Workshop Manual - DriveLine/Axle

2011 - RX-8

General Procedures
GENERAL PROCEDURES (FRONT AND REAR AXLES)

cardiagn.com
Front Axle
FRONT AXLE LOCATION INDEX
WHEEL HUB, STEERING KNUCKLE INSPECTION
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
FRONT WHEEL HUB BOLT REPLACEMENT

Rear Axle
REAR AXLE LOCATION INDEX
WHEEL HUB, REAR KNUCKLE INSPECTION
WHEEL HUB, REAR KNUCKLE REMOVAL/INSTALLATION

Drive Shaft
REAR DRIVE SHAFT LOCATION INDEX
REAR DRIVE SHAFT INSPECTION
REAR DRIVE SHAFT REMOVAL/INSTALLATION
REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

Differential
REAR DIFFERENTIAL LOCATION INDEX
DIFFERENTIAL OIL INSPECTION
DIFFERENTIAL OIL REPLACEMENT
OIL SEAL (SIDE GEAR) REPLACEMENT
OIL SEAL (COMPANION FLANGE) REPLACEMENT
REAR DIFFERENTIAL REMOVAL/INSTALLATION
REAR DIFFERENTIAL DISASSEMBLY
REAR DIFFERENTIAL ASSEMBLY

Propeller Shaft
 PROPELLER SHAFT LOCATION INDEX
PROPELLER SHAFT REMOVAL/INSTALLATION
PROPELLER SHAFT INSPECTION

Technical Data
DRIVELINE/AXLE TECHNICAL DATA

Maintenance/Service Tools
DRIVELINE/AXLE SST

cardiagn.com
  Next >

2011 - RX-8 - DriveLine/Axle

GENERAL PROCEDURES (FRONT AND REAR AXLES)

Wheel And Tire Installation

1. When installing the wheels and tires, tighten the wheel nuts in a criss-cross pattern to the
following tightening torque.

cardiagn.com
Tightening torque

88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}

Connector Disconnection

1. Perform the following works, before the connectors are disconnected.

a. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [13B-

MSP].)

b. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [13B-MSP].)

c. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION

[13B-MSP].)

Suspension Links Removal/Installation

1. For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily
 tighten the installation bolts and nuts. Lower the vehicle to the ground and tighten them
completely with the specified torque.

  Next >
Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

FRONT AXLE LOCATION INDEX

1Wheel hub, steering knuckle cardiagn.com

(See WHEEL HUB, STEERING KNUCKLE INSPECTION.)

(See WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION.)

2Front wheel hub bolt

(See FRONT WHEEL HUB BOLT REPLACEMENT.)

< Previous   Next >
Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

FRONT WHEEL HUB BOLT REPLACEMENT

1. Remove the brake caliper component and disc plate.

2. Remove the wheel hub bolt using the SST as shown in the figure.

cardiagn.com
3. Place a new wheel hub bolt in the wheel hub.

4. Install the wheel hub bolt by placing a proper sized washer on the hub, and tightening the
nut as shown in the figure.

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

WHEEL HUB, STEERING KNUCKLE INSPECTION

Wheel Bearing Looseness Inspection

1. Install the magnetic vase and dial gauge as shown in the figure, and inspect the wheel
bearing for axial looseness.

cardiagn.com
If it exceeds the maximum specification, replace the wheel hub component.

Maximum front wheel bearing play

0.05 mm {0.002 in}

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION

CAUTION:

Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit
in the wiring harness if it is pulled by mistake. Before performing the following procedures, disconnect the ABS wheel-speed
sensor or ABS wheel-speed sensor harness connector (axle side) and fix it to an appropriate place where the sensor will not
be pulled by mistake while servicing the vehicle.

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

3. After installation, inspect the front wheel alignment. (See FRONT WHEEL ALIGNMENT.)

cardiagn.com
 cardiagn.com
1 ABS wheel-speed sensor harness connector (With ABS)

ABS wheel-speed sensor (With DSC)

2 Brake caliper component

(See Brake Caliper Component Removal Note.)

3 Disc plate
4 Tie-rod end

(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

5 Stabilizer control link nut (lower)

6 Front upper arm ball joint

(See FRONT UPPER ARM REMOVAL/INSTALLATION.)

7 Front upper arm bolt

8 Front lower arm ball joint

(See FRONT LOWER ARM REMOVAL/INSTALLATION.)

9 Wheel hub, steering knuckle component

10Steering knuckle

11Dust cover

cardiagn.com
12Wheel hub bolt

13Wheel hub component

Brake Caliper Component Removal Note

1. Suspend the brake calliper component using a cable or equivalent.

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR AXLE LOCATION INDEX

cardiagn.com
1Wheel hub, rear knuckle

(See WHEEL HUB, REAR KNUCKLE INSPECTION.)

(See WHEEL HUB, REAR KNUCKLE REMOVAL/INSTALLATION.)

< Previous   Next >

 Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

WHEEL HUB, REAR KNUCKLE INSPECTION

Wheel Bearing Looseness Inspection

1. Install the magnetic vase and dial gauge as shown in the figure, and inspect the wheel
bearing for axial looseness.

cardiagn.com
If it exceeds the maximum specification, replace the wheel hub component.

Maximum rear wheel bearing play

0.05 mm {0.002 in}

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

WHEEL HUB, REAR KNUCKLE REMOVAL/INSTALLATION

CAUTION:

Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in
the wiring harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor
(axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Remove the rear auto leveling sensor. (See REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

4. After installation, inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT.)

cardiagn.com

1 ABS wheel-speed sensor

2 Locknut

(See Locknut Removal Note.)

(See Locknut Installation Note.)

3 Parking brake cable

4 Brake caliper component

(See Brake Caliper Component Removal Note.)

5 Disc plate

(See REAR BRAKE (DISC) REMOVAL/INSTALLATION.)

6 Rear lateral link (upper) ball joint

(See REAR LATERAL LINK (UPPER) REMOVAL/INSTALLATION.)

7 Stabilizer control link nut (lower)

(See REAR STABILIZER REMOVAL/INSTALLATION.)

cardiagn.com
8 Rear lateral link (lower) ball joint

(See REAR LATERAL LINK (LOWER) REMOVAL/INSTALLATION.)

9 Shock absorber bolt (lower)

10Rear trailing link (lower) outside bolt

11Rear trailing link (upper) ball joint

(See REAR TRAILING LINK (UPPER) REMOVAL/INSTALLATION.)

12Toe control link ball joint

13Rear drive shaft

(See Rear Drive shaft Removal Note.)

14Rear knuckle component

(See Rear Knuckle Component Installation Note.)

15Wheel hub component

(See Wheel Hub Component Removal Note.)

(See Wheel Hub Component Installation Note.)

16Retaining ring

17Wheel bearing

(See Wheel Bearing Removal Note.)

(See Wheel Bearing Installation Note.)

18Dust cover

(See Dust Cover Removal Note.)

(See Dust Cover Installation Note.)

19Bushing

(See Bushing Removal Note.)

(See Bushing Installation Note.)

20Rear knuckle

21Wheel hub bolt

(See Wheel Hub Bolt Removal Note.)

(See Wheel Hub Bolt Installation Note.)

Locknut Removal Note

1. Lock the disc plate by applying the brakes.

cardiagn.com
2. Knock the crimped portion of the locknut outward using a chisel and a hammer.

3. Remove the locknut.

Brake Caliper Component Removal Note

1. Suspend the brake calliper component using a cable or equivalent.

Rear Drive shaft Removal Note

 1. Temporarily install a spare nut onto the end of the rear drive shaft.

2. Tap the nut with a copper hammer to loosen the drive shaft from the wheel hub.

3. Separate the rear drive shaft from the wheel hub.

Wheel Hub Component Removal Note

1. Remove the wheel hub component using the SSTs.

cardiagn.com
2. If the bearing inner race remains on the wheel hub component, use a chisel to secure a sufficient space for installing the SST
between wheel hub component and bearing inner race.

3. Remove the bearing inner race using the SST.

Wheel Bearing Removal Note

1. Remove the wheel bearing from the rear knuckle using the SSTs.

cardiagn.com
Dust Cover Removal Note

NOTE:

Remove the dust cover only if there is an abnormality.

1. Place an alignment mark on the dust cover and rear knuckle for proper installation.

2. Remove the dust cover using a chisel.

Bushing Removal Note

1. Remove the bushing from the rear knuckle using the SSTs.

cardiagn.com
Wheel Hub Bolt Removal Note

NOTE:

Remove the dust cover only if there is an abnormality.

1. Remove the wheel hub bolts from the wheel hub using a press.

Wheel Hub Bolt Installation Note

1. Press in new wheel hub bolts into the wheel hub using a press.
Bushing Installation Note

1. Press the new bushing into the rear knuckle using the SSTs.

cardiagn.com
Dust Cover Installation Note

1. Align the new and old dust covers and place alignment marks on the new dust cover.

2. Align the marks on the new dust cover and rear knuckle.

3. Press the new dust cover onto the rear knuckle using the SSTs.
Wheel Bearing Installation Note

1. Install a new wheel bearing using the SSTs.

cardiagn.com
Wheel Hub Component Installation Note

1. Install the wheel hub component using the SSTs.

Rear Knuckle Component Installation Note

1. Apply grease (L2Y1 33247) to the wheel bearing inner race and drive shaft contact surface (Area A in figure).
 2. Install the rear knuckle component.

Locknut Installation Note

1. Tighten a new locknut.

2. Install a new locknut and indent as shown to crimp the locknut, using a chisel and hammer.

cardiagn.com
< Previous   Next >
Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DRIVE SHAFT REMOVAL/INSTALLATION

CAUTION:

Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit
in the wiring harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed
sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the
vehicle.

1. Drain the rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)

2. Remove the rear auto leveling sensor. (See REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Add rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)

cardiagn.com
6. After installation, inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT.)
 cardiagn.com
1 ABS wheel-speed sensor

2 Locknut

(See Locknut Removal Note.)

(See Locknut Installation Note.)

3 Parking brake cable

4 Brake caliper component

(See Brake Caliper Component Removal Note.)

5 Rear lateral link (upper) ball joint

(See REAR LATERAL LINK (UPPER) REMOVAL/INSTALLATION.)

6 Stabilizer control link nut (lower)

 (See REAR STABILIZER REMOVAL/INSTALLATION.)

7 Rear lateral link (lower) ball joint

(See REAR LATERAL LINK (LOWER) REMOVAL/INSTALLATION.)

8 Shock absorber bolt (lower)

9 Rear trailing link (upper) ball joint

(See REAR TRAILING LINK (UPPER) REMOVAL/INSTALLATION.)

10Toe control link (outer)

11Rear drive shaft

(See Rear Drive Shaft Removal Note.)

(See Rear Drive Shaft Installation Note.)

12Rear drive shaft clip

(See Rear Drive Shaft Clip Installation Note.)

cardiagn.com
Locknut Removal Note

1. Lock the disc plate by applying the brakes.

2. Knock the crimped portion of the locknut outward using a chisel and a hammer.

3. Remove the locknut.

Brake Caliper Component Removal Note

1. Suspend the brake calliper component using a cable or equivalent.

 2. Temporarily tighten the wheel nut to prevent the disc plate from falling off.

Rear Drive Shaft Removal Note

1. Temporarily install a spare nut to the end of the rear drive shaft.

2. Knock the nut with copper hammer lightly and remove the rear drive shaft from the wheel hub.

cardiagn.com
3. Separate the rear drive shaft from the wheel hub.

4. Insert a tire lever or equivalent between the rear differential and differential side outer ring, and then remove the rear drive
shaft.

CAUTION:

The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when
removing the drive shaft from the differential.

5. Pull the rear drive shaft to the outer side of the vehicle and disconnect it from the rear differential.

6. To hold the rear knuckle component, install the rear lateral link (upper) to the rear knuckle temporarily after disconnecting the
rear drive shaft.
Rear Drive Shaft Clip Installation Note

1. Point the opening of the new drive shaft clip upward, install it to the clip groove at the end of the rear drive shaft with the
installation width within the specification.

Standard

32 mm {1.3 in}

2. After installing the clip, measure the outer diameter. If it exceeds the specification, reinstall the new clip.

Rear Drive Shaft Installation Note

cardiagn.com
1. Apply differential oil to the differential oil seal lip.

CAUTION:

The sharp edges of the rear drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal
when installing the rear drive shaft from the rear differential.

2. Apply grease (L2Y1 33247) to the wheel bearing inner race and rear drive shaft contact surface (Area A in figure).

3. Insert the rear drive shaft into the rear differential with the clip opening facing upward.

4. Insert the rear drive shaft to the wheel hub.

5. After installation, verify that the rear drive shaft is securely held by the clip by pulling the outer ring on the differential side
towards the axle.

Locknut Installation Note

1. Tighten a new locknut.

2. Crimp the locknut, using a chisel and hammer.

< Previous   Next >
Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

cardiagn.com
1Boot band (axle side)

(See Boot Band (Axle Side) Disassembly Note.)

(See Boot Band (Axle Side) Assembly Note.)

2Boot band (differential side)

(See Boot Band (Differential Side) Disassembly Note.)

(See Boot Band (Differential Side) Assembly Note.)

3Outer ring

(See Outer Ring Disassembly Note.)

(See Outer Ring Assembly Note.)

 4Snap ring

(See Snap Ring, Tripod Joint Disassembly Note.)

(See Tripod Joint, Snap Ring Assembly Note.)

5Tripod joint

(See Snap Ring, Tripod Joint Disassembly Note.)

(See Tripod Joint, Snap Ring Assembly Note.)

6Boot

(See Boot Disassembly Note.)

(See Boot Assembly Note.)

7Shaft and ball joint component

cardiagn.com
Boot Band (Axle Side) Disassembly Note

NOTE:

Remove the boot band only if there is an abnormality.

1. Remove the boot band using end clamp pliers.

Boot Band (Differential Side) Disassembly Note

1. Remove the crimp of the clip using a flathead screwdriver.

Outer Ring Disassembly Note

1. Place an alignment mark on the drive shaft and the outer ring.

cardiagn.com
2. Remove the outer ring.

Snap Ring, Tripod Joint Disassembly Note

1. Place an alignment mark on the shaft and tripod joint.

2. Remove the snap ring using a snap ring plier.

3. Remove the tripod joint from the shaft.

CAUTION:
 To prevent damage to the component, do not use a hammer when removing it.

Boot Disassembly Note

NOTE:

Remove the axle side boot only if there is an abnormality.

1. Wrap the shaft spline with vinyl tape.

2. Remove the boot.

cardiagn.com
Boot Assembly Note

NOTE:

The boot shapes on the axle side and the differential side are different so do not misinstall them.

1. Fill the inside of the new dust boot (wheel side) with grease.

NOTE:

Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from
entering the boot.

Grease amount

MT: 110—130 g {3.89—4.59 oz}

AT: 85—105 g {3.00—3.70 oz}

2. Install the boot with the drive shaft spline still wrapped with vinyl tape.

3. Remove the vinyl tape.

Tripod Joint, Snap Ring Assembly Note

1. Align the tripod joint with the shaft mark and insert it using a brass bar.
 CAUTION:

To prevent damage to the component, do not tap the roller part when installing.

2. Install the new snap ring to the shaft installation slot securely using a snap ring pliers.

Outer Ring Assembly Note

1. Fill the outer ring and boot (differential side) with the repair kit grease.

NOTE:

Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from

cardiagn.com
entering the boot.

Grease amount

MT: 170—190 g {6.00—6.70 oz}

AT: 135—155 g {4.77—5.46 oz}

2. Assemble the outer ring.

3. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped
screwdriver.

CAUTION:

Do not let the grease leak.

Do not damage the boot.

4. Set the drive shaft length to the specification when the inside of the boots is at ambient pressure. Rear drive
shaft standard length

Left side 792.6—802.6 mm {31.21—31.59 in}

MT
Right side 832.6—842.6 mm {32.78—33.17 in}
 Left side 791.1—801.1 mm {31.15—31.53 in}
AT
Right side 831.1—841.1 mm {32.71—33.11 in}

5. After installation, verify that there is no boot damage or grease leakage.

Boot Band (Differential Side) Assembly Note

1. Using pliers, pull the boot band around the boot slot in opposite direction of drive shaft forward rotation
direction and tighten.

cardiagn.com
2. Insert the end of the boot band between the boot band clip and fold back the clip tabs using a flathead
screwdriver to secure the boot band.

3. Verify that the boot band is installed to the boot slot securely.

Boot Band (Axle Side) Assembly Note

Boot band (small diameter side)

1. Adjust clearance A by turning the adjusting bolt of the SST.

Clearance A

2.9 mm {0.11 in}

 2. Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.

If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot
again.

If clearance B is less than the specification, replace the boot band, increase clearance A of the
SST, and crimp the new boot.

Clearance B

cardiagn.com
2.4—2.8 mm {0.095—0.110 in}

3. Verify that the boot band does not protrude from the boot band installation area.

If it does, replace the boot band and repeat Steps 2 and 3.

Boot band (Large diameter side)

1. Adjust clearance C by turning the adjusting bolt of the SST.

Clearance C

3.2 mm {0.13 in}

2. Crimp the wheel side large boot band using the SST. Verify that clearance D is within the specification.
 If clearance D is more than the specification, reduce clearance C of the SST and crimp the boot
again.

If clearance D is less than the specification, replace the boot band, increase clearance C of the
SST, and crimp the new boot.

Clearance D

2.4—2.8 mm {0.095—0.110 in}

cardiagn.com
3. Verify that the boot band does not protrude from the boot band installation area.

If it does, replace the boot band and repeat Steps 2 and 3.

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DRIVE SHAFT INSPECTION

1. Verify that the drive shaft is not twisted or damaged.

If there is any malfunction, replace the applicable part.

2. Inspect the dust boot for damage and cracks.

If there is any malfunction, replace the applicable part.

3. Move the spline and joint up and down, left and right by hand and verify that there is no
roughness.

cardiagn.com
If there is any malfunction, replace the applicable part.

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DRIVE SHAFT LOCATION INDEX

cardiagn.com
1Rear drive shaft

(See REAR DRIVE SHAFT INSPECTION.)

(See REAR DRIVE SHAFT REMOVAL/INSTALLATION.)

(See REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY.)

< Previous   Next >
Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

DIFFERENTIAL OIL INSPECTION

1. Position the vehicle on level ground.

2. Remove the oil-fill plug and the washer.

3. Inspect if the oil level is close to the rim of the oil-fill plug hole.

4. If the oil is not close to the rim of the oil-fill plug hole, add oil.

5. Install the oil-fill plug with a new washer and tighten.

cardiagn.com
Tightening torque

39.2—53.9 N·m {4.00—5.49 kgf·m, 29.0—39.7 ft·lbf}

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

DIFFERENTIAL OIL REPLACEMENT

1. Position the vehicle on level ground.

2. Remove the oil-fill plug.

3. Remove the drain plug and drain the oil.

cardiagn.com
4. Install the drain plug with a new washer and tighten.

Tightening torque

39.2—53.9 N·m {4.00—5.49 kgf·m, 29.0—39.7 ft·lbf}

5. Add the specified oil through the oil-fill plug hole.

Differential oil grade/viscosity:

API service GL-5 (SAE 90)

API service GL-5 (SAE 80W-90)

API service GL-5 (SAE 75W-90) (Not available from Mazda)

Differential oil capacity (approx. quantity):

1.2—1.4 L {1.3— 1.4 US qt, 1.1—1.2 Imp qt}

6. After adding the oil, perform the oil level inspection.

7. Install the oil-fill plug with a new washer and tighten.

 Tightening torque

39.2—53.9 N·m {4.00—5.49 kgf·m, 29.0—39.7 ft·lbf}

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DIFFERENTIAL LOCATION INDEX

cardiagn.com
1Differential oil

(See DIFFERENTIAL OIL INSPECTION.)

(See DIFFERENTIAL OIL REPLACEMENT.)

2Oil seal (side gear)

(See OIL SEAL (SIDE GEAR) REPLACEMENT.)

3Oil seal (companion flange)

(See OIL SEAL (COMPANION FLANGE) REPLACEMENT.)

4Rear differential

(See REAR DIFFERENTIAL REMOVAL/INSTALLATION.)

(See REAR DIFFERENTIAL DISASSEMBLY.)

(See REAR DIFFERENTIAL ASSEMBLY.)

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DIFFERENTIAL REMOVAL/INSTALLATION

CAUTION:

Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in
the wiring harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor
(axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Drain the rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)

2. Remove the rear auto leveling sensor. (See REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

3. Remove the tunnel member. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

4. Remove the middle pipe and main silencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

5. Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

6. Remove the heat insulator. (See TRANSMISSION REMOVAL/INSTALLATION [P66M-D].) (See AUTOMATIC TRANSMISSION

cardiagn.com
REMOVAL/INSTALLATION [SJ6A-EL].)

7. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

8. Remove in the order indicated in the table.

9. Install in the reverse order of removal.

10. Add rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)

11. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT.)
 cardiagn.com
1 ABS wheel-speed sensor

2 Parking brake cable

3 Brake caliper component

(See Brake Caliper Component Removal Note.)

4 Rear lateral link (upper) ball joint

(See REAR LATERAL LINK (UPPER) REMOVAL/INSTALLATION.)

5 Stabilizer control link nut (lower)

(See REAR STABILIZER REMOVAL/INSTALLATION.)

6 Rear lateral link (lower) ball joint

(See REAR LATERAL LINK (LOWER) REMOVAL/INSTALLATION.)

7 Shock absorber bolt (lower)

8 Rear trailing link (upper) ball joint

(See REAR TRAILING LINK (UPPER) REMOVAL/INSTALLATION.)

9 Toe control link ball joint

10Rear drive shaft, rear knuckle component

(See Rear Drive Shaft, Rear Knuckle Component Removal Note.)

(See Rear Drive Shaft, Rear Knuckle Component Installation Note.)

11Power plant frame

cardiagn.com
(See Power Plant Frame Removal Note.)

(See Rear Differential, Power Plant Frame Installation Note.)

12Rear differential

(See Rear Differential Removal Note.)

(See Rear Differential, Power Plant Frame Installation Note.)

13Differential mount

Brake Caliper Component Removal Note

1. Suspend the brake calliper component using a cable or equivalent.

2. Temporarily tighten the wheel nut to prevent the disc plate from falling off.

Rear Drive Shaft, Rear Knuckle Component Removal Note

1. Insert a tire lever or equivalent between the rear differential and differential side outer ring, and remove the rear drive shaft.
 CAUTION:

The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when
removing the drive shaft from the differential.

2. Pull the rear drive shaft and rear knuckle component to the outer side, and detach the rear drive shaft from the rear differential.

3. To hold the rear drive shaft and rear knuckle component, install the rear lateral link (upper) to the rear knuckle temporarily after
disconnecting the rear drive shaft.

Power Plant Frame Removal Note

cardiagn.com
1. Support the transmission using a jack.

2. Support the rear differential using a jack.

3. Remove the power plant frame.

Rear Differential Removal Note

WARNING:

If the rear differential falls off, it can cause serious injuries or death, and damage to the vehicle. When removing the rear
 differential, verify that it is supported securely with a jack.

1. Support the rear differential using a jack.

2. Remove the differential mounting installation bolts.

3. Lower the jack slowly and remove the rear differential.

Rear Differential, Power Plant Frame Installation Note

WARNING:

cardiagn.com
If the rear differential falls off, it can cause serious injuries or death, and damage to the vehicle. When installing the rear
differential, verify that it is supported securely with a jack.

CAUTION:

Tighten the differential mounting installation bolts completely only after performing the power plant frame installation and
adjustment. If the differential mounting bracket is installed at an incorrect angle, the differential mounting bracket bushings
will twist and cause an abnormal noise while the vehicle is moving.

1. Support the rear differential using a jack.

2. Temporarily tighten the differential mounting installation bolts.

3. Install the power plant frame.

4. Install the plate.

5. Temporarily tighten the bolts and nuts as shown in the figure.

6. Tighten the nut B until the power plant frame is seated in the rear differential.

7. Install the heat insulator, TWC, middle pipe, main silencer and front tunnel member. (See TRANSMISSION
REMOVAL/INSTALLATION [P66M-D].) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL].) (See EXHAUST
SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

8. Raise the power plant frame front end (transmission side) or transmission using a jack so that dimension A (between power plant
frame lower surface and front tunnel member lower surface) shown in the figure is within the adjustment value.

cardiagn.com
Adjustment dimension A

55—57 mm {2.17—2.24 in}

NOTE:

When raising the power plant frame without a transmission jack, use bolts (M12x1.25) with a thread length of 55
mm {2.17 in} or more. Tighten the bolts from the underside of the front tunnel member as shown in the figure
and raise the power plant frame.

When using bolts, the underside of the power plant frame could be damaged. Affix tape to the underside of the
frame to prevent damage.

If there is the possibility of age-related bending/deterioration of the mount, adjust dimension A to approx. 15 mm
{0.59 in} higher than the adjustment value to facilitate obtaining the specification.

9. Tighten the bolts and nuts on the rear differential side in the order shown in the figure.
 Tightening torque
StepBolt, nut
(N·m {kgf·m, ft·lbf}

1 A 126.0—154.0 {12.9—15.7, 93.0—113.5}

2 B 126.0—154.0 {12.9—15.7, 93.0—113.5}

3 C 126.0—154.0 {12.9—15.7, 93.0—113.5}

4 F 74.5—93.2 {7.60—9.50, 55.0—68.7}

10. Tighten the bolts and nuts on the transmission side as shown in the figure.

cardiagn.com
Tightening torque

126.0—154.0 N·m {12.9—15.7 kgf·m, 93.0—113.5 ft·lbf}

11. Verify that dimension A is within the specification with the transmission jack and the adjustment bolt removed.

If not within the specification, adjust dimension A again.

Standard dimension A

48.4—56.4 mm {1.91—2.22 in}

12. Temporarily loosen the differential mount installation bolts, straighten the differential mounting bracket bushings, and then
tighten the differential mounting installation bolts again to the specified torque.

CAUTION:

Never support the rear differential using a jack when tightening the differential mounting installation bolts.
Otherwise, the differential mounting bracket bushings will twist and cause an abnormal noise while the vehicle is
moving.

Tightening torque

74.5—105.0 N·m {7.60—10.70 kgf·m, 55.0—77.44 ft·lbf}

Rear Drive Shaft, Rear Knuckle Component Installation Note

1. Install a new drive shaft clip to the clip groove at the top of the rear drive shaft with the clip opening facing upward and the clip
width within the specification.
 Standard

32 mm {1.3 in}

2. After installing the clip, measure the outer diametric if it exceeds the specification, reinstall a new clip.

3. Apply differential oil to the differential oil seal lip.

CAUTION:

The sharp edges of the rear drive shaft can slice or puncture the oil seal Be careful not to damage the oil seal when
installing the rear drive shaft from the rear differential.

4. Insert the rear drive shaft into the rear differential with the clip opening facing upward.

5. After installation, verify that the rear drive shaft is securely held by the clip by pulling the outer ring on the differential side

cardiagn.com
towards the axle.

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DIFFERENTIAL DISASSEMBLY

WARNING:

The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted, the self-lock mechanism
could become inoperative. If the rear differential unexpectedly rotates, it could cause injury, therefore do not maintain the rear
differential tilted. When turning the rear differential, grasp the rotation handle firmly.

1. Disassemble in the order indicated in the table.

cardiagn.com
1 Rear cover

2 Baffle plate

3 Differential component

(See Differential Component Disassembly Note.)

4 Bearing cap

(See Bearing Cap Disassembly Note.)

5 Adjustment shim

(See Adjustment Shim, Side Bearing Outer Race Disassembly Note.)

6 Differential gear case component

7 Side bearing outer race

cardiagn.com
(See Adjustment Shim, Side Bearing Outer Race Disassembly Note.)

8 Side bearing

(See Side Bearing Disassembly Note.)

9 Ring gear

10Gear case

11Roll pin

(See Roll Pin Disassembly Note.)

12Pinion shaft

13Pinion gear

14Thrust washer

15Side gear

16Washer

17Locknut

(See Locknut Disassembly Note.)

18Washer

19Companion flange

(See Companion Flange Disassembly Note.)

20Oil seal (companion flange)

 21Spacer

22Front bearing

23Drive pinion component

(See Drive Pinion Component Disassembly Note.)

24Collapsible spacer

25Rear bearing

(See Rear Bearing Disassembly Note.)

26Spacer

27Drive pinion

28Front bearing outer race

(See Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note.)

cardiagn.com
29Rear bearing outer race

(See Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note.)

30Oil seal (side gear)

31Differential carrier

32Breather plug

33Oil-fill plug

34Drain plug

Differential Component Disassembly Note

1. Install the differential component to the SSTs.

Bearing Cap Disassembly Note

1. Mark the bearing cap and differential carrier for proper installation.

Adjustment Shim, Side Bearing Outer Race Disassembly Note

1. Remove the adjustment shim using a flathead screwdriver.

cardiagn.com
2. Put left and right identification marks on the removed adjustment shims and side bearing outer races.

Side Bearing Disassembly Note

1. Remove the side bearing using the SST.

 2. Put left and right identification marks on the removed side bearings.

Roll Pin Disassembly Note

1. Tap the roll pin out from the direction shown in the figure using a pin punch.

cardiagn.com
Locknut Disassembly Note

1. Remove the locknut while fixing the companion flange using the SST.

Companion Flange Disassembly Note

1. Remove the companion flange using the SST.

Drive Pinion Component Disassembly Note

1. Install the removed locknut to the drive pinion top to prevent damage to the thread.

cardiagn.com
2. Remove the drive pinion component by tapping the locknut lightly using a plastic hammer.

3. Remove the locknut installed in Step 1.

Rear Bearing Disassembly Note

CAUTION:

The drive pinion could be damaged if it falls off. Support the drive pinion with your hand when removing the rear bearing.

1. Remove the rear bearing using the SST and a press.

Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note

1. Remove the bearing outer race by lightly tapping the edge of the bearing outer race using a flathead screwdriver.
< Previous   Next >
Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

REAR DIFFERENTIAL ASSEMBLY

WARNING:

The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted, the self-lock mechanism could
become inoperative. If the rear differential unexpectedly rotates, it could cause injury, therefore do not maintain the rear differential
tilted. When turning the rear differential, grasp the rotation handle firmly.

NOTE:

Clean away the old silicone sealant before applying the new silicone sealant.

Install the rear cover before the applied sealant starts to harden.

Allow the sealant to set at least 30 min or more after installation before filling the differential with differential oil.

1. Assemble in the order indicated in the table.

cardiagn.com
 cardiagn.com
1 Gear case

2 Side gear

3 Thrust washer

4 Pinion gear

5 Pinion shaft
6 Washer

(See Washer Assembly Note.)

7 Roll pin

(See Roll Pin Assembly Note.)

8 Ring gear

(See Ring Gear Assembly Note.)

9 Side bearing

(See Side Bearing Assembly Note.)

10Differential gear case component

11Differential carrier

12Oil seal (side gear)

(See Oil Seal (Side Gear) Assembly Note.)

cardiagn.com
13Rear bearing outer race

(See Rear Bearing Outer Race Assembly Note.)

14Front bearing outer race

(See Front Bearing Outer Race Assembly Note.)

15Spacer

(See Spacer Assembly Note.)

16Drive pinion

17Rear bearing

(See Rear Bearing Assembly Note.)

18Drive pinion component

(See Drive Pinion Component Assembly Note.)

19Collapsible spacer

20Front bearing

21Spacer

22Oil seal (companion flange)

(See Oil Seal (Companion Flange) Assembly Note.)

23Companion flange

24Washer

25Locknut
 (See Locknut Assembly Note.)

26Adjustment shim

(See Adjustment Shim Assembly Note.)

27Side bearing race

28Bearing cap

(See Bearing Cap Assembly Note.)

29Baffle plate

30Rear cover

31Breather plug

32Oil-fill plug

33Drain plug

cardiagn.com
Washer Assembly Note

1. Assemble the side gear, thrust washer, pinion gear, and the pinion shaft to the gear case.

2. Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of one of the pinion gear teeth.

3. Fix either one of the side gears.

4. Move the pinion gear and measure the backlash at the pinion gear top.

If it is not within the specification, adjust by choosing the proper washer.

Backlash of pinion gear and side gear

0.1 mm {0.004 in} or less

Washer table

Identification mark Part name Thickness (mm {in})

0 0578 27 252 2.00 {0.0787}

05 P016 27 252 2.05 {0.0807}

1 0578 27 253 2.10 {0.0827}

 15 P016 27 253 2.15 {0.0846}

2 0578 27 254 2.20 {0.0866}

Roll Pin Assembly Note

1. Align the differential gear case and pinion shaft pin holes.

2. Tap the roll pin in using a pin punch.

Ring Gear Assembly Note

CAUTION:

The gear case and ring gear could be damaged if the ring gear is installed with old thread-locking compound remaining on the bolt
threads. Before installing the ring gear, completely remove the old thread-locking compound from the bolt threads.

1. Apply a small amount of thread-locking compound to each of points A on the back of the ring gear, and bolt thread areas B (around
the entire ring).

cardiagn.com
Application thickness

Back of ring gear points A:

Approx. 0.4 cm3 {0.4 cc, 0.024 cu in}

(1 location approx. 0.04 cm3

{0.04 cc, 0.0024 cu in})

Ring gear bolt thread points B:

Approx. 0.4 cm3 {0.4 cc, 0.024 cu in}

(1 location approx. 0.04 cm3

{0.04 cc, 0.0024 cu in})

2. Install the ring gear to the differential gear case and tighten the bolts in a criss-cross pattern.

Tightening torque

68.6—83.3 N·m {7.00—8.49 kgf·m, 50.6—61.4 ft·lbf}

Side Bearing Assembly Note

NOTE:

When assembling the side bearings, do not mix the left and right side bearings that were identified during disassembly.

1. Press the side bearing in using the SST and a press.

Oil Seal (Side Gear) Assembly Note

1. Apply differential oil to the lip of a new oil seal.

2. Assemble the oil seal using the SSTs.

cardiagn.com
Rear Bearing Outer Race Assembly Note

1. Press the rear bearing outer race into the differential carrier using the SST and a press.

Front Bearing Outer Race Assembly Note

1. Press the front bearing outer race into the differential carrier using the SST and a press.
Spacer Assembly Note

Pinion height adjustment

NOTE:

Use the installed spacer when adjusting.

Install the spacer with the chamfer on the SST side.

cardiagn.com
1. Assemble the spacer, bearing inner race (rear side), and the SST (O-ring) to the SST (49 8531 565) as shown in the figure.

2. Insert the set assembled in Step 1 from the rear side of the differential carrier.

3. Assemble the SST (49 8531 567), front bearing, companion flange, and a washer from the front side of the differential carrier.

4. Tighten the locknut to the extent that the SST (49 8531 565) can be turned by hand.
5. Place the SST (49 8531 565) on top of the SST (49 0660 555).

6. Place the SST on the surface plate and set the dial gauge to zero.

7. Set the SSTs as shown in the figure.

cardiagn.com
8. Place the measuring probe of the dial gauge at the point where the side bearing is installed in the differential carrier and measure at
the lowest position. Measure the left and right sides.

9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total by 2. From this sum,
subtract the sum of the number inscribed on the end of the drive pinion divided by 100. (If there is no figure inscribed, use 0.) This is the
pinion height adjustment value.

Differential pinion height

0.038 mm {0.0015 in} or less

NOTE:

When the values obtained by the measurements taken in Step 8, 9 are 0.06 mm {0.0024 in}, 0.04 mm {0.0016 in} and
the tip surface of the drive pinion value is 2, the formula is ((0.06+0.04)/2)-(2/100)=0.03. Therefore, assemble a spacer
0.03 mm {0.0012} thicker than the currently assembled one. The thickness settings are in increments of 0.015 mm
{0.0006}, so choose one closest in thickness and install.
 Spacer table

Identification markThickness (mm {in}) Identification markThickness (mm {in})

08 3.080 {0.1213} 29 3.290 {0.1295}

09 3.095 {0.1219} 30 3.305 {0.1301}

11 3.110 {0.1224} 32 3.320 {0.1307}

12 3.125 {0.1230} 33 3.335 {0.1313}

14 3.140 {0.1236} 35 3.350 {0.1319}

15 3.155 {0.1242} 36 3.365 {0.1325}

17 3.170 {0.1248} 38 3.380 {0.1331}

18 3.185 {0.1254} 39 3.395 {0.1337}

cardiagn.com
20 3.200 {0.1260} 41 3.410 {0.1343}

21 3.215 {0.1266} 42 3.425 {0.1348}

23 3.230 {0.1272} 44 3.440 {0.1354}

24 3.245 {0.1278} 45 3.455 {0.1360}

26 3.260 {0.1283} 47 3.470 {0.1366}

27 3.275 {0.1289} — —

Rear Bearing Assembly Note

NOTE:

Install the spacer with the chamfer on the gear side.

1. Assemble the spacer selected in the pinion height adjustment to the drive pinion.

2. Press the drive pinion into the rear bearing using the SSTs and a press.
Drive Pinion Component Assembly Note

Drive pinion preload adjustment

NOTE:

Perform preload adjustment with the oil seal uninstalled.

1. Assemble the following parts to the drive pinion.

New collapsible spacer

Front bearing

New spacer

Companion flange

New washer

New locknut

2. Turn the serrated part of the drive pinion by hand to seat the bearing.

3. Tighten the locknut temporarily tightened in Step 1 from the lower limit of the specified tightening torque using the SST, and obtain the
specified preload. Record the tightening torque at this time.

cardiagn.com
Tightening torque

128—284 N·m {13—29 kgf·m, 95—209 ft·lbf}

Differential drive pinion preload

1.3—1.7 N·m {14—17 kgf·cm, 12—15 in·lbf}

If the specified preload cannot be obtained within the specified tightening torque, replace with a new collapsible spacer
and adjust again.

4. Remove the locknut, washer, and companion flange.

Oil Seal (Companion Flange) Assembly Note

1. Apply differential oil to the lip of a new oil seal.

2. Assemble the oil seal using the SST.

Locknut Assembly Note

1. Apply differential oil to the thread of a new locknut.

2. Tighten a new locknut with the torque recorded at the drive pinion preload adjustment using the SST.

cardiagn.com
3. Verify that the drive pinion preload is within the specification.

If not within the specification, perform the preload adjustment again.

Differential drive pinion preload

1.3—1.7 N·m {14—17 kgf·cm, 12—15 in·lbf}

Adjustment Shim Assembly Note

Ring gear backlash adjustment

1. Stack the side bearing race and differential gear case component on the surface plate as shown in the figure, and measure the height
using a caliper and a ruler. This is value A.
 Standard Height A

158.1—159.5 mm {6.224—6.280 in}

2. Measure the width of the section of the differential gear case component installed in the differential carrier. This is value B.

cardiagn.com
Standard width B

170.9—171.1 mm {6.729—6.736 in}

3. The combined thickness of the left and right adjustment shims is obtained by the following formula.

Shim thickness (mm {in}) =B-A+ (0.01—0.03 {0.0004—0.0118 in})

4. If the combined thickness of the previously assembled adjustment shims is equal to the calculated thickness, use the shims as they are.

5. If the combined thickness of the previously assembled adjustment shims is not equal to the calculated thickness, or if the adjustment
shims have to be replaced, select two appropriate adjustment shims from the table below. Adjustment shim table

Identification markThickness (mm {in}) Identification markThickness (mm {in})

550 5.50 {0.217} 605 6.05 {0.238}

560 5.60 {0.220} 610 6.10 {0.240}

565 5.65 {0.222} 615 6.15 {0.242}

570 5.70 {0.224} 620 6.20 {0.244}

575 5.75 {0.226} 625 6.25 {0.246}

580 5.80 {0.228} 630 6.30 {0.248}

585 5.85 {0.230} 635 6.35 {0.250}

590 5.90 {0.232} 640 6.40 {0.252}

595 5.95 {0.234} 650 6.50 {0.256}

 600 6.00 {0.236} — —

NOTE:

If the adjustment shims are to be reused, assemble the left and right shims that were identified during disassembly.

When assembling the side bearing races, do not mix the left and right side bearings that were identified during
disassembly.

6. Assemble the differential gear case component and the side bearing race to the differential carrier.

7. Tap the selected adjustment shim between the differential carrier and the side bearing race with a plastic hammer as shown in the
figure.

cardiagn.com
8. Align the bearing cap alignment marks, assemble the bearing cap, and then temporarily tighten the bolts.

9. Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of one of the ring gear teeth.

10. Secure the drive pinion and measure the backlash of the ring gear.

Backlash of drive gear and ring gear

Standard: 0.09—0.11 mm {0.0035—0.0043 in}

Minimum value: 0.05 mm {0.0020 in} or more

Variance: 0.07 mm {0.0028 in} or less

NOTE:

Measure the backlash at 4 locations around the ring gear. Make sure all of the 4 locations are within specification, and
the minimum value for the 4 locations is 0.05 mm {0.0020in} or more and the variance is 0.07 mm {0.0028 in} or
less

11. If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
 12. Measure the ring gear preload between the backlash.

Ring gear preload

0.49—2.45 N·m {5.0—24.9 kgf·cm, 4.4—21.6 in·lbf}

NOTE:

When moving the gear case component in the axial direction, replace the adjustment shims. If the adjustment shim on the right side
is replaced with one that is 0.05 mm {0.0020 in} thicker, replace the one on the left with one that is 0.05 mm {0.0020 in}
thinner.

Bearing Cap Assembly Note

cardiagn.com
1. Align the bearing cap alignment marks and assemble the bearing cap with the arrow facing outward.

Tightening torque

72.6—106.9 N·m {7.41—10.91 kgf·m, 53.5—78.84 ft·lbf}

2. Perform the drive pinion and ring gear tooth contact inspection.

Drive Pinion, Ring Gear Tooth Contact Inspection

1. Apply tooth marking compound evenly to both surfaces of the ring gear.

2. Rotate the ring gear back and forth for several times.

3. Inspect the tooth contact pattern in 4 locations around the ring gear, and verify that the tooth contact points exhibit the pattern shown
in the figure.

If the tooth contact points are normal, wipe off the marking compound.

If the tooth contact points are not normal, adjust the pinion height, then adjust the backlash.
 4. If the toe and flank contact points appear as shown in the figure after the drive pinion and ring gear teeth contact inspection, replace
the spacer with a thinner one, and move the drive pinion outward.

cardiagn.com
5. If the heel and face contact points appear as shown in the figure after the drive pinion and ring gear teeth contact inspection, replace
the spacer with a thicker one, and move the drive pinion inward.

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

OIL SEAL (SIDE GEAR) REPLACEMENT

1. Remove the drain plug and drain the oil.

2. Install the drain plug with a new washer and tighten.

Tightening torque

39.2—53.9 N·m {4.00—5.49 kgf·m, 29.0—39.7 ft·lbf}

3. Disconnect the rear drive shaft on the differential side. (See REAR DIFFERENTIAL
REMOVAL/INSTALLATION.)

cardiagn.com
4. Remove the clip from the rear drive shaft.

CAUTION:

To prevent damaging the inside of the differential casing, wrap cloth on the end
of the flathead screwdriver.

5. Remove the oil seal from the differential carrier using a flathead screwdriver.

6. Apply differential oil to the lip of a new oil seal.

7. Tap in the new oil seal until it reaches the differential carrier using the SSTs.
 NOTE:

Install the oil seal at a straight angle.

8. After installing a new clip to the rear drive shaft, insert it into the rear differential. (See REAR
DIFFERENTIAL REMOVAL/INSTALLATION.)

cardiagn.com
9. Verify that the rear drive shaft is held securely by the clip by pulling the outer ring on the
differential side towards the axle.

10. Add differential oil.

11. After adding the oil, perform the oil level inspection. (See DIFFERENTIAL OIL INSPECTION.)

12. Install the oil-fill plug with a new washer and tighten.

Tightening torque

39.2—53.9 N·m {4.00—5.49 kgf·m, 29.0—39.7 ft·lbf}

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

OIL SEAL (COMPANION FLANGE) REPLACEMENT

1. Remove the rear differential. (See REAR DIFFERENTIAL REMOVAL/INSTALLATION.)

2. Replace the oil seal (companion flange) referring to the rear differential disassembly/assembly
procedure. (See REAR DIFFERENTIAL DISASSEMBLY.) (See REAR DIFFERENTIAL ASSEMBLY.)

3. Install the rear differential. (See REAR DIFFERENTIAL REMOVAL/INSTALLATION.)

< Previous   Next >

cardiagn.com
Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

PROPELLER SHAFT LOCATION INDEX

1Propeller shaft
cardiagn.com
(See PROPELLER SHAFT REMOVAL/INSTALLATION.)

(See PROPELLER SHAFT INSPECTION.)

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

PROPELLER SHAFT REMOVAL/INSTALLATION

For Carbon-Fiber Propeller Shaft

CAUTION:

The carbon-fiber-reinforced propeller shaft could be chipped or cracked if dropped. To

prevent any damage, handle the shaft with careful attention when removing/installing.

Replace the propeller shaft if it is dropped.

cardiagn.com
1. Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

2. Remove the insulator (front). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

3. Remove the insulator (middle). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-

MSP].)

4. Protect the propeller shaft with rubber padding or similar protective cover to prevent damage.

CAUTION:

Remove the rubber padding or similar protective cover after propeller shaft
 installation is complete.

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Remove the rubber padding or similar protective cover from the propeller shaft.

cardiagn.com
1Bolt, nut

2Propeller shaft

(See Propeller Shaft Removal Note.)

(See Propeller Shaft Installation Note.)

For Steel Propeller Shaft

1. Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

2. Remove the insulator (front). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

3. Remove the insulator (middle). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [13B-

MSP].)

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

 1Bolt, nut

cardiagn.com
2Propeller shaft

(See Propeller Shaft Removal Note.)

(See Propeller Shaft Installation Note.)

Propeller Shaft Removal Note

CAUTION:

When replacing with a new propeller shaft, mark the companion flange to match the
position of the tag on the propeller shaft.

1. Before removing the propeller shaft, make alignment marks on the yoke and differential
companion flange.
 2. Insert a slab of wood behind the rear differential, and remove the propeller shaft.

3. Install the SST to the extension housing.

cardiagn.com
Propeller Shaft Installation Note

1. Align the marks and install the propeller shaft.

CAUTION:

When installing a new carbon-fiber propeller shaft, install the shaft with the
protective cover still on and then remove after completion.

Handle the propeller shaft with careful attention.

2. When installing a new propeller shaft, align the differential companion flange mark with the
tag on the propeller shaft and assemble.
< Previous   Next >
Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

PROPELLER SHAFT INSPECTION

For Carbon-Fiber Propeller Shaft

CAUTION:

Replace the propeller shaft if it is dropped.

Handle the propeller shaft with care so that the pipe is not damaged from striking
surrounding objects or other impacts.

cardiagn.com
Replace the propeller shaft if there is any chipping or warping of the pipe.

Protect the propeller shaft from damage and handle with careful attention when working.

1. Use a dial gauge to measure the runout of the propeller shaft at each position.

If it exceeds the maximum specification, replace the propeller shaft.

Propeller shaft maximum runout

0.6 mm {0.024 in}

2. Inspect the play and rotation of the joint by turning the universal joint in the directions shown
by the arrows.
 cardiagn.com
Propeller shaft initial torque (Reference value)

0.29—0.98 N·m {3.0—10 kgf·cm, 2.7—8.6 in·lbf}

If there is any play or excessive initial torque, replace the propeller shaft.

3. Verify that the propeller shaft has no bends or damage.

If there is any malfunction, replace the propeller shaft.

4. Verify that there is a gap between the pipe and yoke flange.

If there is any malfunction, replace the propeller shaft.

5. Verify that there is no cracking, peeling or similar damage to the seal (where the pipe and
 yoke connect).

If there is any malfunction, replace the propeller shaft.

For Steel Propeller Shaft

1. Use a dial gauge to measure the runout of the propeller shaft at each position.

If it exceeds the maximum specification, replace the propeller shaft.

Propeller shaft maximum runout

cardiagn.com
0.6 mm {0.024 in}

2. Inspect the play and rotation of the joint by turning the universal joint in the direction shown
by the arrow.
 Propeller shaft initial torque (Reference value)

0.29—0.98 N·m {3.0—10 kgf·cm, 2.7—8.6 in·lbf}

If there is excessive play or initial torque, replace the propeller shaft.

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous   Next >

2011 - RX-8 - DriveLine/Axle

DRIVELINE/AXLE TECHNICAL DATA

Item Specification

Maximum front wheel bearing play 0.05 mm {0.002 in}

Maximum rear wheel bearing play 0.05 mm {0.002 in}

cardiagn.com
API service GL-5 (SAE 90)

Differential oil grade/viscosity API service GL-5 (SAE 80W-90)

API service GL-5 (SAE 75W-90) (Not available from Mazda)

Differential oil capacity (approx. quantity) 1.2—1.4 L {1.3— 1.4 US qt, 1.1—1.2 Imp qt}

Differential pinion height 0.038 mm {0.0015 in} or less

Differential drive pinion preload 1.3—1.7 N·m {14—17 kgf·cm, 12—15 in·lbf}

Standard: 0.09—0.11 mm {0.0035—0.0043 in}

Backlash of drive gear and ring gear Minimum value: 0.05 mm {0.0020 in} or more

Variance: 0.07 mm {0.0028 in} or less

Propeller shaft maximum runout 0.6 mm {0.024 in}

Propeller shaft initial torque (Reference value) 0.29—0.98 N·m {3.0—10 kgf·cm, 2.7—8.6 in·lbf}

Rear drive shaft standard length

Left side 792.6—802.6 mm {31.21—31.59 in}

MT
Right side 832.6—842.6 mm {32.78—33.17 in}

Left side 791.1—801.1 mm {31.15—31.53 in}

AT
Right side 831.1—841.1 mm {32.71—33.11 in}

< Previous   Next >

Back to Top
© 2010 Mazda North American Operations, U.S.A.

cardiagn.com
< Previous  

2011 - RX-8 - DriveLine/Axle

DRIVELINE/AXLE SST

49 T028 49 G030 49 G033

3A0 338 102

Ball joint Attachment Handle

puller set E

cardiagn.com
49 G033 49 H027 49 F026
105 002 105

Attachment Bearing Support

remover block

49 F027 49 F027 49 F401

007 003 331

Attachment Handle Body

for ø72
bearing

49 8531 49 F027 49 H034

565 004 201

Drive Attachment Support

pinion for ø80 block
model bearing

49 F027 49 T025 49 G030

009 001 797

Attachment Boot clamp Handle

for crimper
ø68&ø77
bearing

49 U027 49 S120 49 0839

003 710 425C

Oil seal Coupling Bearing

installer flange puller set
holder

49 V001 49 0107 49 M005

cardiagn.com
795 680A 561

Oil seal Engine Differential

installer stand carrier
hanger

49 0636 49 UB71 49 J027

145 525 001

Water Bearing Bearing

pump installer installer
pulley boss
puller

49 J027 49 8038 49 0660

002 785A 555

Collar Dust boot Gauge

installer block

49 0727 49 S120 49 F026

570A 440 103

Pinion Mainshaft Wheel hub

height holder puller
gauge
body

49 W010 49 8531 49 B001

107A 567 795

Oil seal Collar A Oil seal

installer installer
(Part of

49 8531
565)

< Previous  

cardiagn.com
Back to Top
© 2010 Mazda North American Operations, U.S.A.