2002 MAZDA 6 boot

H–4
CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY (A65M-R MANUAL TRANSAXLE MODELS)A6E4918419202021. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
End Of Sie
56
7
5.9—8.8 N.
m
{60—90 kgf.
cm,53—78 in.
lbf}
4
BRAKEFLUID
BRAKEFLUID3
1
2
A6E4918W011
1 Boot
2 Push rod
3 Piston and cap
4 Return spring5 Bleeder cap
6 Bleeder screw
7 Release cylinder body

CLUTCH UNIT
H–5
H
CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS)A6E4920160002011. Remove in the order indicated in the table.
2. Install in the reverse order oremoval.
.
CLUTCH UNIT
SST
SST
SSTSEALANT
25—33
{2.6—3.3, 19—24}
151.3—161.1
{15.43—16.42, 111.6—118.8} 18.6—25.5
{1.90—2.60, 13.8—18.8}
1
GREASE
GREASE
GREASE
GREASE
GREASE
5
6
7
8
4
3
2
(MOLYBDENUM SULFIDE) TRANSAXLE SIDE ENGINE SIDE
N·m {kgf·m, ft·lbf}
A6E4920W010
1 Clutch release cylinder
2 Manual transaxle
(See J2–7 MANUAL TRANSAXLE REMOVAL/
INSTALLATION)
3Boot
4 Clutch release collar
5 Clutch release fork6 Clutch cover
(See H–6 Clutch Cover and Disc Removal Note)
(See H–7 Clutch Cover Installation Note)
7Clutch disc
(See H–6 Clutch Cover and Disc Removal Note)
(See H–7 Clutch Disc Installation Note)
8 Flywheel
(See H–6 Flywheel Removal Note)
(See H–6 Flywheel Installation Note)

J2–12
SHIFT MECHANISM
SHIFT MECHANISM REMOVAL/INSTALLATIONA6E5214460102011. Remove the battery and battery tray.
2. Remove the air cleaner component. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the dashboard compleat. (See Section S.)
4. Remove the SAS control module. (See Section T.)
5. Remove the climate control unit. (See Section U.)
6. Remove the rear heat duct. (See Section U.)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. After installation, verify that the shift lever can be shifted smoothly into each position.
.
SHIFT MECHANISM
7
5
A
A
4
3
3
6
6.86—9.8
{70—99 kgf·cm, 61—85 in·lbf}
15.68—22.54
{1.599—2.298,
11.57—16.62} 7.8—10.8
{80—110 kgf·cm,
69.5—95.4 in·lbf}
1
2
N·m {kgf·m, ft·lbf}
15.68—22.54
{1.599—2.298,
11.57—16.62}
A6E5214W001
1 Shift lever knob
2 Boot panel
3 Clip
4 Seal plate5 Select cable
(See J2–13 Select Cable Installation Note)
6 Shift cable
7 Sift lever component

DRIVE SHAFT
M–5
M
DRIVE SHAFT OUTLINEA6E631625500201Features
Improved drivability, reduced noise and vibration
•Concurrent with the MZR-CD (RF Turbo) engine and 4WD system, the configuration of the front drive shaft and
the joint shaft has been optimized.
•For 4WD models, a constant velocity joint system has been adopted for the rear drive shaft.
End Of Sie
STRUCTURAL VIEWA6E631625500202
.
End Of Sie
REAR DRIVE SHAFTA6E631625500203Structure
•Engine noise and vibration have been reduced due to adoption of a bell joint on the wheel side of the constant
velocity joint.
•A low noise and vibration double offset joint with low slide resistance has been adopted for the differential side
of the constant velocity joint. Due to this booming resonance at high speed is reduced.
•An extremely durable plastic has been adopted for the wheel side boot.
.
DRIVE SHAFT
3
1
2
A6E63162101
1 Front drive shaft
2 Joint shaft3 Rear drive shaft
5
4
31
2
A6E63162102
1 Wheel side
2 Bell joint
3 Differential side4 Double offset joint
5 Plastic boot

M–34
FRONT DRIVE SHAFT
FRONT DRIVE SHAFT (MZR-CD (RF TURBO)) DISASSEMBLY/ASSEMBLYA6E6315255002011. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
9
9
8
7
5
4
3
10
11
6
1
1
2
2
12
SST
R
R
SST
R
SST
R
R
R
R
R
R
GREASEGREASE
GREASEGREASE
A6E6316W009
1 Boot band (wheel side)
(See M–35 Boot Band (Wheel Side) Disassembly
Note)
(See M–38 Boot Band (Wheel Side) Assembly
Note)
2 Boot band (transaxle side)
(See M–35 Boot Band (Transaxle Side)
Disassembly Note)
(See M–38 Boot Band (Transaxle Side) Assembly
Note)
3 Clip
(See M–35 Clip Disassembly Note)
(See M–37 Outer Ring, Clip Assembly Note)
4 Outer ring
(See M–37 Outer Ring, Clip Assembly Note)
5 Snap ring
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
6Balls
(See M–36 Balls, Inner Ring, Cage Disassembly
Note)
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)7 Inner Ring
(See M–36 Balls, Inner Ring, Cage Disassembly
Note)
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
8Cage
(See M–36 Balls, Inner Ring, Cage Disassembly
Note)
(See M–37 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
9Boot
(See M–37 Boot Assembly Note)
10 Dynamic damper
(See M–37 Dynamic Damper Assembly Note)
11 ABS sensor rotor
(See M–36 ABS Sensor Rotor (With ABS)
Disassembly Note)
(See M–36 ABS Sensor Rotor (With ABS) Assembly
Note)
12 Shaft and ball joint component

FRONT DRIVE SHAFT
M–35
M
Boot Band (Wheel Side) Disassembly Note
Note
•The boot band does not need to be removed unless it is being replaced.
1. Remove the boot clamp with end clamp pliers as
shown and discard the clamp.
Boot Band (Transaxle Side) Disassembly Note
1. Pry up the locking clips using a screwdriver.
2. Pull back the end of the band.
Clip Disassembly Note
1. Mark the drive shaft and outer ring for proper
assembly.
Caution
•Mark with paint; do not use a punch.
2. Remove the clip.
A6E6316W004
A6E6316W005
MARK
A6E6316W010

FRONT DRIVE SHAFT
M–37
M
Dynamic Damper Assembly Note
1. Install the dynamic damper as shown in the figure.
Standard length
334.7—340.7 mm {13.2—13.4 in}
2. Install the new boot band onto the dynamic
damper.
Boot Assembly Note
Note
•The wheel side and transaxle side boots are different.
1. Fill the boot (wheel side) with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
105—125 g {3.71—4.40 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
Cage, Inner Ring, Balls, Snap Ring Assembly Note
1. Align the marks and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution
•Install the cage with the offset facing the
snap ring groove. If incorrectly installed,
the drive shaft may become disengaged.
2. Install a new snap ring.
Outer Ring, Clip Assembly Note
1. Fill the outer ring and boot (transaxle side) with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
120—140 g {4.24—4.93 oz}
2. Align the marks, and install the outer ring on to the shaft.
3. Install a new clip.
4. Install the boot.
5. Set the drive shaft to the standard length.
DYNAMIC DAMPER
A6E6316W006
CAGEBALLS
SNAP RING
GROOVEINNER
RING
MARK
A6E6316W011

M–38
FRONT DRIVE SHAFT
Standard length
mm {in}
6. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Be careful not to allow the grease to leak.
•Do not damage the boot.
7. Verify that the drive shaft length is within the
specification.
•If not, repeat from Step 5.
Boot Band (Transaxle Side) Assembly Note
1. Fold the band in the direction opposite to the
forward revolving direction of the drive shaft and
use pliers to pull it tight.
2. Lock the end of the band by bending the locking
clips.
Caution
•Install the band into the groove securely.
Boot Band (Wheel Side) Assembly Note
1. Adjust clearance A by turning the adjusting bolt of
the SST.
Clearance A
2.9 mm {0.11 in}
2. Crimp the wheel side small boot band using the
SST. Verify that clearance B is within the
specification.
•If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
•If clearance B is less than the specification,
replace the boot band, increase clearance A
of the SST, and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
3. Verify that the boot band does not protrude from
the boot band installation area.
•If it does, replace the boot band and repeat Steps 2 and 3.
Left side Right side
666.3—676.3
{26.24—26.62}615.6—625.6
{24.24—24.62}
A6E6316W007
A6E6316W008
A
49 T025 001
ADJUSTING BOLT
A6E0350W012
B
49 T025 001
A6E0350W013