Case Assembly - Mazda 1983 RX7 Service Manual

friction plate, friction disc, pressure ring, side gear, pinion gear
and spider. Keep parts in order for reassembly. See Fig. 1.
5) On conventional differentials, drive out differential
pinion shaft lock pin with a punch and remove pinion shaft. Rotate
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pinion gears 90
equipped) and differential side gears.
6) Remove pinion nut and pinion flange. Remove drive pinion
and rear bearing assembly, adjusting shims (if equipped), spacer and
bearing collar (if used). Remove front oil seal and withdraw front
pinion bearing.
7) Using a press, remove rear bearing from drive pinion,
then lift off pinion adjusting shim. If necessary for replacement,
use a drift punch and remove pinion bearing races from carrier.
8) Inspect all parts for chipped or worn teeth, damaged
bearing journals, cracks, flaking or any damage. Replace defective
parts as necessary.
NOTE: It may be necessary to tap end of pinion with a soft hammer
to remove from carrier.
REASSEMBLY & ADJUSTMENT

Case Assembly

1) Install a thrust washer on each differential side gear
and install into case. Through openings in gear case, insert pinion
gears exactly 180
holes in gears line up with pinion shaft holes in gear case. Insert
pinion shaft through case and pinion gears.
2) On limited slip differential, install parts in the
following order: Thrust washer, conical spring, friction plate,
friction disc, friction plate, friction disc and pressure ring. See
Fig. 1.
3) Check backlash between side gears and pinion gears.
Backlash should be less than .008" (.2 mm) on Pickups and less than
.004" (.1 mm) on all other models. If not, install selective thrust
washers to bring backlash within specifications.
NOTE: Always use same thickness thrust washer for both side gears.
4) If equipped with thrust block, remove pinion shaft,
install thrust block and reinstall pinion shaft. On all models,
install lock pin into case to secure pinion shaft. Using a punch,
stake lock pin hole to prevent pin from working loose.
5) On all models, mount ring gear on case, then install and
tighten ring gear attaching bolts. If removed, install differential
side bearings.
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and remove gears, thrust washer, thrust block (if
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opposite each other. Rotate pinion gears 90
DRIVE AXLE
Article Text (p. 4)
1983 Mazda RX7
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