oil MAZDA 6 2002 Workshop Manual Suplement

REAR DRIVE SHAFT
M–43
M
REAR DRIVE SHAFT REMOVAL/INSTALLATIONA6E631725500202
Caution
•Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (wheel side) and fix it to an
appropriate place where the sensor will not be pulled by mistake while the vehicle is being
serviced.
1. Drain the rear differential oil into a container. (See M–48 DIFFERENTIAL OIL REPLACEMENT.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
.
SST
R
R
R
OILOIL
4
3
1
2
235.2—318.5
{24.0—32.4,
173.5—234.9}
N·m {kgf·m, ft·lbf}
A6J63172001
1 Trailing link, knuckle component
(See M–22 WHEEL HUB, KNUCKLE REMOVAL/
INSTALLATION)
2 Rear drive shaft
(See M–44 Rear Drive Shaft Removal Note)3Oil seal
(See M–49 OIL SEAL (SIDE GEAR)
REPLACEMENT)
4Clip
(See M–44 Clip Installation Note)

M–44
REAR DRIVE SHAFT
Rear Drive Shaft Removal Note
1. Deform the metal cover of the oil seal using a bar,
and disengage the drive shaft.
Note
•Oil seal cannot be reused. Always replace
the oil seal with a new one.
Clip Installation Note
1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does
not exceed the specification on installation.
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Steps 1—2
using a new clip.
Outer diameter specification
26.0 mm {1.02 in} max.
End Of Sie
A6J63172201
OUTER
DIAMETER OPENING
CLIP
A6E0313W021

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

REAR DIFFERENTIAL
M–51
M
REAR DIFFERENTIAL REMOVAL/INSTALLATIONA6E6319271002071. Drain the rear differential oil into a container.
2. Remove the after silencer, presilencer, and catalytic converter. (See F1–30 EXHAUST SYSTEM REMOVAL/
INSTALLATION.)
3. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove the rear drive shaft. (See M–43 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Add the specified rear differential oil.
.
SEALANTSEALANT
5
3
12
6
86.2—116.6
{8.8—11.9,
63.6—85.9}
74.5—104.9
{7.6—10.6, 55.0—77.3}
43.1—60.8
{4.4—6.1,
31.8—44.8}
22.6—26.4
{2.4—2.6,
16.7—19.4}
4
N·m {kgf·m, ft·lbf}
A6E63192201
1 Differential oil temperature sensor connector
2 4WD solenoid connector
3 Coupling component and rear differential
component
(See M–52 Coupling Component and Rear
Differential Component Removal/installation Note)
4 Rear differential bracket 5 Coupling component
(See M–68 COUPLING COMPONENT REMOVAL/
INSTALLATION)
6 Rear differential

REAR DIFFERENTIAL
M–53
M
Rear Cover Disassembly Note
1. Install the SSTs to the engine stand.
2. Install the rear differential to the SSTs.
3. Remove the rear cover using an oil seal cutter.
Bearing Cap Disassembly Note
1. Place alignment marks on the bearing cap and
carrier.
1 Differential oil temperature sensor
2 Rear cover
(See M–53 Rear Cover Disassembly Note)
3 Bearing cap
(See M–53 Bearing Cap Disassembly Note)
4 Rear differential component
(See M–54 Rear Differential Component
Disassembly Note)
5 Side bearing outer race
6 Adjusting shim
7Spacer
8 Locknut
(See M–54 Locknut Disassembly Note)
9 Drive pinion
(See M–54 Drive Pinion Disassembly Note)
10 Collapsible spacer
11 Bearing inner race (front bearing)12 Bearing inner race (rear bearing)
(See M–54 Bearing Inner Race (Rear Bearing)
Disassembly Note)
13 Spacer
14 Bearing outer race
(See M–55 Bearing Outer Race Disassembly Note)
15 Differential carrier
16 Ring gear
(See M–55 Ring Gear Disassembly Note)
17 Knock pin
18 Pinion shaft
19 Pinion gear
20 Side gear
21 Thrust washer
22 Side bearing inner race
(See M–55 Side Bearing Inner Race Disassembly
Note)
23 Oil seal
24 Gear case
49 L027 0A2
49 0107 680A
A6A63192009
49 L027 0A2
49 0107 680A
A6A63192010
MARK
A6E63192011

M–56
REAR DIFFERENTIAL
REAR DIFFERENTIAL ASSEMBLYA6E631927100209
Warning
•The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a
tilted condition, the self-lock mechanism could become inoperative. If the rear differential
unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted
condition. When turning the rear differential, grasp the rotation handle firmly.
Note
•Clean away the old sealant before applying the new sealant.
•Install the rear cover 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. Assemble in the order indicated in the table.
.
SST
SST
SST
SSTSST
SST
SST
9
8
7
54
4
3
3
12
2
10
10
19
19
18
17
15
16
14
13
1112
20
25
25
24
23
21
22
22
R
SST
R
R
R
SSTR
RR
6
SEALANTSEALANT
SEALANTSEALANT
OILOIL
OILOIL
15.7—22.6
{1.6—2.3, 11.6—16.6}
37—51
{3.8—5.2,
27.3—37.6}
240—441
{24.5—44.9, 177—325} 12.7—17.3
{1.3—1.7,
9.4—12.7}69—83
{7.1—8.4,
50.9—61.2}
N·m {kgf·m, ft·lbf}
R
A6E63192019
1 Gear case
2 Side bearing inner race
(See M–57 Side Bearing Inner Race Assembly
Note)
3 Thrust washer
(See M–57 Thrust washer assembly note)
4 Side gear
5 Pinion gear
6Pinion shaft
7 Knock pin
8 Ring gear
(See M–58 Ring Gear Assembly Note)
9 Differential carrier10 Bearing outer race
(See M–58 Bearing Outer Race Assembly Note)
11 Spacer
(See M–59 Spacer, Bearing Inner Race Assembly
Note)
12 Bearing inner race (rear bearing)
(See M–59 Spacer, Bearing Inner Race Assembly
Note)
13 Bearing inner race (front bearing)
(See M–59 Spacer, Bearing Inner Race Assembly
Note)
14 Collapsible spacer
15 Drive pinion
16 Locknut
(See M–61 Locknut Assembly Note)

REAR DIFFERENTIAL
M–57
M
Side Bearing Inner Race Assembly Note
Caution
•Do not mix up the left and right side bearing inner races.
1. Press the side bearing inner races into the gear
case using the SSTs.
Thrust washer assembly note
1. Assemble the side gears, thrust washers and pinion gears to the gear case, then assemble the knock pin.
2. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.
3. Set a dial gauge to the pinion gear as indicated in
the figure.
4. Secure one of the side gears.
5. Move the pinion gear and measure the backlash
at the end of the pinion gear.
•If the backlash exceeds the standard, use the
thrust washers to adjust.
Standard backlash
0.1 mm {0.004 in} or less
Thrust washer thickness
mm {in}
17 Adjusting shim (L)
(See M–61 Adjusting Shim Assembly Note)
18 Spacer
19 Side bearing outer race
20 Rear differential component
21 Adjusting shim (R)22 Bearing cap
(See M–63 Bearing Cap Assembly Note)
23 Rear cover
(See M–64 Rear Cover Assembly Note)
24 Differential oil temperature sensor
25 Oil seal
(See M–64 Oil Seal Assembly Note)
49 F401 331
49 F401 337A
A6A63192020
Identification mark Thickness
F001 27 252 2.0 {0.079}
F001 27 253 2.1 {0.083}
F001 27 254 2.2 {0.086}
A6A63192021

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