Mazda Car 2002-04

Overhaul

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  

Two types of CV-joints are used. The inboard CV-joints are the tri-Pot type. All outboard CV-joints are Birfield type. The Birfield CV-joint cannot be disassembled; if an outboard CV-joint boot needs replacement, the inboard CV-joint must be removed. If the outboard CV-joint needs to be replaced, replace the entire halfshaft as an assembly.

  1. Remove the halfshaft from the vehicle and clamp it in a vise equipped with jaw caps, to prevent damage to the machined surfaces. Do not allow the vise to contact the boot or its clamps.
  2.  
  3. Remove the large boot clamp from the inboard CV-joint, using side cutters. After removing the clamp, roll the boot back over the shaft.
  4.  


NOTE
Check the grease for contamination by rubbing it between 2 fingers. Any gritty feeling indicates a contaminated CV-joint, in which case the entire CV-joint must be disassembled, cleaned and inspected. If the grease is not contaminated and the CV-joint has been operating satisfactorily, continue with the boot replacement procedure and add the required lubricant.

  1. Paint alignment marks on the outer race and shaft for assembly reference. Remove the wire ring bearing retainer and remove the outer race.
  2.  
  3. Paint alignment marks on the tri-pot bearing and shaft for assembly reference. Remove the tri-pot bearing snapring and, using a brass drift and hammer, remove the tri-pot bearing from the shaft.
  4.  
  5. Remove the small clamp and remove the inner boot from the halfshaft. If the boot is to be reused, wrap the shaft splines with tape before removing.
  6.  
  7. If the outer CV-joint boot is to be replaced, remove the clamps and slide the boot off the shaft from the inboard side.
  8.  

To install:

  1. If the outboard boot was removed, slide the boot onto the shaft from the inboard side. Wrap tape on the splines before installing to protect the boot.
  2.  
  3. Install the inboard boot and remove the tape from the shaft.
  4.  
  5. Install the tri-pot assembly on the halfshaft. Tap the assembly onto the shaft using a hammer and brass drift. Install the tri-pot assembly retaining ring.
  6.  
  7. Fill the CV-joint outer race with high temperature CV-joint grease. Install the outer race over the tri-pot joint and install the wire ring bearing retainer.
  8.  
  9. Position the CV-joint boot(s). Make sure the boot is fully seated in the grooves in the shaft and outer race.
  10.  
  11. Insert a small prybar with rounded edges between the boot and the outer bearing race to allow trapped air to escape from the boot. Install new boot clamps.
  12.  
  13. Wrap the clamps around the boots in a clockwise direction, pull tight with pliers and bend the locking tabs to secure in position.
  14.  
  15. Work the CV-joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly.
  16.  
  17. Install the halfshaft into the vehicle.
  18.  

Two types of CV-joints are used. The inboard CV-joints are the tri-Pot type. All outboard CV-joints are Birfield type. The Birfield CV-joint cannot be disassembled; if an outboard CV-joint boot needs replacement, the inboard CV-joint must be removed. If the outboard CV-joint needs to be replaced, replace the entire halfshaft as an assembly.

  1. Remove the halfshaft from the vehicle and clamp it in a vise equipped with jaw caps, to prevent damage to the machined surfaces. Do not allow the vise to contact the boot or its clamps.
  2.  
  3. Remove the large boot clamp from the inboard CV-joint, using side cutters. After removing the clamp, roll the boot back over the shaft.
    NOTE
    Check the grease for contamination by rubbing it between 2 fingers. Any gritty feeling indicates a contaminated CV-joint, in which case the entire CV-joint must be disassembled, cleaned and inspected. If the grease is not contaminated and the CV-joint has been operating satisfactorily, continue with the boot replacement procedure and add the required lubricant.

  4.  
  5. Paint alignment marks on the outer race and shaft for assembly reference. Remove the wire ring bearing retainer and remove the outer race.
  6.  
  7. Paint alignment marks on the tri-pot bearing and shaft for assembly reference. Remove the tri-pot bearing snapring and, using a brass drift and hammer, remove the tri-pot bearing from the shaft.
  8.  
  9. Remove the small clamp and remove the inner boot from the halfshaft. If the boot is to be reused, wrap the shaft splines with tape before removing.
  10.  
  11. If the outer CV-joint boot is to be replaced, remove the clamps and slide the boot off the shaft from the inboard side.
  12.  

To install:

  1. If the outboard boot was removed, slide the boot onto the shaft from the inboard side. Wrap tape on the splines before installing to protect the boot.
  2.  
  3. Install the inboard boot and remove the tape from the shaft.
  4.  
  5. Install the tri-pot assembly on the halfshaft. Tap the assembly onto the shaft using a hammer and brass drift. Install the tri-pot assembly retaining ring.
  6.  
  7. Fill the CV-joint outer race with high temperature CV-joint grease. Install the outer race over the tri-pot joint and install the wire ring bearing retainer.
  8.  
  9. Position the CV-joint boot(s). Make sure the boot is fully seated in the grooves in the shaft and outer race.
  10.  
  11. Insert a small prybar with rounded edges between the boot and the outer bearing race to allow trapped air to escape from the boot. Install new boot clamps.
  12.  
  13. Wrap the clamps around the boots in a clockwise direction, pull tight with pliers and bend the locking tabs to secure in position.
  14.  
  15. Work the CV-joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly.
  16.  
  17. Install the halfshaft into the vehicle.
  18.  

 
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