Mazda Car 2005-06

Halfshafts

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CV-Joints



Overhaul


Click image to see an enlarged view

Fig. Exploded view of the rear driveshaft assembly-MX-5 Miata

  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.

  2.  
  3. Remove the boot band on the axle side using end clamp pliers.

    Click image to see an enlarged view

    Fig. Remove the boot band on the axle side using end clamp pliers-MX-5 Miata



    Click image to see an enlarged view

    Fig. Remove the boot band on the differential side using a flathead screwdriver-MX-5 Miata

  4.  
  5. Remove the boot band on the differential side using a flathead screwdriver.
  6.  
  7. Remove the tripod joint socket by placing an alignment mark on the drive shaft and the outer ring and then removing the outer ring.
  8.  
  9. Place an alignment mark on the shaft and tripod joint.
  10.  
  11. Remove the snap ring using snap ring pliers.
  12.  
  13. Remove the tripod joint from the shaft.
    CAUTION
    To prevent damage to the component, do not use a hammer when removing it.

  14.  
  15. Wrap the shaft spline with vinyl tape and remove the boot.
  16.  
  17. Remove the shaft and ball joint assembly.

    Click image to see an enlarged view

    Fig. Place an alignment mark on the shaft and tripod joint-MX-5 Miata



    Click image to see an enlarged view

    Fig. Remove the snap ring using snap ring pliers-MX-5 Miata

  18.  

To install:

  1. Install the shaft and ball joint assembly.
    NOTE
    The boot shapes on the axle side and the differential side are different so do not miss install them.

  2.  
  3. Fill the inside of the new dust boot on the wheel side with 90-110g (3.18-3.88 oz.) of grease.
    NOTE
    Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

  4.  
  5. Install the boot with the drive shaft spline still wrapped with vinyl tape.
  6.  
  7. Remove the vinyl tape.
  8.  
  9. Align the tripod joint with the shaft mark and insert it using a brass bar.
    CAUTION
    To prevent damage to the assembly, do not tap the roller part when installing.



    Click image to see an enlarged view

    Fig. Align the tripod joint with the shaft mark and insert it using a brass bar-MX-5 Miata

  10.  
  11. Install the new snap ring to the shaft installation slot securely using snap ring pliers.
  12.  
  13. Fill the outer ring and boot on the differential side with the 135-155g (4.77-5.46 oz.) of grease.
    NOTE
    Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

  14.  
  15. Assemble the outer ring.
  16.  
  17. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.
    CAUTION
    Do not let the grease leak and be careful not to damage the boot.



    Click image to see an enlarged view

    Fig. Using pliers, pull the differential side boot band around the boot slot in opposite direction of drive shaft forward rotation. Insert the end of the boot band between the boot band clip and fold back the clip tabs using a flathead screwdriver to secure the boot band-MX-5 Miata

  18.  
  19. Set the drive shaft length to the specification when the inside of the boots is at ambient pressure.
  20.  
  21. The drive shaft length should be:
    1. On the left side: 778.5-788.5 mm (30.65-31.04 in.).
    2.  
    3. On the right side: 818.5-828.5 mm (32.22-32.62 in.).
    4.  

  22.  
  23. After installation, verify that there is no boot damage or grease leakage.
  24.  
  25. Using pliers, pull the differential side boot band around the boot slot in opposite direction of drive shaft forward rotation direction and tighten.
  26.  
  27. Insert the end of the boot band between the boot band clip and fold back the clip tabs using a flathead screwdriver to secure the boot band.
  28.  
  29. Verify that the boot band is installed to the boot slot securely.
  30.  
  31. Turn the adjusting bolt of tool 49 T025 001 and adjust the opening size A to the specification to 2.9 mm (0.11 in.).

    Click image to see an enlarged view

    Fig. Turn the adjusting bolt of tool 49 T025 001 and adjust the opening size A to the specification to 2.9 mm (0.11 in.)-MX-5 Miata



    Click image to see an enlarged view

    Fig. Crimping the boot bands-MX-5 Miata

  32.  
  33. Crimp the small side of the boot band using tool 49 T025 001.
  34.  
  35. Verify that the crimp value B is within 2.4-2.8 mm (0.095-0.110 in.).
  36.  
  37. If the crimp value exceeds the specification, reduce opening length A of the tool 49 T025 001 and recrimp the boot band.
  38.  
  39. If the crimp value B is less than the specification, increase opening length A of the tool 49 T025 001 and crimp the new boot band.
  40.  
  41. Verify that the boot band does not protrude from the boot band installation area.
  42.  
  43. If the boot band protrudes from the installation area, replace it with a new band and repeat the band installation steps.
  44.  
  45. Fill the boot with the repair kit grease.
  46.  
  47. Adjust opening length A of the tool to the 3.2 mm (0.13 in.).
  48.  
  49. Crimp the large side boot band using the tool 49 T025 001.
  50.  
  51. Verify that the boot band crimp value B is within the 2.4-2.8 mm (0.095-0.110 in.) specification.
  52.  
  53. If crimp value B exceeds the specification, reduce opening length A of the tool 49 T025 001 and recrimp the boot band.
  54.  
  55. If the crimp value B is less than the specification, replace the boot band, increase the opening length of A of the tool 49 T025 001, and then recrimp the new boot band.
  56.  
  57. Verify that the boot band does not protrude from the boot band installation area.
  58.  
  59. If the boot band protrudes from the installation area, replace it with a new band.
  60.  

  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.
    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.  

Removal & Installation



  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
    Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

  2.  
  3. Disconnect the ABS wheel-speed sensor.
  4.  
  5. Lock the disc plate by applying the brakes.
  6.  
  7. Knock the crimped portion of the locknut outward using a chisel and a hammer.
  8.  
  9. Remove the locknut.
  10.  
  11. Disconnect the parking brake cable.
  12.  
  13. Disconnect the brake caliper and position aside with the hose still attached. Secure the caliper so that no strain is put on the hose.
  14.  
  15. Remove the rotor.
  16.  
  17. Remove the rear upper lateral link ball joint.
  18.  
  19. Remove the lower stabilizer control link.
  20.  
  21. Remove the rear lower lateral link ball joint.
  22.  
  23. Remove the shock absorber lower bolt.
  24.  
  25. Remove the toe control link ball joint.
  26.  
  27. Remove the rear trailing link upper ball joint.
  28.  
  29. Remove the rear trailing link lower bolt on the outer side.
  30.  
  31. Temporarily install a spare nut to the end of the rear drive shaft.
  32.  
  33. Strike the nut with copper hammer lightly and remove the rear drive shaft from the wheel hub.
  34.  
  35. Separate the rear drive shaft from the wheel hub.
  36.  
  37. Insert a prybar between the rear differential and differential side outer ring, and then remove the rear drive shaft.
    CAUTION
    The drive shaft edges are sharp and can damage the oil seal. Be careful not to damage the oil seal when removing the drive shaft from the differential.

  38.  
  39. Pull the rear drive shaft to the outer side of the vehicle and disconnect it from the rear differential.
  40.  
  41. Secure the rear knuckle component by installing the upper rear lateral link to the rear knuckle temporarily after disconnecting the rear drive shaft.

    Click image to see an enlarged view

    Fig. Exploded view of the rear axle assembly-MX-5 Miata

  42.  

To install:

  1. Apply differential oil to the differential oil seal lip.
    CAUTION
    The drive shaft edges are sharp and can damage the oil seal. Be careful not to damage the oil seal when installing the rear drive shaft to the rear differential.

  2.  
  3. Insert the rear drive shaft into the rear differential with the clip opening facing upward. Point the opening of the new drive shaft clip upward, install it to the clip groove at the end of the rear drive shaft with the installation width within the specification shown in the illustration. After installing the clip, measure the outer diameter. If it exceeds the specification, reinstall the new clip.

    Click image to see an enlarged view

    Fig. Drive shaft clip installation width-MX-5 Miata

  4.  
  5. After installation, verify that the rear drive shaft is securely held by the clip by pulling the outer ring on the differential side towards the axle.
  6.  
  7. Install the rear trailing link lower bolt.
  8.  
  9. Install the rear trailing link upper ball joint.
  10.  
  11. Install the toe control link ball joint.
  12.  
  13. Install the shock absorber lower bolt.
  14.  
  15. Install the rear lower lateral link ball joint.
  16.  
  17. Install the lower stabilizer control link.
  18.  
  19. Install the rear upper lateral link ball joint.
  20.  
  21. Install the rotor.
  22.  
  23. Install the brake caliper.
  24.  
  25. Connect the parking brake cable.
  26.  
  27. Install the locknut and tighten to 235-275 Nm (173-202 ft. lbs.).
  28.  
  29. Crimp the locknut, using a chisel and hammer.

    Click image to see an enlarged view

    Fig. Crimp the locknut, using a chisel and hammer-MX-5 Miata

  30.  
  31. Connect the parking brake cable.
  32.  
  33. Install the remaining components in the reverse order of removal.
  34.  



Click image to see an enlarged view

Fig. Exploded view of a typical halfshaft mounting-Mazda3

  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
     
    Halfshaft lockbolt
     

  6.  
  7. Install a spare bolt onto the halfshaft, tap the bolt with a copper hammer and separate the halfshaft from the knuckle.
  8.  
  9. 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
     
    Lower ball joint pinch bolt and nut
     
    Lower ball joint from the knuckle
     

  10.  
  11. 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.
  12.  
  13. Pull outward on the hub/knuckle assembly, push the outer CV-joint stub shaft through the hub and 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.

  14.  

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 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 lockbolt
     
    Lower ball joint into the knuckle. Torque the pinch bolt to 31-43 ft. lbs. (43-58 Nm).
     
    Stabilizer bar to the lower control arm. Tighten to 29-40 ft. lbs. (40-54 Nm).
     
    Tie rod end to the steering knuckle. Torque the nut to 27-37 ft. lbs. (37-50 Nm.
     
    Tighten the nut, if necessary, to align the ball stud hole with the nut castellation.
     
    halfshaft lockbolt. Torque it to 23-28 ft. lbs. (31-38 Nm), then tighten an additional 85-95 degrees.
     
    ABS sensor
     
    Splash shield
     
    Wheels
     

  2.  
  3. Fill the transaxle.
  4.  

2.3L (L3) Engines


Click image to see an enlarged view

Fig. Exploded view of the halfshaft assembly and related components-Mazda6 and Mazdaspeed6 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.
    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.

  12.  
  13. If removing the left side halfshaft, insert a prybar between the outer ring and the transaxle and pry the halfshaft from the transaxle.
  14.  
  15. If removing the right side halfshaft, separate it from the joint shaft by tapping on a bar positioned between the halfshaft and joint shaft.
    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.



    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-Mazda6 and Mazdaspeed6 models equipped with the 2.3L (L3) engine

  16.  

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-Mazda6 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.
    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.

  14.  
  15. If removing the left side halfshaft, insert a prybar between the outer ring and the transaxle and pry the halfshaft from the transaxle.
  16.  
  17. 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.
    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.



    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-Mazda6 models equipped with the 3.0L (AJ) engine

  18.  

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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