Rear Cover Assembly Note

WARNING: This page is about a different car, the 2016 Mazda CX-5. However, it is still accessible from the selected car via links, so may be relevant.

Clean the alignment surface of the carrier and rear cove.
Apply pressure to the case using a press and install the rear cover using the SSTs (49 B032 335A) as shown in the figure.

Fig 1: Applying Pressure To Case Using Press
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Do not apply pressure of 2 t or more.
Install the bolts with the specified torque as shown in the figure.

Fig 2: Identifying Rear Cover Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the commercially-available tool (vise clamp) to the drive pinion shaft and measure 100 mm {3.94 in} of backlash from the center of the shaft axle.

Fig 3: Measuring Shaft Axle Backlash Dimension
Courtesy of MAZDA MOTORS CORP.

Rear differential backlash of drive pinion and ring gear
- Standard: 0.13-0.21 mm {0.0052-0.0082 in}
- Minimum value: 0.07 mm {0.003 in}
If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
NOTE:
- When moving the gear case component in the axial direction, replace the adjusting shims. If the adjusting shim on the right side is replaced with one that is 0.05 mm {0.002 in} thicker, replace the one on the left with one that is 0.05 mm {0.002 in} thinner.
Inspect the drive pinion and ring gear teeth contact points.

Fig 4: Identifying Drive Pinion And Ring Gear Teeth Contact Points
Courtesy of MAZDA MOTORS CORP.
1. Coat both surfaces of the ring gear uniformly with a thin red lead coating.
2. While rotating the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact.
3. Inspect the tooth contacts in four locations around the ring gear, and check that the tooth contacts showing the red lead coating are the same as the pattern indicated in the figure.
  - If the tooth contact is good, wipe off the red lead coating.
  - If it is not good, adjust the pinion height, then adjust the backlash.
4. If toe and flank contact appears as shown in the figure, replace the spacer with a thinner one, and move the drive pinion outward.
  
  Fig 5: Identifying Toe And Flank Contact Surfaces
  Courtesy of MAZDA MOTORS CORP.
5. If heel and face contact appears as indicated in the figure, replace the spacer with a thicker one and move the drive the pinion inward.
Fig 6: Identifying Heel And Face Contact Surfaces
Courtesy of MAZDA MOTORS CORP.
If the backlash is within the specification and the tooth contact is correct, install the rear cover.
CAUTION:
- Clean away the old sealant before applying the new sealant.
- Install the rear cover before the applied sealant starts to harden.
- Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil.
Clean the alignment surface of the carrier and rear cover, and apply a thin coat of sealant (TB1217C or equivalent).
Apply pressure to the case using a press and install the rear cover using the SSTs (49 B032 335A) as shown in the figure.

Fig 7: Applying Pressure To Case Using Press
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Do not apply pressure of 2 t or more.
Install the bolts with the specified torque as shown in the figure.

Fig 8: Identifying Rear Cover Case Bolts With Torque Specifications

Courtesy of MAZDA MOTORS CORP.