wheel MAZDA 6 2002 Suplement Manual Online

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

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

FRONT DRIVE SHAFT
M–41
M
Dynamic Damper Assembly Note
1. Install the dynamic damper as shown in the
figure.
Standard length
Left side: 281.7—287.7 mm {11.10—11.32 in}
Right side: 334.7—340.7 mm {13.2—13.4 in}
2. Install a 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
90—110 g {3.18—3.88 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
Tripod Joint, Snap Ring Assembly Note
1. Align the marks and install the tripod joint using a
bar and a hammer.
Caution
•Do not damage the roller.
2. Install the new snap ring using snap-ring pliers.
Caution
•Be sure the snap ring engages correctly
in the groove of the shaft.
Outer Ring 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
Left side: 185—205 g {6.53—7.23 oz}
Right side: 195—215 g {6.88—7.58 oz}
2. Install the outer ring.
3. Set the drive shaft to the standard length.
DYNAMIC DAMPER
A6E6316W006
MARK
A6E0313W051

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–80
ON-BOARD DIAGNOSTIC
End Of Sie
DTC U0100A6E637027100205
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
End Of Sie
DTC U0101A6E637027100206
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
End Of Sie
DTC U0121A6E637027100207
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
End Of Sie
4INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR SHORT TO
GROUND
•Inspect for continuity between 4WD CM
terminal A and ground.
•Is there continuity?Yes Repair or replace harness for short to ground between 4WD
CM and differential oil temperature sensor, then go to Step
7.
No Go to next step.
5INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR OPEN
CIRCUIT
•Inspect for continuity between 4WD CM
terminal C and differential oil temperature
sensor terminal B.
•Is there continuity?Yes Go to next step.
No Repair or replace harness for open circuit between 4WD CM
and differential oil temperature sensor, then go to Step 7.
6INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR SHORT TO
GROUND
•Inspect for continuity between 4WD CM
terminal C and ground.
•Is there continuity?Yes Repair or replace harness for short to ground between 4WD
CM and differential oil temperature sensor, then go to next
step.
No Replace 4WD CM, then go to next step.
7VERIFY TROUBLESHOOTING COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from memory.
(See M–76 Clearing DTCs Procedures)
•Drive vehicle.
•Is the same DTC present?Yes Replace 4WD CM, then go to next step.
No Go to next step.
8VERIFY AFTER REPAIR PROCEDURE
•Is there any other DTC present?Yes Go to applicable DTC inspection.
No Troubleshooting completed. STEP INSPECTION ACTION
DTC U0100 PCM communication
DETECTION
CONDITION•4WD CM detects that communication signals (throttle opening angle and engine speed signals) from
PCM are abnormal.
POSSIBLE
CAUSE•PCM signals have communication error.
DTC U0101 TCM communication
DETECTION
CONDITION•4WD CM detects that communication signals (selector lever position and gear position signals) from
TCM are abnormal.
POSSIBLE
CAUSE•TCM signals have communication error.
DTC U0121 ABS/DSC communication
DETECTION
CONDITION•4WD CM detects that communication signals (four-wheel speed, ABS/DSC operation condition, and
coupling torque request signals) from DSC HU/CM are abnormal.
POSSIBLE
CAUSE•DSC HU/CM signals have communication error.