MAZDA 6 2002 Workshop Manual Suplement

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

FRONT DRIVE SHAFT
M–33
M
Joint Shaft Assembly Note
1. Assemble the joint shaft using a press and the
SST.
End Of Sie
49 S231 626
JOINT SHAFT
A6E0313W029

M–34
FRONT DRIVE SHAFT
FRONT DRIVE SHAFT (MZR-CD (RF TURBO)) DISASSEMBLY/ASSEMBLYA6E6315255002011. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
9
9
8
7
5
4
3
10
11
6
1
1
2
2
12
SST
R
R
SST
R
SST
R
R
R
R
R
R
GREASEGREASE
GREASEGREASE
A6E6316W009
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 (transaxle side)
(See M–35 Boot Band (Transaxle Side)
Disassembly Note)
(See M–38 Boot Band (Transaxle Side) Assembly
Note)
3 Clip
(See M–35 Clip Disassembly Note)
(See M–37 Outer Ring, Clip Assembly Note)
4 Outer ring
(See M–37 Outer Ring, Clip Assembly Note)
5 Snap ring
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
6Balls
(See M–36 Balls, Inner Ring, Cage Disassembly
Note)
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)7 Inner Ring
(See M–36 Balls, Inner Ring, Cage Disassembly
Note)
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
8Cage
(See M–36 Balls, Inner Ring, Cage Disassembly
Note)
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
9Boot
(See M–37 Boot Assembly Note)
10 Dynamic damper
(See M–37 Dynamic Damper Assembly Note)
11 ABS sensor rotor
(See M–36 ABS Sensor Rotor (With ABS)
Disassembly Note)
(See M–36 ABS Sensor Rotor (With ABS) Assembly
Note)
12 Shaft and ball joint component

FRONT DRIVE SHAFT
M–35
M
Boot Band (Wheel Side) Disassembly Note
Note
•The boot band does not need to be removed unless it is being replaced.
1. Remove the boot clamp with end clamp pliers as
shown and discard the clamp.
Boot Band (Transaxle Side) Disassembly Note
1. Pry up the locking clips using a screwdriver.
2. Pull back the end of the band.
Clip Disassembly Note
1. Mark the drive shaft and outer ring for proper
assembly.
Caution
•Mark with paint; do not use a punch.
2. Remove the clip.
A6E6316W004
A6E6316W005
MARK
A6E6316W010

M–36
FRONT DRIVE SHAFT
Balls, Inner Ring, Cage Disassembly Note
1. Mark the inner ring and cage.
Caution
•Mark with paint; do not use a punch.
2. Remove the snap ring using snap-ring pliers.
3. Turn the cage approximately 22.5 degree and
pull the cage and balls away from the inner ring.
ABS Sensor Rotor (With ABS) Disassembly Note
Caution
•Do not remove the sensor rotor unless it is necessary.
•Do not reuse the sensor rotor if removed.
1. Tap the ABS sensor rotor off the drive shaft using
a chisel.
ABS Sensor Rotor (With ABS) Assembly Note
1. Set a new ABS sensor rotor on the drive shaft
and press it on using the SSTs.
22.5°
A6E6316W015
A6E63162201
49 B025 006A
1.5{0.06}
STEEL
26.0{1.02}
mm {in}
A6E0313W050

FRONT DRIVE SHAFT
M–37
M
Dynamic Damper Assembly Note
1. Install the dynamic damper as shown in the figure.
Standard length
334.7—340.7 mm {13.2—13.4 in}
2. Install the new boot band onto the dynamic
damper.
Boot Assembly Note
Note
•The wheel side and transaxle side boots are different.
1. Fill the boot (wheel 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
105—125 g {3.71—4.40 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, 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 with the offset facing the
snap ring groove. If incorrectly installed,
the drive shaft may become disengaged.
2. Install a new snap ring.
Outer Ring, Clip Assembly Note
1. Fill the outer ring and boot (transaxle 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
120—140 g {4.24—4.93 oz}
2. Align the marks, and install the outer ring on to the shaft.
3. Install a new clip.
4. Install the boot.
5. Set the drive shaft to the standard length.
DYNAMIC DAMPER
A6E6316W006
CAGEBALLS
SNAP RING
GROOVEINNER
RING
MARK
A6E6316W011

M–38
FRONT DRIVE SHAFT
Standard length
mm {in}
6. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Be careful not to allow the grease to leak.
•Do not damage the boot.
7. Verify that the drive shaft length is within the
specification.
•If not, repeat from Step 5.
Boot Band (Transaxle Side) Assembly Note
1. Fold the band in the direction opposite to the
forward revolving direction of the drive shaft and
use pliers to pull it tight.
2. Lock the end of the band by bending the locking
clips.
Caution
•Install the band into the groove securely.
Boot Band (Wheel Side) Assembly Note
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
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.
Left side Right side
666.3—676.3
{26.24—26.62}615.6—625.6
{24.24—24.62}
A6E6316W007
A6E6316W008
A
49 T025 001
ADJUSTING BOLT
A6E0350W012
B
49 T025 001
A6E0350W013

FRONT DRIVE SHAFT
M–39
M
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of the SST.
Clearance A
3.2 mm {0.13 in}
6. Crimp the wheel side big boot band using the SST.
7. 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
2.4—2.8 mm {0.095—0.110 in}
8. Verify that the boot band does not protrude from the boot band installation area.
•If it does, replace the boot band and repeat Steps 7 and 8.
End Of Sie
FRONT DRIVE SHAFT (4WD) DISASSEMBLY/ASSEMBLYA6E6315255002021. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
A6E0313W043
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 (transaxle side)
(See M–35 Boot Band (Transaxle Side)
Disassembly Note)
(See M–38 Boot Band (Transaxle Side) Assembly
Note)
3 Outer ring
(See M–40 Outer Ring Disassembly Note)
(See M–41 Outer Ring Assembly Note)
4 Snap ring
(See M–40 Snap Ring, Tripod Joint Disassembly
Note)
(See M–41 Tripod Joint, Snap Ring Assembly Note)5 Tripod joint
(See M–40 Snap Ring, Tripod Joint Disassembly
Note)
(See M–41 Tripod Joint, Snap Ring Assembly Note)
6 Free ring
7Boot
(See M–40 Boot Disassembly Note)
(See M–41 Boot Assembly Note)
8 ABS sensor rotor (with ABS)
(See M–36 ABS Sensor Rotor (With ABS)
Disassembly Note)
(See M–36 ABS Sensor Rotor (With ABS) Assembly
Note)
9 Shaft and ball joint component
10 Dynamic damper
(See M–41 Dynamic Damper Assembly Note)

M–40
FRONT DRIVE SHAFT
Outer Ring Disassembly Note
1. Mark the outer ring and the shaft for proper
assembly.
2. Remove the outer ring.
Snap Ring, Tripod Joint Disassembly Note
1. Mark the shaft and tripod joint for proper assembly.
2. Remove the snap ring using snap-ring pliers.
3. Remove the tripod joint from the shaft.
Caution
•Do not tap the tripod joint with a hammer.
Boot Disassembly Note
Note
•The wheel side boot does not need to be removed unless replacing it or the ball joint and shaft
component.
•Do not strip the tape until the boot is assembled.
1. Wrap the shaft splines with tape.
2. Remove the boot.
MARK
A6E0313W046
MARK
A6E0313W047
TAPE
A6E0313W048