Mazda Car 2002-04

Strut (MacPherson Strut) Assembly 1

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Overhaul (Coil Spring Removal & Installation)



  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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
     
    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 specification.
  10.  
  11. Be sure that the spring is well seated in the upper seats.
  12.  
  13. Install the strut to the vehicle.
  14.  

  1. Before servicing the vehicle, refer to the precautions section.
    NOTE
    Refer the exploded view illustration for component locations and if applicable, their retainer torque specifications.


    CAUTION
    Removing or installing the shock absorber and coil spring is dangerous. The shock absorber and coil spring could fly off and cause serious injury or death, and damage the vehicle.

  2.  
  3. Remove the front shock absorber and coil spring.
    WARNING
    Before removing the piston rod nut, secure the shock absorber and spring in a suitable spring compressor. Otherwise, the shock absorber and spring could fly off under tremendous pressure and cause serious injury or death, or damage to vehicle parts.

  4.  
  5. Protect the coil spring from scratches using a piece of cloth and install the spring compressor.
  6.  
  7. Compress the coil spring and remove the piston rod nut.
  8.  
  9. Remove the following:

    Retainer
     
    Bushing
     
    Upper spring seat
     
    Dust boot
     
    Spacer
     
    Bushing
     
    Stopper casing and bound stopper
     
    Bound stopper
     
    Stopper casing
     
    Coil spring
     
    Shock absorber
     

  10.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the front coil spring assembly-MX-5 Miata



Click image to see an enlarged view

Fig. Compress the front coil spring and remove the piston rod nut-MX-5 Miata

To install:

  1. Install the following:

    Shock absorber
     
    Coil spring
     
    Stopper casing
     
    Bound stopper
     
    Stopper casing and bound stopper
     
    Bushing
     
    Spacer
     
    Dust boot
     
    Upper spring seat
     
    Bushing
     
    Retainer
     

  2.  
  3. Protect the coil spring from scratches using a piece of cloth and install the spring compressor.
  4.  
  5. Compress the coil spring using the spring compressor.
  6.  
  7. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.
  8.  
  9. When installing the upper spring seat:
    1. Align the mark on the upper spring seat with the dust boot projection.
    2.  
    3. Install the upper spring seat so that the upper spring seat stud is at a 27-33 degree angle to the shock absorber installation shaft (lower side).

      Click image to see an enlarged view

      Fig. Align the mark on the upper spring seat with the dust boot projection-MX-5 Miata



      Click image to see an enlarged view

      Fig. Install the front strut upper spring seat so that the upper spring seat stud is at a 27-33 degree angle to the shock absorber installation shaft-MX-5 Miata

    4.  

  10.  
  11. Install the piston rod nut and tighten to 38-46 Nm (28-34 ft. lbs.).
  12.  
  13. Install the strut assembly.
  14.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the strut assembly from the vehicle.
  4.  
  5. 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.

  6.  
  7. Remove the upper strut nut.
  8.  
  9. Slowly release the coil spring tension
  10.  
  11. Remove the mounting rubber, bearing, dust boot, bound stopper and coil spring.

    Click image to see an enlarged view

    Fig. Install a coil spring compressor and compress the coil spring-Mazda3

  12.  

To install:

  1. Compress the coil spring in the compressor tool and install the shock absorber so the lower end of the spring is seated on the step of the lower spring seat.
  2.  
  3. Install the bound stopper.
  4.  
  5. Install the dust boot by hooking the bottom edge over the shock absorber lip as illustrated.
  6.  
  7. Install the bearing by hooking the upper end of the dust boot to the bearing lip and align the projection A on the lower part of the shock absorber with the bearing projection B, as illustrated.
  8.  
  9. Install the mounting rubber.
  10.  
  11. Install the piston rod nut and tighten to 42-56 ft. lbs. (57-76 Nm) and remove the spring compressor.
  12.  
  13. Install the stiffener so the mark LH or RH is facing upwards as shown.
  14.  
  15. Align the piston rod nut with the center part where the shock absorber is installed by placing the piston rod nut with lengths A all the same and tighten the shock absorber upper bolts.
  16.  
  17. Use a jack to raise the lower control arm, attach the shock absorber and tighten the bolts.

    Click image to see an enlarged view

    Fig. Install the dust boot by hooking the bottom edge over the shock absorber lip-Mazda3



    Click image to see an enlarged view

    Fig. Install the bearing by hooking the upper end of the dust boot to the bearing --.-Mazda3



    Click image to see an enlarged view

    Fig. -- and align the projection A on the lower part of the shock absorber with the bearing projection B-Mazda3



    Click image to see an enlarged view

    Fig. The stiffener should be positioned as shown-Mazda3

  18.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the strut assembly from the vehicle.
  4.  
  5. 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.

  6.  
  7. Remove the upper strut nut.
  8.  
  9. Slowly release the coil spring tension
  10.  
  11. Remove the mounting rubber, bound stopper, dust boot and coil spring.

    Click image to see an enlarged view

    Fig. Install a coil spring compressor and compress the coil spring-Mazda6 and Mazdaspeed6 models

  12.  

To install:

  1. Temporarily install the spring, dust boot and mounting so the lower end of the coil spring is seated on the step of the lower seat.
  2.  
  3. Mark the spring, dust boot and rubber for correct installation as shown in the accompanying illustration.
  4.  
  5. Align the mark of the coil spring and dust boot, use a piece of cloth to protect the spring and boot and install the compressor.
  6.  
  7. Compress the coil spring in the compressor tool and install the shock absorber so the lower end of the spring is seated on the step of the lower spring seat.
  8.  
  9. Ensure the marks on the shock absorber and dust boot are aligned to the marks made earlier, install the mounting rubber and the rod not and tighten the nut to 29-39 ft. lbs. (39-52 Nm)
  10.  
  11. Install the shock assembly.

    Click image to see an enlarged view

    Fig. Mark the spring, dust boot and rubber for correct installation as shown when assembly the front shock assembly-Mazda6 and Mazdaspeed6 models

  12.  

  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.  

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

    Strut from the vehicle

    Click image to see an enlarged view

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

     
    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-Protégé

     

  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
     
    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 so that the lower end of the spring is seated on the step of the lower spring seat. 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-Protégé



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Make sure the bearing, rubber and nut are aligned as shown on the front suspension.-Protégé

     
    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. Make sure that the marks on the shock absorber and upper spring seat are aligned. Tighten the piston rod upper nut.
  8.  
  9. Make sure the bearing, rubber and nut are aligned as shown on the front suspension.
  10.  
  11. Remove the spring compressor from the strut. Secure the upper mounting block in the vise and tighten the nut to 58-81 ft. lbs. (79-109 Nm) on the front strut and 41-49 ft. lbs. (55-67 ft. lbs. on the rear strut.
  12.  
  13. Be sure that the spring is well seated in the upper seats.
  14.  
  15. Install the strut to the vehicle.
  16.  

  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 equipped
     
    Piston rod upper nut 1 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
     
    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. Make sure the lower end of the stopper does not contact the cylinder.
     
    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 seat, shock and spring assembly as illustrated for reassembly-Miata



    Click image to see an enlarged view

    Fig. Tighten the lower nut so that 0.62-0.69-17.7mm) of the rod is exposed-Miata

     
    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. Apply an anti-rust compound on the piston rod thread and tighten the lower nut so that 0.62-0.69-17.7mm) of the rod is exposed. Then, tighten the upper nut to 17 ft. lbs. (23 Nm)
     

  6.  
  7. Install the strut to the vehicle.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the strut assembly from the vehicle.
  4.  
  5. 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.

  6.  
  7. Remove the upper strut nut.
  8.  
  9. Slowly release the coil spring tension
  10.  
  11. Remove the mounting rubber, bearing, dust boot, bound stopper and coil spring.

    Click image to see an enlarged view

    Fig. Install a coil spring compressor and compress the coil spring-Mazda 3

  12.  

To install:

 
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