Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Differential Carrier

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REMOVAL & INSTALLATION



Except 323 With 4WD and 1986-89 RX-7

See Figure 1

  1. Raise the vehicle and support it safely with jackstands.
  2.  
  3. Using wrench 49-0259-730 or equivalent, remove the differential drain plug and drain the lubricant from the differential. Install the plug after all of the fluid has drained. On the 929 this special tool is not required; use a socket to remove the drain plug.
  4.  
  5. Remove the axle shafts.
  6.  
  7. Remove the driveshaft.
  8.  
  9. Remove the carrier-to-differential housing retaining fasteners and remove the carrier assembly from the housing. On the 929, remove the fasteners which secure the differential assembly to the rear subframe and lower the unit to the floor.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the differential carrier

  1. Clean the carrier and axle housing mating surfaces.
  2.  
  3. If the differential originally used a gasket between the carrier and the differential housing, replace the gasket. If the unit had no gasket, apply a thin film of oil-resistant silicone sealer to the mating surfaces of both the carrier and the housing, then allow the sealer to set according to the manufacturer's instructions.
  4.  
  5. Place the carrier assembly onto the housing and install the carrier-to-housing fasteners. Torque the fasteners to 12-17 ft. lbs. (16-23 Nm). On the 929, torque the subframe fasteners to 69-86 ft. lbs. (93-117).
  6.  
  7. Install the driveshaft(s) and axle shafts as previously outlined.
  8.  
  9. Install the brake drums and wheels.
  10.  
  11. Fill the differential with the proper amount of SAE 80W-90 fluid (see the Capacities Chart in General Information & Maintenance ).
  12.  

323 With 4WD
  1. Drain the differential fluid into a suitable drain pan.
  2.  
  3. Remove the driveshaft.
  4.  
  5. Raise the rear of the vehicle and support safely.
  6.  
  7. Mark the relationship between the driveshaft and output flanges, then separate the driveshafts from the differential.
  8.  
  9. Have an assistant apply the brakes and remove the axle nut.
  10.  
  11. Disconnect the stabilizer from the crossmember.
  12.  


CAUTION
Never remove both ends of the stabilizer.

  1. Disconnect the lateral and trailing links.
  2.  
  3. Grasp the wheel hub by the rotor disc and pull it out until the driveshaft can be disconnected from the spline.
  4.  
  5. Support the differential with a jack and remove the mounting hardware from the front and rear attachment points. Lower the differential to the floor.
  6.  

To install:
  1. Raise the differential up into the frame, then install the front and rear fasteners. Torque the front fasteners to 33-50 ft. lbs. (45-68 Nm) and the rear fasteners to 80-97 ft. lbs. (108-131 Nm).
  2.  
  3. Insert the driveshaft spline into the wheel hub and align the matchmarks on the driveshaft with the output shaft. Install the flange fasteners and torque them to 36-43 ft. lbs. (49-58 Nm).
  4.  
  5. Connect the lateral link and torque the mounting bolt to 69-86 ft. lbs. (93-117). Connect the trailing link to the crossmember and torque the mounting bolt to 9-13 ft. lbs. (12-18 Nm).
  6.  
  7. Install the driveshaft and torque the flange bolts to 20-22 ft. lbs. (27-30 Nm).
  8.  
  9. Mount the wheels and lower the vehicle.
  10.  
  11. Fill the differential to the proper level (see Capacities Chart) and install the drain plug.
  12.  

1986-89 RX-7

See Figure 2

  1. Raise and safely support the rear of the vehicle.
  2.  
  3. Remove all necessary exhaust system components needed to gain removal clearance.
  4.  
  5. Drain the fluid from the differential.
  6.  
  7. Matchmark the relationship between the driveshaft and output flanges (no. 1 in the illustration).
  8.  
  9. Unbolt and separate the driveshafts (halfshafts) from each side of the differential. Support the driveshafts from the frame with a piece of rope so they will not interfere with the removal of the differential.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Differential assembly-1986-89 RX-7

  1. Matchmark and remove the driveshaft (no. 2 in the illustration).
  2.  
  3. Remove the mounting nut located at the left side of the differential support member, and allow the member to hang down.
  4.  
  5. Remove the sub-link fasteners.
  6.  
  7. Support the differential with a jack, then remove the differential carrier, case and member fasteners. Lower the differential from the vehicle.
  8.  

To install:
  1. Raise the differential assembly into position with the jack. Install the member, carrier and case fasteners. Torque the carrier fasteners to 65-77 ft. lbs. (91-104 Nm) and the case fasteners to 54-69 ft. lbs. (73-93 Nm). Torque the left member nut and the sub-link fasteners to 54-69 ft. lbs. (73-93 Nm).
  2.  
  3. Install the driveshaft and torque the bolts to 36-43 ft. lbs. (49-58 Nm).
  4.  
  5. Install the driveshafts and torque the flange bolts to 40-47 ft. lbs. (54-64 Nm).
  6.  
  7. Fill the differential to the proper level. Install and tighten the drain plug to 29-40 ft. lbs. (39-54 Nm).
  8.  
  9. Install all removed exhaust system components.
  10.  
  11. Lower the vehicle.
  12.  

 
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