torque MAZDA 6 2002 Workshop Manual Suplement

M–48
REAR DRIVE SHAFT, REAR DIFFERENTIAL
5. 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 grease leak.
•Do not damage the boot.
6. Set the drive shaft to the standard length.
Standard length
mm {in}
7. Verify that the drive shaft length is within the standard.
•If not, repeat from Step 5.
End Of Sie
DIFFERENTIAL OIL INSPECTIONA6E6319271002031. Place the vehicle on level ground.
2. Remove the filler plug and washer.
3. Verify that the oil is at the brim of the filler plug
hole.
4. If it is low, add the specified oil.
5. Install a new washer and the filler plug, and
tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7
ft·lbf}
End Of SieDIFFERENTIAL OIL REPLACEMENTA6E6319271002041. Place the vehicle on level ground.
2. Remove the filler plug.
3. Remove the drain plug and drain the differential
oil into a container.
4. Install a new washer and the drain plug, and
tighten.
Tightening torque
39—53 N·m {4.0—5.4 kgf·m, 29—39 ft·lbf}
5. Add the specified differential oil from the filler plug
until the level reaches the brim of the plug hole.
Specified oil
Type (API service GL-5)
Above -18°C {0°F}: SAE 90
Below -18°C {0°F}: SAE 80
Capacity (Approximate quantity):
1.00 L {1.06 US qt, 0.88 Imp qt}
6. After filling with differential oil, perform oil level inspection.
7. Install a new washer and the drain plug, and tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7 ft·lbf}
Left side Right side
805.4—815.4
{31.71—32.10}852.4—862.4
{33.56—33.95}A6E6316W007
REAR DIFFERENTIAL
FILLER PLUG
A6E63192101
FILLER PLUG
DRAIN PLUG
A6E63192102

REAR DIFFERENTIAL
M–49
M
End Of SieOIL SEAL (SIDE GEAR) REPLACEMENTA6E6319271002051. Remove the drain plug and the drain differential oil into a container.
2. Install a new washer and the drain plug, and tighten.
3. Remove the rear drive shaft. (See M–43 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
4. Remove the clip from the drive shaft.
Caution
•Wrap the end of a screwdriver with cloth to prevent scratches to the inside of the differential
casing.
5. Remove the oil seal from the differential casing
using a screwdriver.
6. Apply differential oil to the new oil seal lip.
7. Install the new oil seal to the differential carrier
using the SSTs.
8. After installing the new clip onto the drive shaft,
insert the drive shaft into the differential. (See M–
43 REAR DRIVE SHAFT REMOVAL/
INSTALLATION.)
9. Verify that the drive shaft cannot be pulled out.
10. Add the specified differential oil.
11. fter adding the oil, perform an oil level inspection.
(See M–48 DIFFERENTIAL OIL INSPECTION.)
12. Install a new washer and the oil filler plug, and
tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7 ft·lbf}
End Of Sie
OIL SEAL (COMPANION FLANGE) REPLACEMENTA6E6319271002061. Drain the differential oil into a container.
2. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the locknut using the SST.
4. Support the differential using a jack.
A6A63192003
49 G030 79649 G030 797
A6A63192004
49 S120 710
A6A63192005

M–50
REAR DIFFERENTIAL
5. After removing the front side of the differential
mount, gradually lower the jack and tilt the front
side of the differential downward.
6. Pull the companion flange off using the SST.
7. Remove the oil seal from the differential carrier
using a screwdriver or similar tool.
8. Apply differential oil to the new oil seal lip.
9. Install the new oil seal to the differential carrier
using the SST.
10. Install the companion flange to the drive pinion.
11. Jack up the differential and install the front side of
the differential mount.
Tightening torque
74.5—104.9 N·m {7.6—10.7 kgf·m, 55.0—77.3
ft·lbf}
12. Install the washer and a new locknut.
13. Tighten the locknut to the specified torque using
the SST.
Tightening torque
167—226 N·m {17.1—23.0 kgf·m, 124—166
ft·lbf}
14. Install the propeller shaft. (See L–5 PROPELLER
SHAFT REMOVAL/INSTALLATION)
15. Add the specified differential oil from the filler
plug. (See M–48 DIFFERENTIAL OIL
REPLACEMENT)
End Of Sie
JACK
DIFFERENTIAL
A6E63192042
49 0839 425C
A6A63192043
49 W011 102
A6A63192006
49 S120 710
A6A63192007

M–58
REAR DIFFERENTIAL
Ring Gear Assembly Note
Caution
•The differential gear 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).
Application amount
Back of ring gear:
Approx. 0.32 ml {0.32 cc, 0.02 cu in}
Ring gear bolt thread points:
Approx. 0.32 ml {0.32 cc, 0.02 cu in}
(0.04 ml {0.04 cc, 0.002 cu in}
to each point)
2. Align the marks placed on the ring gear case at
the time of disassembly and tighten the bolts in
diagonal order.
Tightening torque
69—83 N·m {7.1—8.4 kgf·m, 50.9—61.2 ft·lbf}
Bearing Outer Race Assembly Note
1. Press in the bearing outer race using the SSTs
and a press.
A
B
A6A63192022
A6A63192023
49 M005 797
49 F027 007
49 F027 005
A6A63192024

REAR DIFFERENTIAL
M–61
M
Locknut Assembly Note
Drive pinion preload adjustment
1. Apply differential oil to a new locknut.
2. Assemble a new collapsible spacer, bearing inner race (front bearing), and locknut to the drive pinion, and
temporarily tighten the locknut.
3. Turn the serrated part of the drive pinion by hand to seat the bearing.
4. Tighten the locknut temporarily tightened in Step
1 from the lower limit of the specified tightening
torque using the SSTs, and make this the
specified preload.
•If the specified preload cannot be obtained
within the specified tightening torque, replace
the collapsible spacer and inspect again.
Tightening torque
240—441 N·m {24.5—44.9 kgf·m, 177—325
ft·lbf}
Drive pinion preload
1.3—1.8 N·m {13.3—18.3 kgf·cm, 11.5—15.9
in·lbf}
5. Crimp the locknut using a chisel and hammer.
Adjusting Shim Assembly Note
1. Assemble the differential carrier to the SSTs.
2. Assemble the spacer to the differential carrier.
3. Stack the side bearing outer race and gear case
component on the surface plate as indicated in
the figure, and measure the height using a caliper
and a ruler. This is value A.
4. Measure the width of the installed differential in
the differential carrier with the spacer installed.
This is value B.
5. The combined thickness of the left and right
adjusting shims is obtained by the following
formula.
C
1 = B – A + 0.15 mm {0.006 in}
C
2 = B – A + 0.44 mm {0.017 in}
6. If the combined thickness of the previously
installed adjusting shims is between C1 and C2,
use the shims as they are.
7. If the combined thickness of the previously
installed adjusting shims is not between C1 and
C2, or if the adjusting shims have to be replaced,
select two appropriate adjusting shims from the table below.
49 L027 006
49 L027 007
A6A63192030
LOCKNUT
1.0 mm {0.04 in}
A6E63192032
A
A6A63192033
B
SPACER
A6E63192034

REAR DIFFERENTIAL
M–63
M
Bearing Cap Assembly Note
1. Align the bearing cap alignment marks to assemble the bearing cap.
Tightening torque
37—51 N·m {3.8—5.2 kgf·m, 28—37 ft·lbf}
2. Inspect the drive pinion and ring gear teeth
contact points.
(1) Coat both surfaces of the ring gear uniformly
with a thin red lead coating.
(2) While rotating the ring gear back and forth by
hand, rotate the drive pinion several times
and inspect the tooth contact.
(3) Inspect the tooth contacts in four locations
around the ring gear, and check that the tooth
contacts showing the red lead coating are the
same as the pattern indicated in the figure.
•If the tooth contact is good, wipe off the
red lead coating.
•If it is not good, adjust the pinion height,
then adjust the backlash.
(4) If toe and flank contact appears as shown in
the figure, replace the spacer with a thinner
one, and move the drive pinion outward.
(5) If heel and face contact appears as indicated
in the figure, replace the spacer with a thicker
one and move the drive the pinion inward.
MARK
A6E63192037
A6A63192038
A6A63192039
A6A63192040

M–64
REAR DIFFERENTIAL
Rear Cover Assembly Note
Caution
•Clean away the old sealant before applying the new sealant.
•Install the rear differential within 10 minutes after applying sealant.
•Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oil.
1. Clean the alignment surface of the carrier and rear cover, and apply a thin coat of sealant.
2. Install the rear cover.
Tightening torque
15.7—22.6 N·m {1.6—2.3 kgf·m, 11.6—16.6 ft·lbf}
Oil Seal Assembly Note
1. Apply differential oil to the new oil seal lip.
2. Assemble the oil seal using the SSTs.
End Of Sie
49 G030 796
49 G030 797
A6A63192041

ELECTRONIC 4WD CONTROL SYSTEM
M–65
M
DIFFERENTIAL OIL TEMPERATURE SENSOR INSPECTIONA6E632227100209
Warning
•Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.
1. Disconnect the negative (-) battery cable.
2. Disconnect the differential oil temperature sensor connector and remove the differential oil temperature sensor.
3. Wrap the differential oil temperature sensor with
plastic wrap and immerse it into a beaker filled
with water. Gradually raise the water
temperature, and measure resistance between
differential oil temperature sensor terminals A and
B.
•If not as specified, inspect the harness for
continuity. If there is normal continuity
between the terminals, replace the differential
oil temperature sensor.
Specification
4. Install the differential oil temperature sensor and connect the connector.
5. Connect the negative (-) battery cable.
End Of Sie
DIFFERENTIAL OIL TEMPERATURE SENSOR REMOVAL/INSTALLATIONA6E632227100210
Warning
•Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.
1. Disconnect the negative (-) battery cable.
2. Disconnect the differential oil temperature sensor connector.
3. Remove the differential oil temperature sensor.
4. Apply differential oil to the O-ring.
5. Install the differential oil temperature sensor.
Tightening torque
12.7—17.3 N·m {1.3—1.7 kgf·m, 9.4—12.7
ft·lbf}
6. Connect the differential oil temperature sensor
connector.
7. Connect the negative (-) battery cable.
End Of Sie
ELECTRONIC 4WD CONTROL SYSTEM
Water temperature (°C {°F}) Resistance (kirohm)
0 {32} 91—100
10 {50} 56—61
20 {68} 35—39
30 {86} 23—25
40 {104} 14—17
50 {122} 10—11
60 {140} 7.1—7.9
70 {158} 5.0—5.6
80 {176} 3.6—4.0
A B
A6J63222101
DIFFERENTIAL OIL
TEMPERATURE SENSOR
A6E63222102

ELECTRONIC 4WD CONTROL SYSTEM
M–69
M
1. Apply sealant to the coupling case surface that contacts the rear differential case.
2. Install the coupling unit to the rear differential so
that the two tabs on the coupling unit engage the
rear differential grooves (two locations).
Tightening torque
22.6—26.4 N·m {2.4—2.6 kgf·m, 16.7—19.4
ft·lbf}
End Of Sie
COUPLING COMPONENT DISASSEMBLYA6E632227100215
Warning
•The engine stand is equipped with a self-lock mechanism, however, if the coupling unit is in a
tilted condition, the self-lock mechanism could become inoperative. If the coupling unit
unexpectedly rotates it could cause injury, therefore do not maintain the coupling unit in a tilted
condition. When turning the coupling unit, grasp the rotation handle firmly.
.
GROOVE
REAR DIFFERENTIAL COUPLING UNITTA B
A6E63222108
SST
SST
SST
SST
9
8
75
4
3
1
2
10
6
A6J63222109
1 Locknut
(See M–70 Locknut Disassembly Note)
2Washer
3 Companion flange
(See M–70 Companion Flange Disassembly Note)
4 Output shaft
(See M–71 Output Shaft Disassembly Note)5 Coupling component
6Oil seal
7Shim
8 Retaining ring
9 Bearing
(See M–71 Bearing Disassembly Note)
10 Coupling case

ELECTRONIC 4WD CONTROL SYSTEM
M–73
M
Output Shaft Assembly Note
1. Install the output shaft to the coupling unit and partially tighten the bolts.
2. Install the companion flange to the output shaft.
3. Secure the companion flange using the SST, and
tighten the bolts.
Tightening torque
36.3—53.9 N·m {3.7—5.4 kgf·m, 26.8—39.7
ft·lbf}
Bearing Assembly Note
1. Assemble the bearing to the coupling case using
the SSTs.
Coupling Case Assembly Note
Caution
•The coupling unit will be damaged if it is pressed directly by a press. Always press the coupling
unit into the coupling case using the SST.
1. Assemble the coupling unit to the coupling case
using the SSTs and a press.
49 S120 710
A6E63222118
49 G030 797
49 G030 796
A6J63222119
49 S032 333
49 W010 107A
A6J63222120