2002 MAZDA 6 boot

FRONT DRIVE SHAFT
M–39
M
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of the SST.
Clearance A
3.2 mm {0.13 in}
6. Crimp the wheel side big boot band using the SST.
7. 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}
8. Verify that the boot band does not protrude from the boot band installation area.
•If it does, replace the boot band and repeat Steps 7 and 8.
End Of Sie
FRONT DRIVE SHAFT (4WD) DISASSEMBLY/ASSEMBLYA6E6315255002021. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
A6E0313W043
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 Outer ring
(See M–40 Outer Ring Disassembly Note)
(See M–41 Outer Ring Assembly Note)
4 Snap ring
(See M–40 Snap Ring, Tripod Joint Disassembly
Note)
(See M–41 Tripod Joint, Snap Ring Assembly Note)5 Tripod joint
(See M–40 Snap Ring, Tripod Joint Disassembly
Note)
(See M–41 Tripod Joint, Snap Ring Assembly Note)
6 Free ring
7Boot
(See M–40 Boot Disassembly Note)
(See M–41 Boot Assembly Note)
8 ABS sensor rotor (with ABS)
(See M–36 ABS Sensor Rotor (With ABS)
Disassembly Note)
(See M–36 ABS Sensor Rotor (With ABS) Assembly
Note)
9 Shaft and ball joint component
10 Dynamic damper
(See M–41 Dynamic Damper Assembly Note)

M–40
FRONT DRIVE SHAFT
Outer Ring Disassembly Note
1. Mark the outer ring and the shaft for proper
assembly.
2. Remove the outer ring.
Snap Ring, Tripod Joint Disassembly Note
1. Mark the shaft and tripod joint for proper assembly.
2. Remove the snap ring using snap-ring pliers.
3. Remove the tripod joint from the shaft.
Caution
•Do not tap the tripod joint with a hammer.
Boot Disassembly Note
Note
•The wheel side boot does not need to be removed unless replacing it or the ball joint and shaft
component.
•Do not strip the tape until the boot is assembled.
1. Wrap the shaft splines with tape.
2. Remove the boot.
MARK
A6E0313W046
MARK
A6E0313W047
TAPE
A6E0313W048

FRONT DRIVE SHAFT
M–41
M
Dynamic Damper Assembly Note
1. Install the dynamic damper as shown in the
figure.
Standard length
Left side: 281.7—287.7 mm {11.10—11.32 in}
Right side: 334.7—340.7 mm {13.2—13.4 in}
2. Install a 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
90—110 g {3.18—3.88 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
Tripod Joint, Snap Ring Assembly Note
1. Align the marks and install the tripod joint using a
bar and a hammer.
Caution
•Do not damage the roller.
2. Install the new snap ring using snap-ring pliers.
Caution
•Be sure the snap ring engages correctly
in the groove of the shaft.
Outer Ring 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
Left side: 185—205 g {6.53—7.23 oz}
Right side: 195—215 g {6.88—7.58 oz}
2. Install the outer ring.
3. Set the drive shaft to the standard length.
DYNAMIC DAMPER
A6E6316W006
MARK
A6E0313W051

M–42
FRONT DRIVE SHAFT, REAR DRIVE SHAFT
Standard length
mm {in}
4. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Do not let grease leak.
•Do not damage the boot.
5. Verify that the drive shaft length is within the
standard.
•If not, repeat from Step 3.
End Of Sie
REAR DRIVE SHAFT PRE-INSPECTIONA6E6317255002011. Inspect each connecting part for looseness.
•Tighten or replace parts if necessary.
2. Inspect the dust boot on the drive shaft for cracks,
damage, leaking grease, and looseness in the
boot band.
3. Inspect the drive shaft for bends, cracks, and
wear in the joints or splines.
•Repair or replace the drive shaft or boot band
if necessary.
End Of Sie
Left side Right side
667—677
{26.26—26.65}631—641
{24.85—25.23}
A6E6316W007
REAR DRIVE SHAFT
A6J63172101

REAR DRIVE SHAFT
M–45
M
REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLYA6E6317255002031. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
SST
R
R
R
R
R
R
R
GREASEGREASE
GREASEGREASE
7
4
3
1
1
10
6
9
9
8
52
2
11
A6J63172003
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 (differential side)
(See M–35 Boot Band (Transaxle Side)
Disassembly Note)
(See M–38 Boot Band (Transaxle Side) Assembly
Note)
3Clip
See M–46 Clip Disassembly Note
See M–47 Outer Ring, Clip Assembly Note
4 Outer ring
(See M–47 Outer Ring, Clip Assembly Note)
5 Snap ring
(See M–46 Snap Ring Disassembly Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)6 Balls
(See M–46 Balls, Inner Ring, Cage Disassembly
Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
7 Inner Ring
(See M–46 Balls, Inner Ring, Cage Disassembly
Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
8Cage
(See M–46 Balls, Inner Ring, Cage Disassembly
Note)
(See M–47 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
9Boot
(See M–47 Boot Assembly Note)
10 ABS sensor rotor
(See M–36 ABS Sensor Rotor (With ABS)
Disassembly Note)
(See M–46 ABS Sensor Rotor Assembly Note)
11 Drive shaft, joint component

REAR DRIVE SHAFT
M–47
M
Boot Assembly Note
Note
•The wheel side and differential side boots are different.
1. Fill the wheel side boot 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
75—95 g {2.65—3.35 oz}
2. With the splines of the shaft wrapped in tape, 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 so that the major
diameter is at the same side as the snap
ring groove. If incorrectly installed, the
drive shaft may become disengaged.
2. Align the marks and install the inner ring to the
shaft.
3. Install a new snap ring.
Outer Ring, Clip Assembly Note
1. Fill the outer ring and boot (differential 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
65—85 g {2.30—2.99 oz}
2. Align the marks, and install the outer ring on to
the shaft.
3. Install a new clip to the outer ring clip groove.
4. Install the boot.
CAGEBALLS
SNAP RING
GROOVEINNER
RING
MARK
A6E6316W011
MARK
A6E6316W010

M–48
REAR DRIVE SHAFT, REAR DIFFERENTIAL
5. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Do not let grease leak.
•Do not damage the boot.
6. Set the drive shaft to the standard length.
Standard length
mm {in}
7. Verify that the drive shaft length is within the standard.
•If not, repeat from Step 5.
End Of Sie
DIFFERENTIAL OIL INSPECTIONA6E6319271002031. Place the vehicle on level ground.
2. Remove the filler plug and washer.
3. Verify that the oil is at the brim of the filler plug
hole.
4. If it is low, add the specified oil.
5. Install a new washer and the filler plug, and
tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7
ft·lbf}
End Of SieDIFFERENTIAL OIL REPLACEMENTA6E6319271002041. Place the vehicle on level ground.
2. Remove the filler plug.
3. Remove the drain plug and drain the differential
oil into a container.
4. Install a new washer and the drain plug, and
tighten.
Tightening torque
39—53 N·m {4.0—5.4 kgf·m, 29—39 ft·lbf}
5. Add the specified differential oil from the filler plug
until the level reaches the brim of the plug hole.
Specified oil
Type (API service GL-5)
Above -18°C {0°F}: SAE 90
Below -18°C {0°F}: SAE 80
Capacity (Approximate quantity):
1.00 L {1.06 US qt, 0.88 Imp qt}
6. After filling with differential oil, perform oil level inspection.
7. Install a new washer and the drain plug, and tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7 ft·lbf}
Left side Right side
805.4—815.4
{31.71—32.10}852.4—862.4
{33.56—33.95}A6E6316W007
REAR DIFFERENTIAL
FILLER PLUG
A6E63192101
FILLER PLUG
DRAIN PLUG
A6E63192102

R–8
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT (WGN)A6E741201015201Specification (Unloaded)*1
2WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1 °30'.*3: Distance between wheel center and fender brim is 405 mm {15.94 in} (reference value).
4WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1 °30'.
Maximum Steering Angle Adjustment 1. Loosen the tie-rod end locknuts.
2. Remove the steering gear boot clamp.
3. Turn the tie rods to equalize the length L.
Maximum left/right difference3 mm {0.12 in}
4. Turn the tie rods equally to provide the correct maximum steering angle.
5. Tighten the tie-rod end locknuts.
Tightening torque68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
6. Verify that the boot is not twisted, and install the boot clamp.
7. Adjust the toe-in after adjusting the steering angle.
WHEEL ALIGNMENT
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner
18 inch wheel specification vehicles: 36
°±3°
Except for above: 39 °±3°
Outer 18 inch wheel specification vehicles: 30
°±3°
Except for above: 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle
*2
(Reference value) normal 3
°30' ±1 ° 3°32' ±1 ° 3°34' ±1° 3°37' ±1° 3°40' ±1 °
elevated*33 °25' ±1 ° 3°27' ±1 ° 3°29' ±1° 3°32' ±1° 3°35' ±1 °
Camber angle
*2
(Reference value) normal -0
°14' ±1 ° -0°15' ±1°
elevated*3-0 °07' ±1 ° -0°08' ±1°
Steering axis inclination
(Reference value) normal 5
°24'
elevated
*35 °15' 5 °16'
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 39
°±3°
Outer 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle*
2 (reference value) 3
°25' ±1 ° 3°27' ±1 ° 3°29' ±1 ° 3°32' ±1 ° 3°35' ±1 °
Camber angle*
2(reference value) -0
°07' ±1 ° -0°08' ±1°
Steering axis inclination (reference value) 5 °15' 5 °16'
LEFT AND RIGHT DIFFERENCE
L
LESS THAN 3 mm {0.12 in}
A6E7412W002