differential MAZDA 6 2002 Suplement Owner's Guide

M–18
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E630201018204•The following additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
Rear wheel hub bolt
•Replacement procedure has been added.
Wheel hub, knuckle
•Removal/installation procedure has been added.
Joint shaft (MZR-CD (RF Turbo))
•Disassembly/assembly procedure has been added.
Joint shaft (4WD)
•Disassembly/assembly procedure has been added.
Front drive shaft (MZR-CD (RF Turbo))
•Disassembly/assembly procedure has been added.
Front drive shaft (4WD)
•Disassembly/assembly procedure has been added.
Rear drive shaft
•Inspection procedure has been added.
•Removal/installation procedure has been added.
•Disassembly/assembly procedure has been added.
Differential oil
•Inspection procedure has been added.
•Replacement procedure has been added.
Oil seal (side gear)
•Replacement procedure has been added.
Oil seal (companion flange)
•Replacement procedure has been added.
Rear differential
•Removal/installation procedure has been added.
•Disassembly procedure has been added.
•Assembly procedure has been added.
Differential oil temperature sensor
•Inspection procedure has been added.
•Removal/installation procedure has been added.
4WD solenoid
•Inspection procedure has been added.
Coupling component
•Removal/installation procedure has been added.
•Disassembly procedure has been added.
•Assembly procedure has been added.
On-board diagnostic
•Electronic 4WD control system have been added.
Troubleshooting
•Electronic 4WD control system have been added.
End Of Sie
OUTLINE

M–20
LOCATION INDEX
REAR DIFFERENTIAL/ELECTRONIC 4WD CONTROL SYSTEM LOCATION INDEXA6E630027100201
.
End Of Sie
8
7
5
4
3
6
1
2
8
7
5
4
3
6
1
2
L.H.D.
R.H.D.
A6J63002002
1 Differential oil
(See M–48 DIFFERENTIAL OIL INSPECTION)
(See M–48 DIFFERENTIAL OIL REPLACEMENT)
2 Oil seal (side gear)
(See M–49 OIL SEAL (SIDE GEAR)
REPLACEMENT)
3 Oil seal (companion flange)
(See M–49 OIL SEAL (COMPANION FLANGE)
REPLACEMENT)
4 Rear differential
(See M–51 REAR DIFFERENTIAL REMOVAL/
INSTALLATION)
(See M–52 REAR DIFFERENTIAL DISASSEMBLY)
(See M–56 REAR DIFFERENTIAL ASSEMBLY)5 Differential oil temperature sensor
(See M–65 DIFFERENTIAL OIL TEMPERATURE
SENSOR INSPECTION)
(See M–65 DIFFERENTIAL OIL TEMPERATURE
SENSOR REMOVAL/INSTALLATION)
6 4WD solenoid
(See M–66 4WD SOLENOID INSPECTION)
7 4WD control module
(See M–66 4WD CONTROL MODURE
INSPECTION)
(See M–67 4WD CONTROL MODURE REMOVAL/
INSTALLATION)
8 Coupling component
(See M–68 COUPLING COMPONENT REMOVAL/
INSTALLATION)
(See M–69 COUPLING COMPONENT
DISASSEMBLY)
(See M–72 COUPLING COMPONENT
ASSEMBLY)

FRONT DRIVE SHAFT
M–29
M
JOINT SHAFT (MZR-CD (RF TURBO)) DISASSEMBLY/ASSEMBLYA6E6315257002011. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
Joint Shaft Disassembly Note
1. Disassemble the joint shaft using the SST.
Bearing Disassembly Note
1. Remove the bearing and the dust seal (both
differential side and wheel side) using the SSTs.
FRONT DRIVE SHAFT
4
1
3
52
SST
SST
R
SST
RSST
R
GREASEGREASE
GREASEGREASE
A6E63152001
1 Joint shaft
(See M–29 Joint Shaft Disassembly Note)
(See M–30 Joint Shaft Assembly Note)
2 Bearing
(See M–29 Bearing Disassembly Note)
(See M–30 Bearing Assembly Note)3 Dust seal (Left)
(See M–30 Dust Seal (Differential Side) Assembly
Note)
4 Dust seal (Right)
(See M–30 Dust Seal (Wheel Side) Assembly Note)
5Bracket
BAR
A6E63152002
49 B014 001
49 W034 301
STEEL PLATE
A6E63152003

M–30
FRONT DRIVE SHAFT
Dust Seal (Wheel Side) Assembly Note
1. Apply grease to the new dust seal lip.
2. Install the new dust seal (wheel side) using the
SSTs.
Bearing Assembly Note
1. Install the new bearing using the SSTs.
Dust Seal (Differential Side) Assembly Note
1. Apply grease to the new dust seal lip.
2. Install the new dust seal (differential side) using a
steel plate and the SSTs.
Joint Shaft Assembly Note
1. Assemble the joint shaft using a press and the
SST.
End Of Sie
49 F027 003
49 B025 004
A6E63152004
49 S231 626
49 F027 005
49 F027 003
A6E63152005
49 S231 626
STEEL PLATE
49 W027 003
A6E63152006
49 S231 626
JOINT SHAFT
A6E63152007

FRONT DRIVE SHAFT
M–31
M
JOINT SHAFT (4WD) DISASSEMBLY/ASSEMBLYA6E6315257002021. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
Joint Shaft Disassembly Note
1. Disassemble the joint shaft using the SST.
Bearing Disassembly Note
When the bearing remains on the bracket
1. Remove the bearing and the dust seals (both
differential side and wheel side) using the SSTs.
SST
SST
R
SST
RSST
R
GREASEGREASE
GREASEGREASE
4
1
3
52
A6J63152001
1 Joint shaft
(See M–31 Joint Shaft Disassembly Note)
(See M–33 Joint Shaft Assembly Note)
2 Bearing
(See M–31 Bearing Disassembly Note)
(See M–32 Bearing Assembly Note)3 Dust seal (Differential side)
(See M–32 Dust Seal (Differential Side) Assembly
Note)
4 Dust seal (Wheel side)
(See M–32 Dust Seal (Wheel Side) Assembly Note)
5Bracket
BAR
49 G030 370
A6E63152102
49 B014 001
49 W034 301
STEEL PLATE
A6E63152101

M–32
FRONT DRIVE SHAFT
When the bearing remains on the shaft
1. Remove the bearing from the joint shaft using the
SST.
Dust Seal (Wheel Side) Assembly Note
1. Apply grease to the new dust seal lip.
2. Install the new dust seal (wheel side) using the
SSTs.
Bearing Assembly Note
1. Install the new bearing using the SSTs.
Dust Seal (Differential Side) Assembly Note
1. Apply grease to the new dust seal lip.
2. Install the new dust seal (differential side) using a
steel plate and the SSTs.
49 H027 002
A6J63152003
49 G033 102
49 B025 004
A6E0313W028
49 S231 626
49 F027 005
49 G033 102
A6E0313W027
49 S231 626
STEEL PLATE
49 W027 003
A6E63152103

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)

REAR DRIVE SHAFT
M–45
M
REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLYA6E6317255002031. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
SST
R
R
R
R
R
R
R
GREASEGREASE
GREASEGREASE
7
4
3
1
1
10
6
9
9
8
52
2
11
A6J63172003
1 Boot band (wheel side)
(See M–35 Boot Band (Wheel Side) Disassembly
Note)
(See M–38 Boot Band (Wheel Side) Assembly
Note)
2 Boot band (differential side)
(See M–35 Boot Band (Transaxle Side)
Disassembly Note)
(See M–38 Boot Band (Transaxle Side) Assembly
Note)
3Clip
See M–46 Clip Disassembly Note
See M–47 Outer Ring, Clip Assembly Note
4 Outer ring
(See M–47 Outer Ring, Clip Assembly Note)
5 Snap ring
(See M–46 Snap Ring Disassembly Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)6 Balls
(See M–46 Balls, Inner Ring, Cage Disassembly
Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
7 Inner Ring
(See M–46 Balls, Inner Ring, Cage Disassembly
Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
8Cage
(See M–46 Balls, Inner Ring, Cage Disassembly
Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
9Boot
(See M–47 Boot Assembly Note)
10 ABS sensor rotor
(See M–36 ABS Sensor Rotor (With ABS)
Disassembly Note)
(See M–46 ABS Sensor Rotor Assembly Note)
11 Drive shaft, joint component

REAR DRIVE SHAFT
M–47
M
Boot Assembly Note
Note
•The wheel side and differential side boots are different.
1. Fill the wheel side boot with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
75—95 g {2.65—3.35 oz}
2. With the splines of the shaft wrapped in tape, install the boot.
3. Remove the tape.
Cage, Inner Ring, Balls, Snap Ring Assembly Note
1. Align the marks and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution
•Install the cage so that the major
diameter is at the same side as the snap
ring groove. If incorrectly installed, the
drive shaft may become disengaged.
2. Align the marks and install the inner ring to the
shaft.
3. Install a new snap ring.
Outer Ring, Clip Assembly Note
1. Fill the outer ring and boot (differential side) with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
65—85 g {2.30—2.99 oz}
2. Align the marks, and install the outer ring on to
the shaft.
3. Install a new clip to the outer ring clip groove.
4. Install the boot.
CAGEBALLS
SNAP RING
GROOVEINNER
RING
MARK
A6E6316W011
MARK
A6E6316W010

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