Mazda Trucks 1994-1998 Repair Guide

Front Driveshaft and U-Joints (4x4)

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REMOVAL & INSTALLATION



Navajo and B Series Pick-up Models

See Figure 1



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Fig. Fig. 1: Exploded view of the front driveshaft and double cardan type U-joint-4WD Navajo and B Series Pick-up

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the bolts and straps or the flange bolts retaining the driveshaft to the transfer case. If necessary, remove the boot from the transfer case to gain access to the slip yoke.
  4.  
  5. Remove the bolts and straps retaining the front U-joint to the front axle and remove the front driveshaft.
  6.  

To install:
  1. If equipped, lubricate the slip yoke splines and the edge of the inner diameter of the rubber boot. Slide the driveshaft into the transfer case, making sure the wide-tooth splines are properly indexed. Reposition the boot and install the clamp.
  2.  
  3. If equipped, install the driveshaft to the transfer case flange and install the retaining bolts. Tighten to 12-16 ft. lbs. (17-22 Nm).
  4.  
  5. Install the driveshaft to the front axle flange with the straps and bolts. Tighten to 10-15 ft. lbs. (14-20 Nm).
  6.  
  7. Lower the vehicle.
  8.  

MPV Models

See Figure 2

  1. Raise and safely support the vehicle.
  2.  
  3. Matchmark the flanges and remove the mounting nuts and bolts at the front differential.
  4.  
  5. Slide the shaft out of the transfer case. Cap the opening to prevent fluid loss.
  6.  
  7. Installation is the reverse of removal. Align the flange marks. Torque the nuts and bolts to 21-22 ft. lbs. (28-30 Nm).
  8.  



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Fig. Fig. 2: Exploded view of the front driveshaft assembly-4WD MPV

U-joint replacement

Single Cardan Type U-Joint

See Figures 3 and 4



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Fig. Fig. 3: U-joint bearing removal



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Fig. Fig. 4: U-joint bearing installation

  1. Remove the driveshaft.
  2.  
  3. If the front yoke is to be disassembled, matchmark the driveshaft and sliding splined yoke (transmission yoke) so that driveline balance is preserved upon reassembly. Remove the snaprings which retain the bearing caps.
  4.  
  5. Select two sockets, one small enough to pass through the yoke holes for the bearing caps, the other large enough to receive the bearing cap.
  6.  
  7. Using a vise or a press, position the small and large sockets on either side of the U-joint. Press in on the smaller socket so that it presses the opposite bearing cap out of the yoke and into the larger socket. If the cap does not come all the way out, grasp it with a pair of pliers and work it out.
  8.  
  9. Reverse the position of the sockets so that the smaller socket presses on the cross. Press the other bearing cap out of the yoke.
  10.  
  11. Repeat the procedure on the other bearings.
  12.  
  13. To install, grease the bearing caps and needles thoroughly if they are not pregreased. Start a new bearing cap into one side of the yoke. Position the cross in the yoke.
  14.  
  15. Select two sockets small enough to pass through the yoke holes. Put the sockets against the cross and the cap, and press the bearing cap 1 / 4 in. (6mm) below the surface of the yoke. If there is a sudden increase in the force needed to press the cap into place, or if the cross starts to bind, the bearings are cocked, They must be removed and restarted in the yoke. Failure to do so will greatly reduce the life of the bearing.
  16.  
  17. Install a new snapring.
  18.  
  19. Start a new bearing into the opposite side. Place a socket on it and press in until the opposite bearing contacts the snapring.
  20.  
  21. Install a new snapring. It may be necessary to grind the facing surface of the snapring slightly to permit easier installation.
  22.  
  23. Install the other bearings in the same manner.
  24.  
  25. Check the joint for free movement. If binding exists, smack the yoke ears with a brass or plastic faced hammer to seat the bearing needles. Do not strike the bearings, and support the shaft firmly. Do not install the driveshaft until free movement exists at all joints.
  26.  

Double Cardan Type U-Joint

See Figures 5 and 6



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Fig. Fig. 5: Pressing the bearing from the center yoke



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Fig. Fig. 6: Center yoke interference point

  1. Place the driveshaft on a suitable workbench.
  2.  
  3. Matchmark the positions of the spiders, the center yoke and the centering socket yoke as related to the stud yoke which is welded to the front of the driveshaft tube.
  4.  

The spiders must be assembled with the bosses in their original position to provide proper clearance.

  1. Remove the snaprings that secure the bearings in the front of the center yoke.
  2.  
  3. Position the U-joint tool, T74P-4635-C or equivalent, on the center yoke. Thread the tool clockwise until the bearing protrudes approximately 3 / 8 in. (10mm) out of the yoke.
  4.  
  5. Position the bearing in a vice and tap on the center yoke to free it from the bearing. Lift the 2 bearing cups from the spider.
  6.  
  7. Re-position the tool on the yoke and move the remaining bearing in the opposite direction so that it protrudes approximately 3 / 8 in. (10mm) out of the yoke.
  8.  
  9. Position the bearing in a vice. Tap on the center yoke to free it from the bearing. Remove the spider from the center yoke.
  10.  
  11. Pull the centering socket yoke off the center stud. Remove the rubber seal from the centering ball stud.
  12.  
  13. Remove the snaprings from the center yoke and from the driveshaft yoke.
  14.  
  15. Position the tool on the driveshaft yoke and press the bearing outward until the inside of the center yoke almost contacts the slinger ring at the front of the driveshaft yoke. Pressing beyond this point can distort the slinger ring interference point.
  16.  
  17. Clamp the exposed end of the bearing in a vice and drive on the center yoke with a soft-faced hammer to free it from the bearing.
  18.  
  19. Reposition the tool and press on the spider to remove the opposite bearing.
  20.  
  21. Remove the center yoke from the spider. Remove the spider form the driveshaft yoke.
  22.  
  23. Clean all serviceable parts in cleaning solvent. If using a repair kit, install all of the parts supplied in the kit.
  24.  
  25. Remove the clamps on the driveshaft boot seal. Discard the clamps.
  26.  
  27. Note the orientation of the slip yoke to the driveshaft tube for installation during assembly. Mark the position of the slip yoke to the driveshaft tube.
  28.  
  29. Carefully pull the slip yoke from the driveshaft. Be careful not to damage the boot seal.
  30.  
  31. Clean and inspect the spline area of the driveshaft.
  32.  

To assemble:
  1. Lubricate the driveshaft slip splines with Multi-purpose Long-Life lubricant C1AZ-19490-B or equivalent.
  2.  
  3. With the boot loosely installed on the driveshaft tube, install the slip yoke into the driveshaft splines in their original orientation.
  4.  
  5. Using new clamps, install the driveshaft boot in its original position.
  6.  
  7. To assemble the double cardan joint, position the spider in the driveshaft yoke. Make certain the spider bosses (or lubrication plugs on kits) will be in the same position as originally installed. Press in the bearing using the U-joint tool. Then, install the snaprings.
  8.  
  9. Pack the socket relief and the ball with Multi-purpose Long-Life lubricant C1AZ-19490-B or equivalent, then position the center yoke over the spider ends and press in the bearing. Install the snaprings.
  10.  
  11. Install a new seal on the centering ball stud. Position the centering socket yoke on the stud.
  12.  
  13. Place the front spider in the center yoke. Make certain the spider bosses (or lubrication plugs on kits) are properly positioned.
  14.  
  15. With the spider loosely positioned on the center stop, seat the first pair of bearings into the centering socket yoke. Then, press the second pair into the centering yoke. Install the snaprings.
  16.  
  17. Apply pressure on the centering socket yoke and install the remaining bearing cup.
  18.  
  19. If a kit was used, lubricate the U-joint through the grease fitting, using Multi-purpose Long-Life lubricant C1AZ-19490-B or equivalent.
  20.  

 
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