626 1999-2001

Struts (MacPherson Struts)

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Overhaul



Specific to:

Mazda 626 1999-2002

Mazda Millenia 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Strut from the vehicle
     
    Cap from the top of the strut, if not equipped with Automatic Adjusting Suspension (AAS)

    Click image to see an enlarged view

    Fig. Be sure the end of the coil spring is in the step of the lower seat-626



    Click image to see an enlarged view

    Fig. Exploded view of the front strut assembly-rear strut is similar

     
    Piston rod upper nut 1 turn but do not remove it

    Click image to see an enlarged view

    Fig. Secure the upper strut mount in a vise and loosen the piston rod nut one turn but do not remove it

     

  4.  
  5. Place the lower end of the strut in the vise.
  6.  
  7. Install a coil spring compressor and compress the coil spring.
    CAUTION
    Failure to fully compress the spring and hold it securely can be extremely dangerous.

  8.  
  9. Remove or disconnect the following:

    Upper strut nut
     
    Slowly release the coil spring tension

    Click image to see an enlarged view

    Fig. Use a coil spring compressor and relieve the spring tension from the upper mount, then remove the piston rod nut

     
    Suspension support, dust seal, spring seat, spring insulators, coil spring and bumper
     

  10.  
  11. While pushing on the piston rod, be sure that the pull stroke is even and that there is no unusual noise or resistance. Also inspect for any oil leakage around the piston rod.
  12.  
  13. Push the piston rod in, then release it. Be sure that the return rate is constant.
  14.  
  15. If the shock absorber does not operate as described, replace it.
  16.  

To assemble:

  1. Install or connect the following:

    Strut assembly into a vise
     
    Bump stopper and dust boot onto the piston rod
     
    Temporarily install the upper spring seat, seat rubber and spring. Mark the seat, shock and spring assembly as illustrated for reassembly. Align the marks of the upper seat and coil spring. Protect the assembly with cloth and install the spring compressor.

    Click image to see an enlarged view

    Fig. Mark the front seat, shock and spring assembly as illustrated for reassembly-Millenia



    Click image to see an enlarged view

    Fig. Mark the rear seat, shock and spring assembly as illustrated for reassembly-Millenia

     
    Coil spring
     

  2.  
  3. Compress the coil spring with the spring compressor
  4.  
  5. Install or connect the following:

    Rubber seat, the spring upper seat, the bearing and the mounting block
     
    Piston rod upper nut
     

  6.  
  7. Be sure that the spring upper seat notched portion is facing inward and tighten the piston rod upper nut.
  8.  
  9. Remove the spring compressor from the strut. Secure the upper mounting block in the vise and tighten the nut to 40-59 ft. lbs. (55-80 Nm) on 626 models and 24-33 ft. lbs. (32-46 ft. lbs. on Millenia models.
  10.  
  11. Be sure that the spring is well seated in the upper seats.
  12.  
  13. Install the strut to the vehicle.
  14.  

Removal & Installation



Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Support the lower control arm with a jack.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Brake hose and/or ABS sensor harness to the strut Bolts or clips
     
    Actuator from the top of the strut, if equipped with Automatic Adjusting Suspension (AAS)
     

  6.  
  7. Paint alignment marks on the upper strut mounting block and strut tower, and on the lower strut mount-to-steering knuckle so the strut can be reinstalled in the same position.
  8.  
  9. Remove or disconnect the following:

    Upper strut mounting nuts
     
    Strut-to-knuckle bolts
     
    Strut assembly
     

  10.  

To install:

  1. Install or connect the following:

    Strut into the strut tower, aligning the paint marks made during removal
     
    Upper mounting nuts and tighten to 34-46 ft. lbs. (47-62 Nm)
     
    Strut-to-knuckle bolts and tighten to 55-61 ft. lbs. (74-83 Nm)
     
    Actuator and engage the electrical connector, if equipped with AAS
     
    Brake hose and/or ABS sensor harness clips or bolts
     
    Wheel
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

 
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