Mazda Car 2002-04

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Wheels
     
    ABS sensor, if equipped
     
    splash shield, if equipped
     

  6.  
  7. Raise the staked portion of the hub locknut with a hammer and chisel.
  8.  
  9. Lock the hub by applying the brakes and remove the nut.
  10.  
  11. Remove or disconnect the following:

    stabilizer bar from the lower control arm
     
    cotter pin and nut from the tie rod end ball stud
     
    Tie rod end from the knuckle
     
    Transverse member, on the 626
     
    lower ball joint pinch bolt and nut
     
    Lower ball joint from the knuckle
     

  12.  
  13. If removing the left side shaft on 626 with automatic transaxle, proceed as follows:
    1. Suspend the engine using engine support tool 49 G017 5A0.
    2.  
    3. Remove the engine mount member.
    4.  

  14.  
  15. Position a prybar between the inner CV-joint and transaxle case. Carefully pry the halfshaft from the transaxle being careful not to 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.
  16.  
  17. 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.
  18.  


    Click image to see an enlarged view

    Fig. Exploded view of a typical halfshaft mounting-Except Mazda 3



NOTE
Install plug tool 49 G030 455 into the transaxle after removing the halfshaft, to keep the differential side gear in position. If the gear becomes positioned incorrectly, 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. Install or connect the following:

    New circlip on the end of the intermediate shaft, if removed, with the end gap facing upward.
     
    intermediate shaft in the transaxle, being careful not to damage the oil seals
     
    Intermediate shaft support bearing bolts. Torque in sequence, to 45 ft. lbs. (61 Nm).
     
    New circlip on the end of the halfshaft, with the end gap facing upward
     
    Halfshaft into the transaxle, being careful not to damage the oil seal
     

  2.  


NOTE
If equipped, push the halfshaft into the intermediate shaft.



Other end of the halfshaft through the hub. Loosely install a new locknut
 

  1. If installing the left side shaft on 626 with automatic transaxle, proceed as follows:
    1. Install the engine mount member. Torque the mount member-to-body bolts to 66 ft. lbs. (89 Nm).
    2.  
    3. Torque the front mount-to-mount member nuts to 77 ft. lbs. (104 Nm) and the side mount bolts to 44 ft. lbs. (60 Nm).
    4.  
    5. Remove the engine support tool.
    6.  

  2.  
  3. Install or connect the following:

    lower ball joint into the knuckle. Torque the pinch bolt to 40 ft. lbs. (54 Nm).
     
    Transverse member, on 626. Torque the bolts to 96 ft. lbs. (132 Nm).
     
    tie rod end to the steering knuckle. Torque the nut to 42 ft. lbs. (57 Nm) on all except 626 and Millenia or to 32 ft. lbs. (44 Nm) for 626 and Millenia.
     
    New cotter pin. Tighten the nut, if necessary, to align the ball stud hole with the nut castellation.
     
    stabilizer bar to the lower control arm
     
    splash shield
     
    Wheels
     
    New hub nut. Torque it to 174-235 ft. lbs. (235-318 Nm). After tightening, stake the locknut using a hammer and dull bladed chisel.
     

  4.  
  5. Fill the transaxle.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Wheels
     
    Splash shield, if equipped
     

  6.  
  7. Raise the staked portion of the hub locknut with a hammer and chisel.
  8.  
  9. Lock the hub by applying the brakes and remove the nut.

    Click image to see an enlarged view

    Fig. Exploded view of a typical halfshaft mounting

  10.  
  11. Remove or disconnect the following:

    Stabilizer bar from the lower control arm
     
    Cotter pin and nut from the tie rod end ball stud
     
    Tie rod end from the knuckle
     
    Transverse member, on the 626 and Millenia
     
    Lower ball joint pinch bolt and nut
     
    Lower ball joint from the knuckle
     

  12.  
  13. If removing the left side shaft on 626 or Millenia with automatic transaxle, proceed as follows:
    1. Suspend the engine using engine support tool 49 G017 5A0.
    2.  
    3. Remove the engine mount member.
    4.  

  14.  
  15. Position a prybar between the inner CV-joint and transaxle case. Carefully pry the halfshaft from the transaxle being careful not to 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.
  16.  
  17. 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.
    NOTE
    Install plug tool 49 G030 455 into the transaxle after removing the halfshaft, to keep the differential side gear in position. If the gear becomes positioned incorrectly, the differential may have to be removed to realign the gear.

  18.  
  19. Remove the intermediate shaft, if necessary, by removing the support bearing bolts and pulling the shaft from the transaxle.
  20.  

To install:

  1. Install or connect the following:
    NOTE
    If equipped, push the halfshaft into the intermediate shaft.



    New circlip on the end of the intermediate shaft, if removed, with the end gap facing upward.
     
    Intermediate shaft in the transaxle, being careful not to damage the oil seals
     
    Intermediate shaft support bearing bolts. Torque in sequence, to 45 ft. lbs. (61 Nm)
     
    New circlip on the end of the halfshaft, with the end gap facing upward
     
    Halfshaft into the transaxle, being careful not to damage the oil seal
     



    Other end of the halfshaft through the hub. Loosely install a new locknut
     

  2.  
  3. If installing the left side shaft on 626 and Millenia with automatic transaxle, proceed as follows:
    1. Install the engine mount member. Torque the mount member-to-body bolts to 66 ft. lbs. (89 Nm).
    2.  
    3. Torque the front mount-to-mount member nuts to 77 ft. lbs. (104 Nm) and the side mount bolts to 44 ft. lbs. (60 Nm).
    4.  
    5. Remove the engine support tool.
    6.  

  4.  
  5. Install or connect the following:

    Lower ball joint into the knuckle. Torque the pinch bolt to 40 ft. lbs. (54 Nm)
     
    Transverse member, on 626 and Millenia. Torque the bolts to 96 ft. lbs. (132 Nm)
     
    Tie rod end to the steering knuckle. Torque the nut to 42 ft. lbs. (57 Nm) on all except 626 and Millenia or to 32 ft. lbs. (44 Nm) for 626 and Millenia
     
    New cotter pin. Tighten the nut, if necessary, to align the ball stud hole with the nut castellation
     
    Stabilizer bar to the lower control arm
     
    Splash shield
     
    Wheels
     
    New hub nut. Torque it to 174-235 ft. lbs. (235-318 Nm). After tightening, stake the locknut using a hammer and dull bladed chisel
     

  6.  
  7. Fill the transaxle.
  8.  

2.3L (L3) Engines





Click image to see an enlarged view

Fig. Exploded view of the halfshaft assembly and related components-Mazda 6 models equipped with the 2.3L (L3) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Raise the staked portion of the hub locknut with a hammer and chisel.
  6.  
  7. Lock the hub by applying the brakes and remove the nut.
  8.  
  9. Remove or disconnect the following:

    Wheels
     
    Tie rod end from the knuckle
     
    stabilizer bar link from the damper fork
     
    Bolt attaching the fork to the knuckle
     
    Front and rear lower arm ball joints
     

  10.  
  11. Install a spare nut onto the drive shaft so the nut is flush with the end of the drive shaft and tap the nut with a copper hammer to separate the halfshaft from the hub assembly.
  12.  


NOTE
The halfshaft edges can be quite sharp and can damage the oil seal. be careful when removing the halfshaft not to cause any damage.

  1. If removing the left side halfshaft, insert a prybar between the outer ring and the transaxle and pry the halfshaft from the transaxle.
  2.  
  3. If removing the right side halfshaft, separate it from the joint shaft by tapping on a bar positioned between the halfshaft and joint shaft.
  4.  


    Click image to see an enlarged view

    Fig. Remove the right side halfshaft by tapping on a bar positioned between the halfshaft and joint shaft-Mazda 6 models equipped with the 2.3L (L3) engine



NOTE
Install plug tool 49 G030 455 into the transaxle after removing the halfshaft, to keep the differential side gear in position. If the gear becomes positioned incorrectly, the differential may have to be removed to realign the gear.

To install:

  1. Install a new circlip on the end of the shaft, if removed, with the end gap facing upward. Measure the outer diameter of the clip, if it exceeds 1.19-1.23 inch (30-31mm) replace the clip.
  2.  
  3. Install the left side shaft as follows:
    1. Insert the shaft into the hub.
    2.  
    3. Apply clean engine oil to the oil seal lip.
    4.  
    5. Push the shaft into the transaxle and once the shaft clicks into place, pull on the outer ring to make sure the clip is engaged.
    6.  

  4.  
  5. Install the right side shaft as follows:
    1. Insert the shaft into the hub.
    2.  
    3. Insert the halfshaft into the joint shaft and once the shaft clicks into place, pull on the outer ring to make sure the clip is engaged.
    4.  

  6.  
  7. Install the remaining components in the reverse order of removal. Refer to the exploded view of the halfshaft assembly and related components for torque specifications.
  8.  
  9. Install a new hub nut. Torque it to 173-202 ft. lbs. (235-274 Nm). After tightening, stake the locknut using a hammer and dull bladed chisel with an indent at least 0.02 inch (0.5mm).
  10.  
  11. Fill the transaxle.
  12.  

3.0L (Aj) Engines





Click image to see an enlarged view

Fig. Exploded view of the halfshaft assembly and related components-Mazda 6 models equipped with the 3.0L (AJ) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove the knuckle and hub assembly.
  6.  
  7. Raise the staked portion of the hub locknut with a hammer and chisel.
  8.  
  9. Lock the hub by applying the brakes and remove the nut.
  10.  
  11. Remove or disconnect the following:

    Wheels
     
    Tie rod end from the knuckle
     
    Damper fork
     
    Front and rear lower arm ball joints
     
    stabilizer bar link from the damper fork
     

  12.  
  13. Install a spare nut onto the drive shaft so the nut is flush with the end of the drive shaft and tap the nut with a copper hammer to separate the halfshaft from the hub assembly.
  14.  


NOTE
The halfshaft edges can be quite sharp and can damage the oil seal. be careful when removing the halfshaft not to cause any damage.

  1. If removing the left side halfshaft, insert a prybar between the outer ring and the transaxle and pry the halfshaft from the transaxle.
  2.  
  3. Remove the joint shaft bracket bolt and remove the right side halfshaft. Secure the shaft in a vise and insert a prybar between the halfshaft and joint shaft and separate them.
  4.  


    Click image to see an enlarged view

    Fig. Remove the right side halfshaft by securing the shaft in a vise, inserting a prybar between the halfshaft and joint shaft and separating them-Mazda 6 models equipped with the 3.0L (AJ) engine



NOTE
Install plug tool 49 G030 455 into the transaxle after removing the halfshaft, to keep the differential side gear in position. If the gear becomes positioned incorrectly, the differential may have to be removed to realign the gear.

To install:

  1. Install a new circlip on the end of the shaft, if removed, with the end gap facing upward. Measure the outer diameter of the clip, if it exceeds 1.26-1.30 inch (32-33mm) replace the clip.
  2.  
  3. Install the left side shaft as follows:
    1. Insert the shaft into the hub.
    2.  
    3. Apply clean engine oil to the oil seal lip.
    4.  
    5. Push the shaft into the transaxle and once the shaft clicks into place, pull on the outer ring to make sure the clip is engaged.
    6.  

  4.  
  5. Install the right side shaft as follows:
    1. Place the halfshaft and joint shaft assembly in a vise.
    2.  
    3. Insert the halfshaft into the joint shaft and use a plastic hammer to attach the joint shaft as illustrated.
    4.  
    5. Tighten the joint shaft bracket bolt to 31-45 ft. lbs. (42-62 Nm).
    6.  

  6.  
  7. Install the remaining components in the reverse order of removal. Refer to the exploded view of the halfshaft assembly and related components for torque specifications.

    New hub nut. Torque it to 173-202 ft. lbs. (235-274 Nm). After tightening, stake the locknut using a hammer and dull bladed chisel with an indent at least 0.02 inch (0.5mm).
     

  8.  
  9. Fill the transaxle.
  10.  

 
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