2002 MAZDA 6 Workshop Manual Suplement

PROPELLER SHAFT
L–9
L
Snap Ring Disassembly Note
1. Mark the yoke and flont propeller shaft or york
and rear propeller shaft for proper reassembly.
2. Clamp the propeller shaft in a vise.
3. Remove the snap ring using a screwdriver.
Bearing Cup Disassembly Note
1. Use a copper hammer to loosen the propeller
shaft bearing cup, then remove the bearing cup.
2. Remove the opposite bearing cup in the same
manner.
3. Separate the propeller shaft and yoke.
4. Clamp the yoke in a vise.
5. Remove the bearing cups and the spider from the
yoke as in Step 1 and 2.
Locknut Disassembly Note
1. Mark the center yoke and center propeller shaft
for proper reassembly.
2. Clamp the center yoke in a vice.
3. Remove the locknut and spring washer.
MARK
A6E6110W004
YTA6110W107
YTA6110W108
MARK
A6E6110W005

L–10
PROPELLER SHAFT
Center Yoke Disassembly Note
1. Remove the center yoke using the SST.
Center yoke (front side)
Center yoke (rear side)
Bearing support Disassembly Note
1. Remove the bearing support using the SST.
Dust Cover and Bearing Disassembly Note
1. Remove the dust cover and bearing from bearing
support using the SST and a press.
49 0839 425C
A6J6110W017
49 0839 425C
49 H027 002
A6J6110W011
49 0839 425C
49 G030 370
A6J6110W012
BEARING BEARING SUPPORT
DUSR COVER
49 F015 002
49 0636 145
A6E6110W007

PROPELLER SHAFT
L–11
L
Bearing Assembly Note
1. Install the bearing onto the bearing support using
the SST and a press.
Dust Cover Assembly Note
1. Install the dust cover onto the bearing support
using the SST and a press.
Bearing Support Assembly Note
1. Install the bearing support using the SST.
Bearing side (front side)
Bearing support (rear side)
49 G030 797
49 H033 101
49 U027 005
A6J6110W014
49 F401 331
49 B034 201
49 U027 005
A6J6110W015
49 F401 335A
49 F401 331
A6J6110W018
49 F401 331
49 B034 201
A6J6110W019

L–12
PROPELLER SHAFT
Locknut Assembly Note
1. Align the mark on the center yoke and shaft, and
install the center yoke.
Tightening torque
137—177 N·m
{16.1—18.0 kgf·m, 116—130 ft·lbf}
Bearing Cup and Snap Ring Assembly Note
1. Apply the grease to the bearing rollers inside the
bearing cups.
2. Set the new spider to the yoke, and assemble the
new bearing cup as the snap ring groove comes
out.
3. Assemble the opposite bearing cup in the same.
4. Insert the bearing cup to the yoke as the snap
ring groove width of bearing cup widens most and
both grooves width are same.
Caution
•Use a snap ring that thickness is same
for both sides.
MARK
A6E6110W005
GREASEGREASE
GREASEGREASE
A6J6110W016
A6E6110W010
BEARING CUPSPIDER
YOKE
A6E6110W011

PROPELLER SHAFT
L–13
L
5. Measure the bearing cup groove width, and select
a new snap ring that thickness is same as the
groove to install.
Snap ring thickness
mm {in}
6. Fit the snap ring to the yoke by lightly tapping
around the yoke with a copper hammer.
7. Verify that there is no play in the spider.
8. Align the mark made during disassembly, and
assemble the propeller shaft and yoke.
9. Install the bearing cup and snap ring to the yoke
as step 1 through 6.
10. Improve the fit by lightly tapping around the
universal joint with a plastic hammer.
11. Inspect the universal joint play and movement.
(See L–14 PROPELLER SHAFT INSPECTION.)
End Of Sie
Snap ring
Part number Thickness
T010 25 071 1.21 {0.0476}
T010 25 071B 1.22 {0.0480}
T010 25 072 1.23 {0.0484}
T010 25 072B 1.24 {0.0488}
T010 25 073 1.25 {0.0492}
T010 25 073B 1.26 {0.0496}
T010 25 074 1.27 {0.0500}
T010 25 074B 1.28 {0.0504}
T010 25 075 1.29 {0.0508}
T010 25 075B 1.30 {0.0512}
T010 25 076 1.31 {0.0516}
T010 25 076B 1.32 {0.0520}
T010 25 077 1.33 {0.0524}
T010 25 077B 1.34 {0.0528}
T010 25 078 1.35 {0.0532
T010 25 078B 1.36 {0.0535}
T010 25 079 1.37 {0.0539}
T010 25 079B 1.38 {0.0543}
T010 25 081 1.39 {0.0547}
A6E6110W012
A6E6110W013
MARK
A6E6110W014

L–14
PROPELLER SHAFT
PROPELLER SHAFT INSPECTIONA6E6110250022031. Disassemble the propeller shaft.
2. Measure the propeller shaft runout with a dial
indicator.
•If the runout is excessive, replace the
propeller shaft.
Runout limit
0.3 mm {0.01 in}
3. Move the universal joint in the direction shown,
and inspect joint play.
•If the joint play is not within the specification,
adjust the universal joint using snap rings.
Starting torque
0.29—0.78 N·m {3.0—7.9 kgf·cm}
End Of Sie
A6E6110W015
YTA6110W120

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

M–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E630201018201•The construction and operation of the front and rear axles is the same as that of the current Mazda6 (GG)
model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
End Of Sie
FEATURESA6E630201018202Improved rigidity, reduced noise and vibration
•Concurrent with the MZR-CD (RF Turbo) engine, the configuration of the front drive shaft and the joint shaft
has been optimized.
•Concurrent with the 4WD system, the configuration of the rear axle, the front/rear drive shafts and the joint
shaft has been optimized.
Improved handling stability and marketability
•An electronic 4WD control system has been adopted.
End Of Sie
SPECIFICATIONSA6E6302010182032WD
Bold frames:New specifications
OUTLINE
ItemSpecification
New Mazda6 (GG)(4SD, 5HB),
New Mazda6 (GY)(Wagon 2WD)Current Mazda6
(GG)(4SD, 5HB)
Engine L8, LF, L3MZR-CD
(RF Turbo)L8, LF, L3
Transaxle MTX ATX MTX MTX ATX
Front axle Bearing type Angular ball bearing
Rear axle Bearing type Angular ball bearing
Drive shaftJoint
typeWheel side Bell joint
Differential sideDouble offset
jointTripod joint
(With free ring)Double offset
jointDouble offset
jointTripod joint
(With free ring)
Shaft diameter (mm {in}) 24.5 {0.96} 24.0 {0.94} 24.0 {0.94} 24.5 {0.96} 24.0 {0.94}
Joint shaft Shaft diameter (mm {in}) 26.0 {1.02} 29.0 {1.14} 26.0 {1.02}