Thrust Washers (Standard) Assembly Note

WARNING: This page is about a different car, the 2004 Mazda MX-5 Miata. However, it is still accessible from the selected car via links, so may be relevant.

Adjust the backlash of the side gears and pinion gear as follows.
1. Set a dial gauge against the pinion gear as shown.
2. Move the pinion gear, and measure the backlash at the end of it.
3. Secure one of the side gears.
  1. Standard backlash 0-0.1 mm {0-0.004 in}
  Fig 1: Measuring Backlash
  Courtesy of MAZDA MOTORS CORP.
4. If the backlash exceeds the standard, use the selectable thrust washers for adjustment.
  Thrust Washer thickness
  
  Fig 2: Thrust Washer Thickness Table
  Courtesy of MAZDA MOTORS CORP.
Install the new knock pin to secure the pinion shaft. Stake the pin with a punch to prevent it from coming out of the case.

Fig 3: Staking Knock Pin With A Punch
Courtesy of MAZDA MOTORS CORP.
Apply thread-locking compound to bolt threads A and points B of the gear back face. Apply approximately 0.04 cm ³ {0.04 cc, 0.0024 cu in} of thread-locking compound at each point and bolt thread.
Install the ring gear onto the gear case.
1. Tightening torque 69-83 N.m {7.0-8.5 kgf.m, 51-61 ft.lbf}
Fig 4: Applying Thread-Locking Compound To Bolt Threads A And Points B Of The Gear Back Face
Courtesy of MAZDA MOTORS CORP.
Press the bearing inner races (side bearing) on using the SST .
Install the differential gear component in the carrier.
Note the identification marks on the adjusting nuts, and install them on their respective sides.

Fig 5: Pressing The Bearing Inner Races (Side Bearing) On
Courtesy of MAZDA MOTORS CORP.
Install the differential bearing caps, making sure that the identification mark on the cap corresponds with the one on the carrier, using the SST. Then temporarily tighten the bolts.
1. Mark the ring gear at four points at approx. 90° intervals. Mount a dial indicator to the carrier so that the feeler comes in contact at a right angle with 1 of the ring gear teeth.
2. Turn both bearing adjusters equally using the SST until the backlash is 0.09-0.11 mm {0.0035-0.0043 in}.
3. Inspect for the backlash at the 3 other marked points, and make sure the maximum backlash is less than 0.07 mm {0.0028 in} .
  
  Fig 6: Checking Backlash
  Courtesy of MAZDA MOTORS CORP.
Tighten or loosen the adjusting nuts equally until the distance between the pilot sections on the bearing caps is 185.428-185.500 mm {7.3003-7.3031 in}.

Fig 7: Measuring Backlash At 4 Points
Courtesy of MAZDA MOTORS CORP.
Reinspect for the backlash.

Fig 8: Measuring Distance Between The Pilot Sections On The Bearing Caps
Courtesy of MAZDA MOTORS CORP.
Inspect the teeth contact as follows.
1. Coat both surfaces of 6-8 teeth of the ring gear with a thin coat of red lead.
2. While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact.
3. If the tooth contact is good, wipe off the red lead.
4. If it is not good, adjust the pinion height, and then adjust the backlash.
  
  Fig 9: Locating Good Contact & Red Lead
  Courtesy of MAZDA MOTORS CORP.
1. Inspect the toe and flank contact by replacing the spacer with a thinner one to move the drive pinion outward.
  
  Fig 10: Locating Toe Contact & Flank Contact
  Courtesy of MAZDA MOTORS CORP.
2. Inspect the heel and face contact by replacing the spacer with a thicker one to bring the drive pinion in.
  
  Fig 11: Locating Heel Contact & Face Contact
  Courtesy of MAZDA MOTORS CORP.