MAZDA 6 2002 Workshop Manual Suplement

GENERAL PROCEDURES
M–21
M
PRECAUTION (FRONT AND REAR AXLE)A6E631001018201Wheel and Tire Removal/Installation
1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a
wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}
Brake Line Disconnection/Connection
Caution
•Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut
tightening torque to allow for use of a torque wrench-SST combination.
2. If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
Suspension Arm Removal/Installation
1. Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and
unloaded.
Note
•Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools
are in designated position.
Connector Disconnection
1. Disconnect the negative (-) battery cable before disconnecting connectors.
Electronic Control 4WD System Parts
1. After servicing the electronic control 4WD system parts, verify that no DTC has been stored. Clear any DTCs
remaining in the memory.
End Of Sie
GENERAL PROCEDURES

M–22
REAR AXLE
WHEEL HUB BOLT REPLACEMENTA6E6314050002011. Remove the brake caliper component and the disc plate.
2. Remove the wheel hub bolt using the SST as
shown in the figure.
Note
•If the dust cover interferes with the wheel
hub bolt and the wheel hub bolt cannot be
removed, tap the part shown in the figure
with a chisel lightly and bend the process
back to the knuckle side.
3. Install a new wheel hub bolt into the wheel hub
and install a washer and hub nut on the hub bolt.
4. Tighten the hub nut while holding the wheel hub
using a brass bar.
End Of Sie
WHEEL HUB, KNUCKLE REMOVAL/INSTALLATIONA6E631405000202
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. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
REAR AXLE
49 T028 3A0
BEND THIS PART
A6E0311W011
HUB BOLT
WHEEL
NUT WHEEL
NUT
WASHER
BRASS
BAR
A6E0311W012

REAR AXLE
M–23
M
.
93.2—131.4
{9.6—13.3,
68.8—96.9}
HHG
G
E
E
F
F
AB
A
B
C
C
D
D
86.2—116.6
{8.8—11.9, 63.6—85.9} 18.6—25.5
{1.90—2.63,
13.8—18.8}75.5—94.5
{7.7—9.6, 55.7—69.6}51.0—66.7
{5.3—6.8,
37.7—49.1}43.1—60.8
{4.4—6.1, 31.8—44.8}
235.2—318.5
{24.0—32.4,
173.5—234.9}
9
8
7
5
4
3
1
2
10
1918
17
15
16
14
13
11
12
20
6SST
SST
R
SST
R
R
R
R
75.5—94.5
{7.7—9.6,
55.7—69.6}
86.2—116.6
{8.8—11.9, 63.6—85.9}
86.2—116.6
{8.8—11.9, 63.6—85.9}
N·m {kgf·m, ft·lbf}
A6E63142101
1 ABS wheel-speed sensor
2 Parking brake cable
3 Locknut
(See M–24 Locknut Removal Note)
(See M–28 Locknut Installation Note)
4 Brake caliper component
5 Disc plate
6 Bolt (stabilizer control link (lower))
7 Bolt (rear lower arm (outer))
(See M–24 Bolt (Rear Lower Arm (Outer)) Removal
Note
8 Rear coil spring
(See M–28 Rear Coil Spring Installation Note)
9 Bolt (rear upper arm (outer))
10 Bolt (shock absorber (lower))
(See M–24 Bolt (Shock Absorber (Lower)) Removal
Note)11 Bolt (lateral link (outer))
(See M–24 Bolt (Lateral Link (Outer)) Removal
Note)
12 Bolt (trailing link (front))
(See M–25 Bolt (Trailing Link (Front)) Removal
Note)
(See M–28 Bolt (Trailing Link (Front)) Installation
Note)
13 Trailing link, knuckle component
14 Wheel hub, knuckle component
15 Wheel hub
(See M–25 Wheel Hub Removal Note)
(See M–27 Wheel Hub Installation Note)
16 Snap ring
17 Wheel bearing
(See M–25 Wheel Bearing Removal Note)
(See M–27 Wheel Bearing Installation Note)

M–24
REAR AXLE
Locknut Removal Note
1. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
2. Lock the hub by applying the brakes.
3. Remove the locknut.
Bolt (Rear Lower Arm (Outer)) Removal Note
1. Support the lower arm with a jack.
2. Loosen the lower arm bolts (inner).
3. Remove the lower arm bolts (outer).
4. Gradually lower the jack and separate the lower
arm (outer) from the knuckle.
Bolt (Shock Absorber (Lower)) Removal Note
1. Support the trailing link and the knuckle
component with a jack.
2. Remove the lower shock absorber bolts.
Bolt (Lateral Link (Outer)) Removal Note
1. Loosen the lateral link bolts (inner).
2. Remove the lateral link bolts (outer), and remove the lateral link (outer) from the knuckle.
18 Dust cover
(See M–26 Dust Cover Removal Note)
(See M–27 Dust Cover Installation Note)
19 Knuckle20 Wheel hub bolt
(See M–26 Wheel Hub Bolt Removal Note)
(See M–26 Wheel Hub Bolt Installation Note)
A6E0312W021
JACK
A6E63142102
JACK
A6E63142103

REAR AXLE
M–25
M
Bolt (Trailing Link (Front)) Removal Note
Warning
•Be sure that the trailing link and the knuckle component are supported securely with a jack.
Otherwise, the trailing link and/or the knuckle component may fall, causing death or injury, or
vehicle damage.
1. Verify that the trailing link and the knuckle
component are supported securely with a jack,
and remove the bolts at the trailing link front.
Wheel Hub Removal Note
1. Remove the wheel hub from the knuckle using
the SSTs.
2. If the bearing inner race remains on the wheel
hub, grind a section of the bearing inner race until
approx. 0.5 mm {0.02 in} remains. Then remove
it using a chisel.
Wheel Bearing Removal Note
1. Remove the wheel bearing from the knuckle
using the SSTs.
JACK
A6E63142103
49 G033 105
49 F026 103
49 G033 102
A6J63142104
A6E6312W002
49 F027 005
49 F026 103
49 G030 797
A6J63142105

M–26
REAR AXLE
Dust Cover Removal Note
Note
•The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and knuckle for proper
installation.
2. Remove the dust cover from the knuckle using a
chisel.
Wheel Hub Bolt Removal Note
Note
•The wheel hub bolts do not need to be removed unless they are being replaced.
1. Remove the wheel hub bolts from the wheel hub
using a press.
Wheel Hub Bolt Installation Note
1. Install the new wheel hub bolts to the wheel hub
using a press.
MARK
A6E63142104
A6E6312W003
A6E6312W004

REAR AXLE
M–27
M
Dust Cover Installation Note
1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.
3. Install the new dust cover to the knuckle using the
SSTs.
Wheel Bearing Installation Note
1. Install the new wheel bearing to the knuckle using
the SSTs.
Wheel Hub Installation Note
1. Install the wheel hub to the knuckle using the
SSTs.
A6J63142107
STEEL
PLATE
49 H026 104
49 G033 107A
A6E63142105
49 F027 004
49 H026 104
49 G030 797
A6J63142109
49 G033 105
49 H026 104
49 G033 102
A6J63142110

M–28
REAR AXLE
Bolt (Trailing Link (Front)) Installation Note
Warning
•Be sure that the trailing link and the knuckle component are supported securely with a jack.
Otherwise, the trailing link and/or the knuckle component may fall, causing death or injury, or
vehicle damage.
1. Support the trailing link and the knuckle
component with a jack.
2. Tighten the bolts at the trailing link (front).
Rear Coil Spring Installation Note
1. Install the coil spring so that its small diameter
end points downward.
2. Set a jack to the bottom of the lower arm, and jack
it up gradually.
Warning
•Be careful when installing the coil spring,
as it may fly out by spring force, causing
death or injury, or vehicle damage.
3. Install the lower arm bolts (outer).
Locknut Installation Note
1. Install a new locknut and stake it as shown.
End Of Sie
JACK
A6E63142103
LOWER SIDE LARGE
DIAMETER
SMALL
DIAMETER
A6E63142106
0.5 mm {0.02 in} OR MORE
A6E0312W015

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