Protege 1999-2000

With Manual Transaxle

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CV-Joints



Inspection

Specific to:

Mazda 3 2004

Mazda 6 2003-2004

Mazda 626 1999-2002

Mazda Miata 1999-2004

Mazda Protege 1999-2003

Mazda Protege5 2002-2003

Check the CV-boots for rips and tears. Check for grease leaking from the CV-boots. Check the boot bands for damage. Replace any component if found to be defective.

Overhaul

Specific to:

Mazda 6 2003

Mazda 626 1999-2002

Mazda Miata 1999-2004

Mazda Protege 1999-2003

Mazda Protege5 2002-2003

  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.
  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.

    Click image to see an enlarged view

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

  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.
    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 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. 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.  

 
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