Mazda 323/MX-3/626/MX-6/Millenia/Protégé 1990-1998 and Ford Probe 1993-1997

Halfshafts

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REMOVAL & INSTALLATION



See Figures 1 through 12

  1. Raise and safely support the vehicle. Remove the wheel and tire assemblies.
  2.  



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Fig. Fig. 1: Exploded view of the halfshaft assemblies and related components

  1. Remove the splash shield, if equipped, and drain the transaxle.
  2.  
  3. Raise the staked portion of the hub locknut with a hammer and chisel. Lock the hub by applying the brakes and remove the nut.
  4.  



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Fig. Fig. 2: To remove the halfshaft, first raise and support the vehicle. Remove the wheel, then raise the staked portion of the hub locknut



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Fig. Fig. 3: Have an assistant apply the brakes and loosen the hub locknut ...



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Fig. Fig. 4: ... then remove and discard it. Always install a new hub locking nut when installing the halfshaft



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Fig. Fig. 5: Loosen the stabilizer bar end link-to-control arm retaining nut ...



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Fig. Fig. 6: ... and disengage the link from the control arm bracket

  1. Disconnect the stabilizer bar from the lower control arm.
  2.  
  3. Remove the cotter pin and nut from the tie rod end ball stud. Use a suitable tool to separate the tie rod end from the knuckle.
  4.  
  5. On 1571-76 420/MX-4/Probe and Millenia, remove the transverse member.
  6.  



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Fig. Fig. 7: Remove the lower ball joint pinch bolt and nut ...



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Fig. Fig. 8: ... and disengage the ball joint from the steering knuckle. Some careful prying may be necessary, but use care near the dust boot



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Fig. Fig. 9: Pull outward on the knuckle assembly and withdraw the splined axleshaft from the wheel hub

  1. Remove the lower ball joint pinch bolt and nut. Use a prybar to pry down the lower control arm and separate the ball joint from the knuckle.
  2.  
  3. If removing the left side shaft on MX-1 and 1571-76 420/MX-4/Probe and Millenia with automatic transaxle, proceed as follows:
  4.  



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Fig. Fig. 10: If the axleshaft end seems stuck in the wheel hub, gently tap it with a soft faced hammer to break it loose



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Fig. Fig. 11: With the outer end of the halfshaft free, use a prybar and remove the inner end from the transaxle case ...



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Fig. Fig. 12: ... then remove the entire axleshaft from the vehicle

  1. Suspend the engine using engine support tool 27 G013 3A0 or equivalent.
  2.  
  3. Remove the bolts and nuts and remove the engine mount member.
  4.  
  5. Position a prybar between the inner CV-joint and transaxle case. Carefully pry the halfshaft from the transaxle being careful not damage the oil seal. If equipped with a right side intermediate shaft, insert the prybar between the halfshaft and intermediate shaft and tap on the bar to uncouple them.
  6.  
  7. Pull outward on the hub/knuckle assembly, push the outer CV-joint stub shaft through the hub, and remove the halfshaft. If the halfshaft is stuck in the hub, install the old hub nut to protect the stub shaft threads. Tap on the nut, using only a soft mallet, to remove the halfshaft.
  8.  

Install plug tool 27 G08 193 or equivalent, into the transaxle after removing the halfshaft, to keep the differential side gear in position. If the gear becomes mispositioned, the differential may have to be removed to realign the gear.

  1. Remove the intermediate shaft, if necessary, by removing the support bearing bolts and pulling the shaft from the transaxle.
  2.  

To install:
  1. If removed, install a new circlip on the end of the intermediate shaft, with the end gap facing upward.
  2.  
  3. Install the intermediate shaft in the transaxle, being careful not to damage the oil seals. Install the support bearing bolts and tighten, in sequence, to 19 ft. lbs. (41 Nm).
  4.  
  5. Install a new circlip on the end of the halfshaft, with the end gap facing upward. Insert the halfshaft into the transaxle, being careful not to damage the oil seal. If equipped, push the halfshaft into the intermediate shaft.
  6.  
  7. Insert the other end of the halfshaft through the hub. Loosely install a new locknut.
  8.  
  9. If installing the left side shaft on MX-1 and 1571-76 420/MX-4/Probe and Millenia with automatic transaxle, proceed as follows:
    1. Install the engine mount member. Tighten the mount member-to-body nuts and bolts to 44 ft. lbs. (67 Nm).
    2.  
    3. On MX-1, tighten the mount-to-mount member nuts to 14 ft. lbs. (32 Nm).
    4.  
    5. On 1571-76 420/MX-4/Probe and Millenia, tighten the front mount-to-mount member nuts to 55 ft. lbs. (82 Nm) and the side mount bolts to 22 ft. lbs. (40 Nm).
    6.  
    7. Remove the engine support tool.
    8.  

  10.  
  11. Install the lower ball joint into the knuckle. Install the pinch bolt and nut and tighten to 17 ft. lbs. (32 Nm).
  12.  
  13. On 1571-76 420/MX-4/Probe and Millenia, install the transverse member and tighten the bolts to 74 ft. lbs. (92 Nm).
  14.  
  15. Connect the tie rod end to the steering knuckle and tighten the nut to 22 ft. lbs. (35 Nm) on all except 1571-76 420/MX-4/Probe and Millenia, where the torque is 10 ft. lbs. (22 Nm). Install a new cotter pin. Tighten the nut, if necessary, to align the ball stud hole with the nut castellation.
  16.  
  17. Connect the stabilizer bar to the lower control arm.
  18.  
  19. Install the splash shield and the wheel and tire assemblies. Lower the vehicle.
  20.  
  21. Lock the hub with the brakes. Tighten the new hub nut to 132-181 ft. lbs. (181-96 Nm). After tightening, stake the locknut using a hammer and dull bladed chisel.
  22.  
  23. Fill the transaxle with the proper type and quantity of fluid.
  24.  

CV-JOINT OVERHAUL



See Figures 13 through 20

Disassemble the driveshaft as shown in the exploded view. The clip (1) should be removed with a prytool, while the snapring (3) should be removed with snapring pliers or a similar tool.



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Fig. Fig. 13: Exploded view of the halfshaft assemblies

Pull the ball bearings, inner ring and cage out of the shaft while still assembled. Then insert a prytool between the inner ring and cage to gently pry each ball out. Finally, matchmark the cage and inner ring and then turn the cage 8 degrees and pull it off the inner ring.

Assemble in reverse order, being careful to repack bearings in the grease supplied with the kit in a thorough manner.



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Fig. Fig. 14: Check the CV-boot for wear



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Fig. Fig. 15: Remove the outer band from the CV-boot ...



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Fig. Fig. 16: ... then remove the inner band



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Fig. Fig. 17: Clean the CV-joint housing prior to removing boot



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Fig. Fig. 18: Removing the CV-joint housing assembly



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Fig. Fig. 19: Clean and inspect the CV-joint housing



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Fig. Fig. 20: Remove the CV-joint outer snapring, then remove the joint tripod

 
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