2002 MAZDA 6 lock

M–50
REAR DIFFERENTIAL
5. After removing the front side of the differential
mount, gradually lower the jack and tilt the front
side of the differential downward.
6. Pull the companion flange off using the SST.
7. Remove the oil seal from the differential carrier
using a screwdriver or similar tool.
8. Apply differential oil to the new oil seal lip.
9. Install the new oil seal to the differential carrier
using the SST.
10. Install the companion flange to the drive pinion.
11. Jack up the differential and install the front side of
the differential mount.
Tightening torque
74.5—104.9 N·m {7.6—10.7 kgf·m, 55.0—77.3
ft·lbf}
12. Install the washer and a new locknut.
13. Tighten the locknut to the specified torque using
the SST.
Tightening torque
167—226 N·m {17.1—23.0 kgf·m, 124—166
ft·lbf}
14. Install the propeller shaft. (See L–5 PROPELLER
SHAFT REMOVAL/INSTALLATION)
15. Add the specified differential oil from the filler
plug. (See M–48 DIFFERENTIAL OIL
REPLACEMENT)
End Of Sie
JACK
DIFFERENTIAL
A6E63192042
49 0839 425C
A6A63192043
49 W011 102
A6A63192006
49 S120 710
A6A63192007

M–52
REAR DIFFERENTIAL
Coupling Component and Rear Differential Component Removal/installation Note
Warning
•Make sure that the coupling component and rear differential component are securely supported
by the jack. If the coupling component and rear differential component fall, it could cause death,
serious injury, or vehicle damage.
1. Make sure that the coupling component and rear
differential component are securely supported by
the jack, and remove/install the component by
operating the jack gradually.
End Of Sie
REAR DIFFERENTIAL DISASSEMBLYA6E631927100208
Warning
•The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a
tilted condition, the self-lock mechanism could become inoperative. If the rear differential
unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted
condition. When turning the rear differential, grasp the rotation handle firmly.
1. Disassemble in the order indicated in the table.
.
A6J63192202
9
7
3
10
SST
SST
SST
SST
SST
6
18
14
14
1312
8
5
5
4
3
1
2
19
17
15
16
11
20
2024
23
23
21
21
22
22
6
A6A63192008

REAR DIFFERENTIAL
M–53
M
Rear Cover Disassembly Note
1. Install the SSTs to the engine stand.
2. Install the rear differential to the SSTs.
3. Remove the rear cover using an oil seal cutter.
Bearing Cap Disassembly Note
1. Place alignment marks on the bearing cap and
carrier.
1 Differential oil temperature sensor
2 Rear cover
(See M–53 Rear Cover Disassembly Note)
3 Bearing cap
(See M–53 Bearing Cap Disassembly Note)
4 Rear differential component
(See M–54 Rear Differential Component
Disassembly Note)
5 Side bearing outer race
6 Adjusting shim
7Spacer
8 Locknut
(See M–54 Locknut Disassembly Note)
9 Drive pinion
(See M–54 Drive Pinion Disassembly Note)
10 Collapsible spacer
11 Bearing inner race (front bearing)12 Bearing inner race (rear bearing)
(See M–54 Bearing Inner Race (Rear Bearing)
Disassembly Note)
13 Spacer
14 Bearing outer race
(See M–55 Bearing Outer Race Disassembly Note)
15 Differential carrier
16 Ring gear
(See M–55 Ring Gear Disassembly Note)
17 Knock pin
18 Pinion shaft
19 Pinion gear
20 Side gear
21 Thrust washer
22 Side bearing inner race
(See M–55 Side Bearing Inner Race Disassembly
Note)
23 Oil seal
24 Gear case
49 L027 0A2
49 0107 680A
A6A63192009
49 L027 0A2
49 0107 680A
A6A63192010
MARK
A6E63192011

M–54
REAR DIFFERENTIAL
Rear Differential Component Disassembly Note
1. Remove the rear differential component using the
SSTs.
2. Mark or otherwise distinguish between the
removed left and right adjusting shims, spacers
and side bearing outer races so that they are not
mixed up at the time of reassembly.
Locknut Disassembly Note
1. Remove the locknut using the SSTs.
Drive Pinion Disassembly Note
1. Remove the drive pinion by lightly tapping with a
copper hammer.
Bearing Inner Race (Rear Bearing) Disassembly Note
1. Remove the bearing inner races (rear bearing)
using the SST and a press.
49 T032 317
49 T032 316
49 L027 004
A6A63192012
49 L027 006
49 L027 007
A6A63192013
A6A63192014
49 H027 002
A6A63192015

M–56
REAR DIFFERENTIAL
REAR DIFFERENTIAL ASSEMBLYA6E631927100209
Warning
•The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a
tilted condition, the self-lock mechanism could become inoperative. If the rear differential
unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted
condition. When turning the rear differential, grasp the rotation handle firmly.
Note
•Clean away the old sealant before applying the new sealant.
•Install the rear cover within 10 minutes after applying sealant.
•Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified
oil.
1. Assemble in the order indicated in the table.
.
SST
SST
SST
SSTSST
SST
SST
9
8
7
54
4
3
3
12
2
10
10
19
19
18
17
15
16
14
13
1112
20
25
25
24
23
21
22
22
R
SST
R
R
R
SSTR
RR
6
SEALANTSEALANT
SEALANTSEALANT
OILOIL
OILOIL
15.7—22.6
{1.6—2.3, 11.6—16.6}
37—51
{3.8—5.2,
27.3—37.6}
240—441
{24.5—44.9, 177—325} 12.7—17.3
{1.3—1.7,
9.4—12.7}69—83
{7.1—8.4,
50.9—61.2}
N·m {kgf·m, ft·lbf}
R
A6E63192019
1 Gear case
2 Side bearing inner race
(See M–57 Side Bearing Inner Race Assembly
Note)
3 Thrust washer
(See M–57 Thrust washer assembly note)
4 Side gear
5 Pinion gear
6Pinion shaft
7 Knock pin
8 Ring gear
(See M–58 Ring Gear Assembly Note)
9 Differential carrier10 Bearing outer race
(See M–58 Bearing Outer Race Assembly Note)
11 Spacer
(See M–59 Spacer, Bearing Inner Race Assembly
Note)
12 Bearing inner race (rear bearing)
(See M–59 Spacer, Bearing Inner Race Assembly
Note)
13 Bearing inner race (front bearing)
(See M–59 Spacer, Bearing Inner Race Assembly
Note)
14 Collapsible spacer
15 Drive pinion
16 Locknut
(See M–61 Locknut Assembly Note)

M–58
REAR DIFFERENTIAL
Ring Gear Assembly Note
Caution
•The differential gear and ring gear could be damaged if the ring gear is installed with old thread-
locking compound remaining on the bolt threads. Before installing the ring gear, completely
remove the old thread-locking compound from the bolt threads.
1. Apply a small amount of thread-locking
compound to each of points A on the back of the
ring gear, and bolt thread areas B (around the
entire ring).
Application amount
Back of ring gear:
Approx. 0.32 ml {0.32 cc, 0.02 cu in}
Ring gear bolt thread points:
Approx. 0.32 ml {0.32 cc, 0.02 cu in}
(0.04 ml {0.04 cc, 0.002 cu in}
to each point)
2. Align the marks placed on the ring gear case at
the time of disassembly and tighten the bolts in
diagonal order.
Tightening torque
69—83 N·m {7.1—8.4 kgf·m, 50.9—61.2 ft·lbf}
Bearing Outer Race Assembly Note
1. Press in the bearing outer race using the SSTs
and a press.
A
B
A6A63192022
A6A63192023
49 M005 797
49 F027 007
49 F027 005
A6A63192024

REAR DIFFERENTIAL
M–59
M
Spacer, Bearing Inner Race Assembly Note
Pinion height adjustment
Note
•Use the same spacer.
•Install the spacer with the chamfer on the SST side.
1. Assemble the spacer, the bearing inner race (rear
bearing), and the SST O-ring to the SST (49 8531
565) as shown in the figure.
2. Insert the set assembled in Step 1 to the
differential gear from the rear.
3. Assemble the bearing inner race (front bearing),
SST (49 8531 567), companion flange, washer,
and locknut from the front of the differential gear.
4. Tighten the locknut to the extent that the SST (49
8531 565) can be turned by hand.
5. Place the SST (49 G027 004) on top of the SST
(49 8531 565).
6. Place the SST on the surface plate and set the
dial indicator to zero.
7. Set the SST as shown in the figure.
8. Place the measuring probe of the dial indicator so
that it contacts the place where the side bearing is
installed in the carrier. Then measure the left and
right side of the lower position.
49 G027 004
49 8531 565
49 8531 568
49 8531 567
49 G032 347
A6A63192025
49 0727 570
A6A63192026
49 0727 570
A6A63192027

REAR DIFFERENTIAL
M–61
M
Locknut Assembly Note
Drive pinion preload adjustment
1. Apply differential oil to a new locknut.
2. Assemble a new collapsible spacer, bearing inner race (front bearing), and locknut to the drive pinion, and
temporarily tighten the locknut.
3. Turn the serrated part of the drive pinion by hand to seat the bearing.
4. Tighten the locknut temporarily tightened in Step
1 from the lower limit of the specified tightening
torque using the SSTs, and make this the
specified preload.
•If the specified preload cannot be obtained
within the specified tightening torque, replace
the collapsible spacer and inspect again.
Tightening torque
240—441 N·m {24.5—44.9 kgf·m, 177—325
ft·lbf}
Drive pinion preload
1.3—1.8 N·m {13.3—18.3 kgf·cm, 11.5—15.9
in·lbf}
5. Crimp the locknut using a chisel and hammer.
Adjusting Shim Assembly Note
1. Assemble the differential carrier to the SSTs.
2. Assemble the spacer to the differential carrier.
3. Stack the side bearing outer race and gear case
component on the surface plate as indicated in
the figure, and measure the height using a caliper
and a ruler. This is value A.
4. Measure the width of the installed differential in
the differential carrier with the spacer installed.
This is value B.
5. The combined thickness of the left and right
adjusting shims is obtained by the following
formula.
C
1 = B – A + 0.15 mm {0.006 in}
C
2 = B – A + 0.44 mm {0.017 in}
6. If the combined thickness of the previously
installed adjusting shims is between C1 and C2,
use the shims as they are.
7. If the combined thickness of the previously
installed adjusting shims is not between C1 and
C2, or if the adjusting shims have to be replaced,
select two appropriate adjusting shims from the table below.
49 L027 006
49 L027 007
A6A63192030
LOCKNUT
1.0 mm {0.04 in}
A6E63192032
A
A6A63192033
B
SPACER
A6E63192034