Differential Assembly Bearing Preload

Remove bearing outer race and adjustment shims from transaxle case. Ensure bearing race is installed in converter housing. Remove ring gear, differential cover, roll pin and short pinion shaft. Install differential cover. Mount differential into converter housing. Turn selector to eliminate gap between two halves. Install bearing race into selector. Mount selector gauge and bearing race on differential assembly. See Fig 1 .
Mount 6 Spacing Collars (49-FT01-384) on differential assembly. See Fig 2 . Mount transaxle case onto converter housing. Tighten bolts (49-G019-021 and 49-D019-001) to 28-38 ft. lbs. (37-52 N.m).
Turn selector halves "A" and "B" in a direction which widens the gap in selector. This will seat bearing race. Turn selector in opposite direction (reducing gap) until preload is eliminated.
Mount Preload Adapter (49-T027-001) into differential until in contacts pinion shaft. Measure preload with Preload Measurement Attachment (49-0180-510B) and torque wrench or pull scale. See Fig 3 . Read preload when differential starts to turn. Measure several times and calculate average value. Adjust clearance of selector to obtain specified preload reading. See DIFFERENTIAL BEARING PRELOAD SPECIFICATIONS table.

Measure clearance between "A" and "B" of selector gauge when specified preload is obtained. Measure clearance around entire circumference and select shims equal to maximum clearance measured. Add .012" (.30 mm) to measured clearance. Maximum of 3 shims may be used. Shims range in thickness from .004-.008" (.10-.20 mm) in increments of .001" (.02 mm). Additional shims are available in the following thicknesses: .020" (.50 mm), .028" (.70 mm) and .040" (1.0 mm).

DIFFERENTIAL BEARING PRELOAD SPECIFICATIONS

Measuring Tool		Specification
Torque Wrench
Start		4.4 INCH Lbs. (.5 N.m)
Final		27-35 INCH Lbs. (3.0-3.9 N.m)
Pull Scale
Start		1.1 Lbs. (.5 kg)
Final		6.6-8.8 Lbs. (3.0-4.0 kg)

Fig 1: Installing Selector Gauge On Differential

Courtesy of MAZDA MOTORS CORP.

Fig 2: Positioning Collars On Differential

Courtesy of MAZDA MOTORS CORP.

Fig 3: Measuring Differential Side Bearing Preload

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL BEARING SHIM

Application

Shim Thickness

GF4A-EL

⁽¹⁾⁽²⁾ .004-.008" (.10-.20 mm)

⁽¹⁾	In increments of .002" (.05 mm).

⁽²⁾	Additional shims are available in the following thicknesses: .020" (.50 mm), .028" (.70 mm) and .040" (1.0 mm).

Remove transaxle case and selector. Install the required amount of shims and press bearing race into transaxle case. Install bearing housing. Check differential bearing preload. See DIFFERENTIAL BEARING PRELOAD SPECIFICATIONS table. If preload is not within specification, repeat measuring and adjusting procedure (as necessary).
Remove differential cover. Install short pinion gear, roll pin, differential cover and ring gear. Tighten bolts to specification. See TORQUE SPECIFICATIONS .