Overhauling a gear set on a Mazda 3 Speed3, or any vehicle for that matter, is a complex task that requires a good understanding of mechanical principles, the right tools, and a suitable workspace. click here for more details on the download manual…..
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Below is a detailed guide on how to perform this task, from preparation to completion.
### Components Required
1. **Tools Needed**:
– Socket set (metric)
– Torque wrench
– Screwdrivers (flathead and Phillips)
– Pliers
– Hammer
– Gear pullers
– Ring compressor
– Precision measuring tools (calipers, micrometers)
– Cleaning supplies (brake cleaner, lint-free cloths)
– Lubricant (gear oil)
– Gasket maker or new gaskets
2. **Replacement Parts**:
– New gear set (ring and pinion)
– Bearings (differential and pinion bearings)
– Seals (input and output shaft seals)
– Shims (if required for proper backlash)
– Differential cover gasket or silicone sealant
3. **Safety Equipment**:
– Safety goggles
– Gloves
– Mechanic’s mat
### Preparation
1. **Workspace**: Ensure you have a clean, well-lit, and organized workspace with plenty of room to maneuver. A garage with a concrete floor is ideal.
2. **Vehicle Preparation**:
– Park the vehicle on a level surface and engage the parking brake.
– Disconnect the battery to avoid any electrical issues.
3. **Lifting the Vehicle**:
– Use a hydraulic jack to lift the rear (or front, depending on the vehicle setup) of the vehicle and secure it with jack stands.
### Disassembly
1. **Remove the Driveshaft**:
– Unbolt the driveshaft from the differential. You may need to remove the exhaust or any heat shields obstructing access.
– slide the driveshaft out of the differential.
2. **Remove the Differential Cover**:
– Unbolt the differential cover using a socket.
– Carefully pry off the cover. If it’s stuck, gently tap it with a hammer to break the seal.
– Drain the old gear oil into a pan.
3. **Remove the Differential Assembly**:
– Note how the differential is set up (take pictures for reference).
– Remove the ring gear bolts and take off the ring gear.
– Use a gear puller to remove the differential from the housing.
4. **Remove the Pinion Gear**:
– Unbolt the pinion gear from the housing.
– Remove the pinion bearing and seal. Use a puller if necessary.
5. **Inspect Components**:
– Check all components for wear, including the bearings, seals, and gears. Replace any damaged parts.
### Overhauling the Gear Set
1. **Install New Bearings and Seals**:
– Press new bearings onto the pinion and differential using a press or a hammer and a proper-sized socket.
– Install new seals using a seal installer or a similar tool to ensure they are seated correctly.
2. **Install New Pinion Gear**:
– Position the pinion gear in the housing and secure it with bolts.
– Use shims as needed to achieve the proper preload on the pinion bearings.
3. **Install New Differential**:
– Place the new or overhauled differential in the housing.
– Reattach the ring gear to the differential, ensuring it is torqued to the manufacturer’s specifications.
### Adjusting Backlash and Preload
1. **Set Gear Backlash**:
– Use a dial indicator to measure the backlash between the ring and pinion gears. Adjust by adding or removing shims as necessary.
2. **Set Pinion Preload**:
– Use a torque wrench to check the torque required to rotate the pinion. It should meet manufacturer specifications.
### Reassembly
1. **Reattach Differential Cover**:
– Clean the mating surfaces
and apply gasket maker or install a new gasket.
– Bolt the differential cover back in place, ensuring all bolts are torqued to spec.
2. **Reinstall Driveshaft**:
– slide the driveshaft back into the differential and secure it with bolts.
3. **Fill with Gear Oil**:
– Fill the differential with the appropriate gear oil through the fill hole until it starts to overflow.
### Final Steps
1. **Lower the Vehicle**:
– Lower the vehicle back to the ground and remove the jack stands.
2. **Reconnect the Battery**:
– Reconnect the battery terminals.
3. **Test Drive**:
– Take the vehicle for a test drive, ensuring that the differential operates smoothly without any unusual noises.
### Conclusion
Overhauling the gear set in a Mazda 3 Speed3 can be a rewarding but intricate task. It involves careful disassembly, precise measurements, and proper installation techniques. Always refer to the service manual for specific torque values and specifications unique to your vehicle model. If you are unsure or uncomfortable with any step, consult with a professional mechanic.
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