Overhauling a gear set on a Mazda RX-7 can be a complex task, but I’ll break it down into simpler steps. click here for more details on the download manual…..
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The process involves disassembling the rear differential, inspecting and replacing worn parts, and reassembling it. Here’s a basic guide to help you understand the process:
### Tools and Materials Needed:
– Basic hand tools (wrenches, sockets, screwdrivers)
– Torque wrench
– Gear oil
– clean rags
– Replacement parts (bearings, seals, gears as needed)
– Differential rebuild kit (if available)
### Safety Precautions:
1. **Wear safety glasses and gloves** to protect your eyes and hands.
2. Make sure the vehicle is on a flat surface and securely lifted with jack stands if you are working under it.
### Step-by-Step Guide:
#### 1. **Preparation:**
– **Disconnect the Battery**: Always start by disconnecting the negative terminal of the battery to avoid any electrical issues.
– **Lift the Vehicle**: Use a jack to lift the rear of the car and secure it with jack stands.
– **Drain the Differential Fluid**: Place a drain pan under the differential and remove the drain plug to let the old fluid drain out.
#### 2. **Remove the Differential:**
– **Remove the Driveshaft**: Unbolt the driveshaft from the differential.
– **Disconnect Suspension Components**: Depending on the setup, you may need to disconnect some suspension components to gain access to the differential.
– **Unbolt the Differential**: Remove the bolts securing the differential to the rear axle housing. Once unbolted, carefully lower the differential.
#### 3. **Disassemble the Differential:**
– **Remove the Cover**: Take off the differential cover to expose the gears inside.
– **Inspect the Gears**: Look for any signs of wear or damage. If the gears are worn, they will need to be replaced.
– **Remove the Ring Gear and Pinion**: This may require special tools to set the correct backlash and ensure proper fitment of the new parts.
#### 4. **Inspect and Replace Parts:**
– **Check Bearings and Seals**: inspect the bearings for wear. Replace any worn or damaged bearings and seals.
– **Replace Gears if Needed**: If the ring and pinion gears are worn, replace them with new ones from a rebuild kit or OEM parts.
– **Clean All Parts**: Remove any old gasket material and clean all components thoroughly before reassembly.
#### 5. **Reassemble the Differential:**
– **Install New Bearings and Seals**: Press in new bearings and seals as necessary.
– **Reinstall the Pinion and Ring Gear**: Align and install the new or refurbished gears, ensuring proper backlash (this often requires precise adjustment).
– **Attach the Differential Cover**: Use a new gasket or sealant to ensure a good seal and bolt the cover back on.
#### 6. **Reinstall the Differential:**
– **Lift the Differential Back into Place**: Secure it with the original bolts.
– **Reconnect the Driveshaft**: Bolt it back to the differential.
– **Reattach Suspension Components**: If you disconnected any suspension parts, reconnect them now.
#### 7. **Fill with New Gear Oil:**
– **Add Gear Oil**: Refill the differential with the recommended type of gear oil through the fill hole until it reaches the proper level.
– **Replace the Fill Plug**: Make sure it is tight to prevent leaking.
#### 8. **Test the Vehicle:**
– **Reconnect the Battery**: Reattach the negative battery terminal.
– **Lower the Vehicle**: Carefully remove the jack s
tands and lower the car.
– **Take it for a Test Drive**: Drive the vehicle at low speeds to listen for any unusual noises and ensure everything is functioning properly.
### Final Thoughts:
This is a simplified overview of the process. Overhauling a gear set requires attention to detail, and it’s crucial to follow the manufacturer’s specifications for torque settings and adjustments. If you feel uncertain about any step, consult a professional mechanic or refer to a service manual specific to the Mazda RX-7 for more detailed instructions.
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