2002 MAZDA 6 service

L–4
PROPELLER SHAFT
PROPELLER SHAFT INSPECTION ON VEHICLEA6E611025002204Joint Play Inspection
1. Move the joint shaft by hand, and verify that there is no play.
If there is play, perform the following service operations.
•Yoke : Universal joint replacement (See L–7 PROPELLER SHAFT DISASSEMBLY/ASSEMBLY.)
•Constant velocity joint : Propeller shaft
replacement (See L–7 PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY.)
Propeller Shaft Runout Inspection
Caution
•Do not rotate the propeller shaft by starting the engine.
1. Shift the select lever to N position and release the parking brake.
2. Rotate the rear wheel by hand, and measure the
propeller shaft runout at 9 points as shown in the
figure.
Limit
0.4 mm {0.02 in}
PROPELLER SHAFT
A6J6110W002
A6J6110W003
A6J6110W004

L–6
PROPELLER SHAFT
Nut Removal Note
Caution
•Do not mark with the ponch to prevent unbalance.
1. Before removing the nut, put marks on the front
companion flange, tripod joint and the rear
companion flange, rear universal joint yoke for
proper reinstallation.
Propeller Shaft Heat Shield Installation Note
Caution
•When assembling the propeller shaft heat shield to the bearing support, narrowing the bolt hole
inner diameter can lower serviceability. Align the bolt hole edge of the propeller shaft heat shield
with the bolt hole inner side of the bearing support to assemble.
1. Set the propeller shaft heat shield to the bearing
support.
Front side
Rear side
2. Bend the edges of the propeller shaft heat shield
toward the bearing support as shown.
A6J6110W006
OK NGBOLT HOLE OF
PROPELLER SHAFT HEAT SHIELD
BOLT HOLE OF
BEARING SUPPORT
A6E6110W022
PROPELLER SHAFT
HEAT SHIELDBEARING SUPPORT
EDGE
4.5—4.7
mm
A6E6110W016
4.5—4.7
mm
PROPELLER SHAFT
HEAT SHIELDBEARING SUPPORT
EDGE
A6E6110W017

M–1
M
MFRONT AND REAR AXLES
OUTLINE............................................................... M-2
OUTLINE OF CONSTRUCTION ........................ M-2
FEATURES ......................................................... M-2
SPECIFICATIONS .............................................. M-2
REAR AXLE.......................................................... M-4
REAR AXLE OUTLINE ....................................... M-4
CROSS-SECTIONAL VIEW ............................... M-4
DRIVE SHAFT....................................................... M-5
DRIVE SHAFT OUTLINE.................................... M-5
STRUCTURAL VIEW.......................................... M-5
REAR DRIVE SHAFT ......................................... M-5
REAR DIFFERENTIAL.......................................... M-6
REAR DIFFERENTIAL OUTLINE ....................... M-6
CROSS-SECTIONAL VIEW ............................... M-6
ELECTRONIC 4WD CONTROL SYSTEM............ M-7
OUTLINE ............................................................ M-7
ELECTRONIC CONTROL COUPLING .............. M-9
DIFFERENTIAL OIL TEMPERATURE
SENSOR ........................................................ M-12
4WD WARNING LIGHT .................................... M-12
4WD CONTROL MODURE .............................. M-13
4WD SYSTEM CONTROL................................ M-14
CONTROLLER AREA NETWORK (CAN) ........ M-15
ON-BOARD DIAGNOSTIC ............................... M-16
OUTLINE............................................................. M-18
SUPPLEMENTAL SERVICE
INFORMATION .............................................. M-18
LOCATION INDEX.............................................. M-19
AXLE/DRIVE SHAFT LOCATION INDEX ......... M-19
REAR DIFFERENTIAL/ELECTRONIC
4WD CONTROL SYSTEM LOCATION
INDEX ............................................................ M-20
GENERAL PROCEDURES................................. M-21
PRECAUTION (FRONT AND REAR AXLE) ..... M-21
REAR AXLE........................................................ M-22
WHEEL HUB BOLT REPL
ACEMENT ..................................................... M-22
WHEEL HUB, KNUCKLE
REMOVAL/INSTALLATION ........................... M-22
FRONT DRIVE SHAFT........................................ M-29
JOINT SHAFT (MZR-CD (RF TURBO))
DISASSEMBLY/ASSEMBLY ......................... M-29
JOINT SHAFT (4WD)
DISASSEMBLY/ASSEMBLY ......................... M-31
FRONT DRIVE SHAFT
(MZR-CD (RF TURBO))
DISASSEMBLY/ASSEMBLY ......................... M-34
FRONT DRIVE SHAFT (4WD)
DISASSEMBLY/ASSEMBLY ......................... M-39REAR DRIVE SHAFT.......................................... M-42
REAR DRIVE SHAFT PRE-INSPECTION ........ M-42
REAR DRIVE SHAFT
REMOVAL/INSTALLATION ........................... M-43
REAR DRIVE SHAFT
DISASSEMBLY/ASSEMBLY ......................... M-45
REAR DIFFERENTIAL........................................ M-48
DIFFERENTIAL OIL INSPECTION ................... M-48
DIFFERENTIAL OIL REPLACEMENT .............. M-48
OIL SEAL (SIDE GEAR) REPLACEMENT ....... M-49
OIL SEAL (COMPANION FLANGE)
REPLACEMENT ............................................ M-49
REAR DIFFERENTIAL
REMOVAL/INSTALLATION ........................... M-51
REAR DIFFERENTIAL DISASSEMBLY ........... M-52
REAR DIFFERENTIAL ASSEMBLY ................. M-56
ELECTRONIC 4WD CONTROL SYSTEM.......... M-65
DIFFERENTIAL OIL TEMPERATURE
SENSOR INSPECTION ................................. M-65
DIFFERENTIAL OIL TEMPERATURE
SENSOR REMOVAL/INSTALLATION ........... M-65
4WD SOLENOID INSPECTION........................ M-66
4WD CONTROL MODURE INSPECTION ........ M-66
4WD CONTROL MODURE
REMOVAL/INSTALLATION ........................... M-67
COUPLING COMPONENT
REMOVAL/INSTALLATION ........................... M-68
COUPLING COMPONENT
DISASSEMBLY .............................................. M-69
COUPLING COMPONENT ASSEMBLY........... M-72
ON-BOARD DIAGNOSTIC.................................. M-75
WIRING DIAGRAM ........................................... M-75
ELECTRONIC 4WD CONTROL SYSTEM
ON-BOARD DIAGNOSIS ............................... M-76
DTC P1887 ....................................................... M-77
DTC P1888 ....................................................... M-79
DTC U0100 ....................................................... M-80
DTC U0101 ....................................................... M-80
DTC U0121 ....................................................... M-80
TROUBLESHOOTING......................................... M-81
SYSTEM WIRING DIAGRAM ........................... M-81
FOREWORD ..................................................... M-82
SYMPTOM TROUBLESHOOTING ................... M-82
NO.1 FREQUENT FRONT WHEEL SLIP ......... M-82
NO.2 TIGHT CORNER BRAKING .................... M-83
NO.3 ABNORMAL NOISE AND/OR
VIBRATION FROM COUPLING
COMPONENT ................................................ M-84 FEATURES
SERVICE

OUTLINE
M–3
M
4WD
Bold frames:New specifications
End Of Sie
ItemSpecification
New Mazda6 (GY)(Wagon 4WD)
EngineL3
TransaxleATX
Front axle Bearing type Angular ball bearing
Rear axle Bearing type Angular ball bearing
Front drive shaftJoint typeWheel side Bell joint
Differential side Tripod joint (With free ring)
Shaft diameter (mm {in}) 24.0 {0.94}
Joint shaft Shaft diameter (mm {in}) 29.0 {1.14}
Rear drive shaftJoint typeWheel side Bell joint
Differential side Double offset joint
Shaft diameter (mm {in}) 22.0 {0.87}
Rear and front wheel torque distribution unit Electronic control coupling
Rear differentialReduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 6.5
Final gear ratio 2.928
Gears:
Number of teethDrive pinion 14
Ring gear 41
Differential oilTypeGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Amount
(Approximate quantity)(L {US qt, lmp qt}) 1.0 {1.1, 0.9}

M–4
REAR AXLE
REAR AXLE OUTLINEA6E631401018201Features
Improved drivability
•An angular ball bearing, with a low rotational resistance, has been adopted.
Improved serviceability
• A unit bearing that does not require pre-load setting has been adopted.
End Of Sie
CROSS-SECTIONAL VIEWA6E631401018202
.
End Of Sie
REAR AXLE
1
A6E63142001
1 Angular ball bearing

ELECTRONIC 4WD CONTROL SYSTEM
M–7
M
OUTLINEA6E632227100201Features
Improved off-road mobility, handling stability, operability, fuel economy and marketability
•An electronic 4WD control system, which automatically optimizes traction distribution to the front and rear
wheels, has been adopted.
Improved serviceability
•A self-diagnostic function has been adopted for the electronic 4WD control system.
Electronic 4WD control system outline
•The newly adopted electronic 4WD control system automatically and optimally controls drive torque distribution
for the front and rear wheels. Due to this off-road mobility, driving stability and fuel economy are improved.
•Based on the input signals from each sensor, the 4WD control modure (4WD CM) determines vehicle driving
and road conditions, and controls output current to the electronic control coupling (4WD solenoid) inside the
rear differential. This control allows for optimal distribution of the drive torque from the engine to the rear
wheels.
•Also, the 4WD CM automatically controls the 4WD, greatly reducing the load on the driver and improving
operability.
Structural view
.
ELECTRONIC 4WD CONTROL SYSTEM
87
5
4
3
6
9
8
7
5
4
3
10
6
1
2
9
10
A6E63222001
1L.H.D.
2 R.H.D.
3 4WD warning light
4 4WD control modure
5 DSC HU/CM6PCM
7TCM
8 Electronic control coupling (4WD solenoid)
9 Differential oil temperature sensor
10 Rear differential

M–16
ELECTRONIC 4WD CONTROL SYSTEM
ON-BOARD DIAGNOSTICA6E632227100208Outline
•The on-board diagnostic function allows for detecting malfunctions in the input/output signals when the ignition
key is at the ON position.
•The DLC-2, which combines the failure detection and detection maintenance connectors, has been adopted to
improve serviceability. By connecting a WDS or equivalent to the DLC-2, malfunction diagnosis can be carried
out.
•Using a WDS or equivalent DTCs can be retrieved or erased, depending on the screen display, thus improving
serviceability.
Block diagram
.
Self-diagnostic function
Failure detection function
•The failure detection function detects malfunctions in the input/output signal systems of the 4WD CM and
displays them when the ignition key is at the ON position.
•When the ignition key is turned to the ON position, the 4WD CM system begins operation, and the 4WD
warning light illuminates for 3 seconds while the function checks for open circuits. At the same time the function
monitors the condition of the power supply voltage and checks for internal malfunctions.
•Then, once the system is running, the function checks the operating conditions of the 4WD solenoid and the
differential oil temperature sensor at regular intervals to determine whether there is any malfunction.
•If any malfunction is detected during these diagnostic tests, the warning light illuminates according to the
malfunction to alert the driver. Also, a DTC is output to DLC-2 via the CAN line. Also, at the same time the
failure detection result is sent to the memory and fail-safe functions.
9
87
5
4
3
10
13
11
12
6
12
A6E63222010
1 Input part
2 Regular control area
3 Output part
4 Fail-safe function
5 Failure detection function
6 Memory function
7 Failure display function8 External tester communication function
9 Failure diagnosis function
10 4WD warning light
11 DLC-2
12 CAN
13 WDS or equivalent

M–18
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E630201018204•The following additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
Rear wheel hub bolt
•Replacement procedure has been added.
Wheel hub, knuckle
•Removal/installation procedure has been added.
Joint shaft (MZR-CD (RF Turbo))
•Disassembly/assembly procedure has been added.
Joint shaft (4WD)
•Disassembly/assembly procedure has been added.
Front drive shaft (MZR-CD (RF Turbo))
•Disassembly/assembly procedure has been added.
Front drive shaft (4WD)
•Disassembly/assembly procedure has been added.
Rear drive shaft
•Inspection procedure has been added.
•Removal/installation procedure has been added.
•Disassembly/assembly procedure has been added.
Differential oil
•Inspection procedure has been added.
•Replacement procedure has been added.
Oil seal (side gear)
•Replacement procedure has been added.
Oil seal (companion flange)
•Replacement procedure has been added.
Rear differential
•Removal/installation procedure has been added.
•Disassembly procedure has been added.
•Assembly procedure has been added.
Differential oil temperature sensor
•Inspection procedure has been added.
•Removal/installation procedure has been added.
4WD solenoid
•Inspection procedure has been added.
Coupling component
•Removal/installation procedure has been added.
•Disassembly procedure has been added.
•Assembly procedure has been added.
On-board diagnostic
•Electronic 4WD control system have been added.
Troubleshooting
•Electronic 4WD control system have been added.
End Of Sie
OUTLINE