caps and install bolts. Measure and record clearance between gauge tube and gauge block. select and check correct drive pinion position shim, as necessary. Position Axle Bearing/Seal Plate (205-090) and Pinion Bearing Replacer (205-011), drive pinion position shim and drive pinion bearing. Using a press, firmly seat drive pinion bearing on drive pinion. Install NEW collapsible spacer.
    NOTE: When tightening drive pinion nut to remove initial end play, torque may exceed maximum specification. Once end play is removed and collapsible spacer has started to collapse, torque should drop into specific range.
  4. Using a Nut Remover (205-503) and Socket Drive Pinion Nut (205-175), install drive pinion and a new drive pinion nut. Rotate drive pinion counterclockwise until all end play is removed then tighten drive pinion nut.
    CAUTION: If rotational torque is less than specification, tighten drive pinion nut in small increments until it is within specification. Do not tighten drive pinion nut more than 50 ft. lbs. (68 N.m) or collapsible spacer will be damaged. If rotation torque is higher than specification, collapsible spacer has been compressed too far and a new collapsible spacer must be installed.
  5. Rotate drive pinion 10 revolutions before taking a reading. Check drive pinion rotational torque and adjust as necessary. Differential case should move freely in axle housing. Using Master Bearing Set (205-207A), install differential case into axle housing. Seat differential case away from drive pinion then push differential case towards drive pinion while measuring and recording differential case total end play. Repeat until a same reading is obtained twice.
    NOTE: Take note which side each master bearing set was removed from so they can be installed on same side of differential case for next measurement with ring gear installed.
    NOTE: If reusing original pinion gears, side gears or thrust washers, install in same locations that they were removed.
  6. Remove differential case and master bearing set. Apply SAE 80W-90 High Performance Rear Axle Lubricant (F1TZ-19580-B) or equivalent meeting Mazda specification (WSP-M2C197-A) to pinion gears, side gears and thrust washers. Install side gears and side gear thrust washers. Rotate pinion gears and pinion gear thrust washers to differential pinion shaft hole in differential case.
  7. Install differential pinion shaft and lock pin. Install ring gear. Install new ring gear bolts in an alternately and evenly pattern. Install master bearing set on same ends of differential case as they were previously installed. Install differential case into axle housing. Seat differential case away from drive pinion then push differential case towards drive pinion while measuring and recording differential case total end play. Repeat until a same reading is obtained twice. Remove differential case and tools.
    NOTE: If master bearing set does not measure .714" (18.136 mm) +/- .001" (.025 mm), the numbers in step 8) will be overstated by difference measured on each master bearing set. Adjustments to shim pack will have to be made in order to prevent bearing pre-loads from becoming excessive. Measure width of master bearing set used on ends of differential case and select differential case bearing shims as necessary.
  8. Calculate for differential case bearing shims by subtracting total differential case end play with ring gear installed from total differential case end play without ring gear installed.
  9. Total shims necessary for ring gear side of differential case is total differential case end play with ring gear installed plus .003" (.076 mm).
  10. Total shims necessary for opposite side of ring gear of differential case is step 8) plus .01" (.25 mm). Using a Differential Bearing Replacer (205-206) and a Handle (205-153), install differential case bearings and correct shims. Using a differential housing spreader and differential carrier spreader, spread axle housing. Install differential case. Remove Tools.
  11. Install bearing caps in same location as removal. Install bolts. Ring gear backlash should be measured at three equally spaced points on ring gear. If reading is high, ring gears must be moved closer to drive pinion by moving shims to ring gear side from opposite side. If reading are low, ring gear must be moved away from drive pinion by moving shims from ring gear side to opposite side.
  12. Position axle assembly with drive pinion stem facing upward. Measure and record total turning torque to rotate drive pinion and adjust as necessary. Total turning torque should be drive pinion rotational torque plus 6-10 INCH lbs. (.68-1.13 N.m). If total turning torque is too high, subtract an equal amount of shims from each side of differential case. If total turning torque is too low, add an equal amount of shims to both sides of differential case.
  13. Lubricate needle bearings with Premium Long-Life Grease (XG-1-C) or equivalent meeting Ford specification (ESA-M1C75-B). Using Axle Bearing Replacer (205-195), Axle Seal Replacer (205-350) and Handle (205-153), install halfshaft bearings and seals. Torque nuts and bolts to specifications. SeeTORQUE SPECIFICATIONS  .
Fig 1: Positioning Of Drive Pinion Bearings
G00034134Courtesy of MAZDA
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