Mazda Car 2002-04

Lower Control Arms

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Bushing Replacement



All Mazda-s use a pressed in control arm bushing, and the pressing can be done using 2 appropriately sized sockets (a press socket and a catch socket) and a large vise.

  1. Position the control arm and the 2 sockets into a vise.
  2.  
  3. Position the press socket onto the control arm bushing.
  4.  
  5. Position the catch socket onto the control arm, opposite of the press socket.
  6.  
  7. Tighten the vise slowly and press the bushing into the catch socket.
  8.  

To install:

  1. Apply soapy water to the new control arm bushing.
  2.  
  3. Position the bushing against the control arm.
  4.  
  5. Using the same sockets, in the same positions, press the new bushing into the control arm.
  6.  

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

All Mazda-s use a pressed in control arm bushing, and the pressing can usually be done using 2 appropriately sized sockets (a press socket and a catch socket) and a large vise.

  1. Position the control arm and the 2 sockets into a vise.
  2.  
  3. Position the press socket onto the control arm bushing.
  4.  
  5. Position the catch socket onto the control arm, opposite of the press socket.
  6.  
  7. Tighten the vise slowly and press the bushing into the catch socket.
  8.  

To install:

  1. Apply soapy water to the new control arm bushing.
  2.  
  3. Position the bushing against the control arm.
  4.  
  5. Using the same sockets, in the same positions, press the new bushing into the control arm.
  6.  

The Mazda6 models have two lower control arms in the front suspension assembly, they are identified as the front lower control arm (Front side) and front lower control arm (rear side). They also have one rear suspension lower control arm, which will be identified as Rear lower control arm.

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

All Mazda-s use a pressed in control arm bushing, and the pressing can usually be done using 2 appropriately sized sockets (a press socket and a catch socket) and a large vise.

  1. Position the control arm and the 2 sockets into a vise.
  2.  
  3. Position the press socket onto the control arm bushing.
  4.  
  5. Position the catch socket onto the control arm, opposite of the press socket.
  6.  
  7. Tighten the vise slowly and press the bushing into the catch socket.
  8.  

To install:

  1. Apply soapy water to the new control arm bushing.
  2.  
  3. Position the bushing against the control arm.
  4.  
  5. Using the same sockets, in the same positions, press the new bushing into the control arm.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Position the control arm into a vise. Cut away the projecting rubber from the front bushing. Use tool 49 B034 2A2 to remove the bushing.
  4.  
  5. Remove the rear bushing using a press and tools 49 B034 212 and 49 G034 202.
  6.  

To install:

Click image to see an enlarged view

Fig. Use tool 49 B034 2A2 to remove and install the front bushing-Protégé



Click image to see an enlarged view

Fig. Use tools 49 B034 212 and 49 G034 202 to remove the rear bushing-Protégé



Click image to see an enlarged view

Fig. Use tools 49 B034 212 and 49 G034 211 to install the rear bushing-Protégé



Click image to see an enlarged view

Fig. Align the mark of the lower arm and the small projection of the lower arm bushing (rear) when installing the rear bushing-Protégé

  1. When installing the rear bushing on the lower arm, align the mark of the lower arm and the small projection of the lower arm bushing (rear) as illustrated, set the arm onto the press and press the bushings into position.
  2.  
  3. Apply soapy water to the new control arm bushing.
  4.  
  5. Install the rear bushing using a press and tools 49 B034 212 and 49 G034 211.
  6.  
  7. Position the control arm into a vise. Use tool 49 B034 2A2 to pull the bushing into the arm bore.
  8.  

The Mazda 6 models have two lower control arms in the front suspension assembly, they are identified as the front lower control arm (Front side) and front lower control arm (rear side). They also have one rear suspension lower control arm, which will be identified as Rear lower control arm.

Front Arm (Front Side)
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the front lower control arm (front).
  4.  
  5. Press the bushing from the front lower control arm (front) inner side using the tools illustrated.
  6.  
  7. Press the bushing from the front lower control arm (front) outer side using the tools illustrated.

    Click image to see an enlarged view

    Fig. Press the bushing from/into the front lower control arm (front) inner side using the removal/installer tools shown-Mazda6 and Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Press the bushing from/into the front lower control arm (front) outer side using the removal/installer tools shown-Mazda6 and Mazdaspeed6 models

  8.  

To install:

  1. Mark the front bushing for the outer side on the front lower arm (front) as illustrated.
  2.  
  3. Press the bushing into the arm up to the marking made on the bushing using the tools and press used to remove the bushing. Make sure the clearance is 0.3445-0.4234 inch (8.75-10.75mm) as illustrated.
  4.  
  5. Mark the front bushing for the inner side on the front lower arm (front) as illustrated.
  6.  
  7. Press the bushing into the arm up to the marking made on the bushing using the tools and press used to remove the outer side bushing.

    Click image to see an enlarged view

    Fig. Mark the front bushing for the outer side on the front lower arm (front) as shown-Mazda6 and Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Make sure the clearance is 0.3445-0.4234 inch (8.75-10.75mm) when installing the front bushing for the outer side on the front lower arm (front)-Mazda6 and Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Mark the front bushing for the inner side on the front lower arm (front) as shown-Mazda6 and Mazdaspeed6 models

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the front lower control arm (front).
  4.  
  5. Press the bushing from the front lower control arm (front) inner side using the tools illustrated.
  6.  
  7. Press the bushing from the front lower control arm (front) outer side using the tools illustrated.

    Click image to see an enlarged view

    Fig. Press the bushing from/into the front lower control arm (front) inner side using the removal/installer tools shown-Mazda 6



    Click image to see an enlarged view

    Fig. Press the bushing from/into the front lower control arm (front) outer side using the removal/installer tools shown-Mazda 6

  8.  

To install:

  1. Mark the front bushing for the outer side on the front lower arm (front) as illustrated.
  2.  
  3. Press the bushing into the arm up to the marking made on the bushing using the tools and press used to remove the bushing. Make sure the clearance is 0.3445-0.4234 inch (8.75-10.75mm) as illustrated.
  4.  
  5. Mark the front bushing for the inner side on the front lower arm (front) as illustrated.
  6.  
  7. Press the bushing into the arm up to the marking made on the bushing using the tools and press used to remove the outer side bushing.

    Click image to see an enlarged view

    Fig. Mark the front bushing for the outer side on the front lower arm (front) as shown-Mazda 6



    Click image to see an enlarged view

    Fig. Make sure the clearance is 0.3445-0.4234 inch (8.75-10.75mm) when installing the front bushing for the outer side on the front lower arm (front)-Mazda 6



    Click image to see an enlarged view

    Fig. Mark the front bushing for the inner side on the front lower arm (front) as shown-Mazda 6

  8.  

Front Arm (Rear Side)
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the front lower control arm (rear).
  4.  
  5. Press the bushing from the front lower control arm (rear) using the tools illustrated. remove the arm from the press and use a hammer to remove the bushing completely.

    Click image to see an enlarged view

    Fig. Press the bushing from/into the front lower control arm (rear) using the removal/installer tools shown-Mazda6 and Mazdaspeed6 models

  6.  

To install:

  1. Mark the rear bushing on the front lower arm (rear) as illustrated.
  2.  
  3. Press the bushing into the arm up to the marking made on the bushing using the tools and press used to remove the bushing.
  4.  
  5. The clearance should be 0.936-1.013 inch (23-25mm) as illustrated once the bushing is seated properly.

    Click image to see an enlarged view

    Fig. Mark the rear bushing on the front lower arm (rear) as shown-Mazda6 and Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Install the rear bushing on the front lower arm (rear) as shown-Mazda6 and Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. The rear bushing on the front lower arm (rear) should be 0.936-1.013 inch (23-25mm) once the bushing is seated properly-Mazda6 and Mazdaspeed6 models

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the front lower control arm (rear).
  4.  
  5. Press the bushing from the front lower control arm (rear) using the tools illustrated. remove the arm from the press and use a hammer to remove the bushing completely.

    Click image to see an enlarged view

    Fig. Press the bushing from/into the front lower control arm (rear) using the removal/installer tools shown-Mazda 6

  6.  

To install:

  1. Mark the rear bushing on the front lower arm (rear) as illustrated.
  2.  
  3. Press the bushing into the arm up to the marking made on the bushing using the tools and press used to remove the bushing.
  4.  
  5. The clearance should be 0.936-1.013 inch (23-25mm) as illustrated once the bushing is seated properly.

    Click image to see an enlarged view

    Fig. Mark the rear bushing on the front lower arm (rear) as shown-Mazda 6



    Click image to see an enlarged view

    Fig. Install the rear bushing on the front lower arm (rear) as shown-Mazda 6



    Click image to see an enlarged view

    Fig. The rear bushing on the front lower arm (rear) should be 0.936-1.013 inch (23-25mm) once the bushing is seated properly-Mazda 6

  6.  

Rear Lower Control Arm
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the lower control arm.
  4.  
  5. Press the bushing from the arm using the tools illustrated.

    Click image to see an enlarged view

    Fig. Press the bushing from the rear suspension lower control arm using the tools shown-Mazda6 and Mazdaspeed6 models

  6.  

To install:

  1. Press the bushing into the arm using the tools illustrated.
  2.  
  3. Install the lower control arm.

    Click image to see an enlarged view

    Fig. Press the bushing into the rear suspension lower control arm using the tools shown-Mazda6 and Mazdaspeed6 models

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the lower control arm.
  4.  
  5. Press the bushing from the arm using the tools illustrated.

    Click image to see an enlarged view

    Fig. Press the bushing from the rear suspension lower control arm using the tools shown-Mazda 6

  6.  

To install:

  1. Press the bushing into the arm using the tools illustrated.
  2.  
  3. Install the lower control arm.

    Click image to see an enlarged view

    Fig. Press the bushing into the rear suspension lower control arm using the tools shown-Mazda 6

  4.  

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Wheel
     
    Lower ball joint pinch bolt from the steering knuckle
     
    Stabilizer bar link from the lower control arm
     
    Lower control arm bolts and nuts
     
    Lower control arm with the lower ball joint
     

  4.  

To install:

  1. Install or connect the following:

    Lower control arm and loosely tighten the mounting nuts and bolts
     
    Stabilizer link to the lower control arm. Torque the nut to 27-39 ft. lbs. (37-53 Nm)
     
    Lower ball joint to the steering knuckle. Torque the bolt to 26-41 ft. lbs. (35-56 Nm)
     
    Wheel
     

  2.  
  3. With the vehicle at normal ride height, tighten the lower control arm mounting bolts. Torque the front bushing through-bolt to 58-78 ft. lbs. (79-106 Nm) and the rear bushing strap bolts to 69-96 ft. lbs. (94-131 Nm).
  4.  
  5. Check and/or adjust the front wheel alignment.
  6.  

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

    Wheel
     
    Lower ball joint pinch bolt from the steering knuckle
     
    Stabilizer bar link from the lower control arm
     
    Lower control arm bolts and nuts
     
    Lower control arm with the lower ball joint
     

  4.  

To install:

  1. Install or connect the following:

    Lower control arm and loosely tighten the mounting nuts and bolts
     
    Stabilizer link to the lower control arm. Torque the nut to 27-39 ft. lbs. (37-53 Nm).
     
    Lower ball joint to the steering knuckle. Torque the bolt to 26-41 ft. lbs. (35-56 Nm).
     
    Wheel
     

  2.  
  3. With the vehicle at normal rode height, tighten the lower control arm mounting bolts. Torque the front bushing through-bolt to 40-59 ft. lbs. (55-80 Nm) and the rear bushing strap bolts to 69-96 ft. lbs. (94-131 Nm).
  4.  
  5. Check and/or adjust the front wheel alignment.
  6.  

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

    Wheel
     
    Rear lower arm bolt
     
    Lower ball joint pinch bolt from the steering knuckle
     
    Bracket
     
    Lower control arm with the lower ball joint
     

  4.  

To install:

  1. Install or connect the following:

    Bracket and tighten the bolts to 68-97 ft. lbs. (94-126 Nm).
     
    Lower control arm and loosely tighten the mounting nuts and bolts
     
    Lower ball joint to the steering knuckle. Torque the bolt to 32-43 ft. lbs. (44-58 Nm).
     
    Wheel
     

  2.  
  3. With the vehicle at normal rode height, tighten the lower control arm rear mounting bolts to 69-94 ft. lbs. (94-126 Nm).
  4.  
  5. Check and/or adjust the front wheel alignment.
  6.  

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

    Wheel
     
    Undercover
     
    Cotter pin and nut from the tie-rod end
     
    Tie-rod end from the steering knuckle
     
    Stabilizer bar link bolt and the lower strut mounting bolt
     
    Cotter pin
     
    Lower ball joint by loosening it
     

  4.  
  5. With the nut protecting the ball joint stud, separate the stud from the knuckle. Remove the nut.

    Dust boot, if necessary
     
    Lower control arm bolts, nuts and adjusting cams
     
    Lower control arm
     

  6.  

To install:

  1. Install or connect the following:

    Dust boot, if removed using a press. Always fill the inside of the new boot with grease prior to installation.
     
    Lower control arm by loosely tightening the bolts and nuts
     
    Lower ball joint to the knuckle. Torque the nut to 42-57 ft. lbs. (57-77 Nm).
     
    New cotter pin
     
    Lower strut and stabilizer link bolts by loosely tightening them
     
    Tie-rod end to the steering knuckle. Torque the nut to 22-32 ft. lbs. (30-44 Nm).
     
    New cotter pin
     
    Wheel and undercover
     

  2.  
  3. With the vehicle at normal rode height, torque the lower control arm bolts to 69-83 ft. lbs. (94-113 Nm) for the inner and 69-86 ft. lbs. (94-112 Nm) for the outer.
  4.  
  5. Torque the lower strut mounting bolt to 69-86 ft. lbs. (94-116 Nm) and the stabilizer link bolt to 32-44 lbs. (44-60 Nm).
  6.  
  7. Check and/or adjust the front wheel alignment.
  8.  

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

    Transverse member
     
    Power steering return hose and pressure pipe
     
    Intermediate steering shaft bolt
     

  4.  
  5. Support the engine from the top.

    Engine mount member
     
    Bolts for engine mount No. 1
     
    Lower strut mounting bolt
     
    Tie-rod end from the steering knuckle
     
    Upper lateral link ball joint
     
    Lower ball joint
     
    Stabilizer control link nut
     
    Gusset
     

  6.  
  7. Support the crossmember using a jack.

    Crossmember mounting nuts and lower the crossmember to gain clearance
     
    Lower arm assembly
     

  8.  

To install:

  1. Install or connect the following:

    Lower arm assembly to the vehicle
     
    Crossmember mounting bolts
     
    Gusset. Torque the bolts to 58-86 ft. lbs. (79-116 Nm).
     
    Stabilizer control link. Torque the nut to 32-44 ft. lbs. (44-60 Nm).
     
    Lower ball joint. Torque the bolts to 58-86 ft. lbs. (79-116 Nm) and the nut to 86-115 ft. lbs. (116-156 Nm).
     
    Upper lateral link nut and bolt. Torque to 58-86 ft. lbs. (79-116 Nm).
     
    Tie-rod end. Torque the nut to 41-59 ft. lbs. (55-80 Nm).
     
    Strut lower mounting bolt. Torque to 73-101 ft. lbs. (98-137 Nm).
     
    No. 1 engine mount. Torque the bolts to 32-44 ft. lbs. (44-60 Nm).
     
    Engine mount member. Torque the bolts to 50-68 ft. lbs. (67-93 Nm) and the nuts to 55-77.3 ft. lbs. (75-104 Nm).
     

  2.  
  3. Remove the engine support tool.

    Intermediate steering shaft. Torque the bolt to 14-19 ft. lbs. (18-26 Nm).
     
    Power steering pressure pipe and return hose
     
    Transverse member
     

  4.  
  5. Check the power steering fluid and fill to proper level, bleed if necessary.
  6.  
  7. Check and/or adjust the front end alignment.
  8.  

The Mazda 6 models have two lower control arms in the front suspension assembly, they are identified as the front lower control arm (Front side) and front lower control arm (rear side). They also have one rear suspension lower control arm, which will be identified as rear lower control arm.

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

    Wheel
     
    Cotter pin
     
    Lower ball joint by loosening it
     

  4.  
  5. With the nut protecting the ball joint stud, separate the stud from the knuckle. Remove the nut.
    NOTE
    If removing the right side lower arm, move the engine and transaxle slightly towards the front side of the vehicle so the engine does not interfere with the lower arm rear side bolt removal.



    Cotter pin and nut from the tie-rod end
     
    Tie-rod end from the steering knuckle
     



    No. 1 engine mount center bolt.
     
    Engine and transaxle assembly slightly towards the front off the vehicle if necessary to remove the right lower arm
     
    Lower arm rear side bolt and the lower arm.
     
    Dust boot, if necessary
     

  6.  

To install:

  1. Install or connect the following:

    Dust boot, if removed using a press. Always fill the inside of the new boot with grease prior to installation.
     
    Lower control arm by loosely tightening the bolts and nuts
     
    No. 1 engine mount bolt and tighten to 68-86 ft. lbs. (93-116 Nm).
     

  2.  
  3. Tighten the lower control arm bolts to the specifications shown in the accompanying illustration.
  4.  
  5. Install the remaining components in the reverse order of removal, refer to the exploded view of the lower control arm assembly and related components illustration for component location and torque specifications.
  6.  
  7. Check and/or adjust the front wheel alignment.

    Click image to see an enlarged view

    Fig. Exploded view of the front lower control arm assembly and related components-Mazda3

  8.  

Front Arm (Front Side)

Refer to the accompanying illustration for component locations and torque specifications.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the three way converter on models with the 3.0L (AJ) engine.
  4.  
  5. Separate the lower control arm (front) ball joint from the knuckle.
  6.  
  7. Remove the front shock lower bolt and the dynamic damper.
  8.  
  9. Remove the lower inner side arm bolt.
  10.  
  11. Remove the front lower arm (front).
  12.  

To install:

  1. Installation is the reverse of removal. refer to the illustration for bolt torque specifications.

    Click image to see an enlarged view

    Fig. Exploded view of the front suspension lower control arm (front) assembly-Mazda 6

  2.  

Front Arm (Rear Side)

Refer to the accompanying illustration for component locations and torque specifications.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the wheels, engine under cover and splash shield.
  4.  
  5. Remove the steering gear and linkage bolts, pipe assembly from the crossmember and wire the assembly aside.
  6.  
  7. Remove the stabilizer bar link nut.
  8.  
  9. Separate the lower control arm (rear) ball joint from the knuckle.
  10.  
  11. Remove the No. 1 center bolt.
  12.  
  13. Support the crossmember with a jack and remove the crossmember bracket.
  14.  
  15. Remove the front lower arm (rear).
  16.  

To install:

  1. Installation is the reverse of removal. refer to the illustration for bolt torque specifications.

    Click image to see an enlarged view

    Fig. Exploded view of the front suspension lower control arm (rear) assembly-Mazda 6

  2.  

 
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