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Differential Assembly: Reassembly

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  1. On bolt fixed type differentials, install ring gear to gear case. Tighten bolts evenly and gradually in sequence. See Fig 1.
  2. On all differentials, install sensor rotor using Support Block (49 S231 626) and a suitable plate. Using press and appropriate adapter, install bearings. Apply ATF to thrust washers and pinion shaft and install thrust washers and pinion gears.
  3. Install pinion shaft. Install and crimp roll pin. Apply ATF to thrust washer and install thrust washers and side gears into the gear case, aligning with drive shaft holes.
  4. Measure backlash of the side gears as follows:
    • Install left and right drive shafts in the differential.
    • Support drive shafts on V-blocks. Measure backlash of both side gears. Backlash should be 0.002-0.005" (0.05-0.15 mm). Maximum backlash is 0.020" (0.5 mm). If backlash is not within specification, replace the differential.
Fig 1: Identifying Ring Gear Bolt Tightening Sequence
G00380246Courtesy of MAZDA MOTORS CORP.
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