2002 MAZDA 6 Workshop Manual Suplement

LOCATION INDEX
M–19
M
AXLE/DRIVE SHAFT LOCATION INDEXA6E630025500201
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LOCATION INDEX
5
4
3
1
2
A6J63002001
1 Wheel hub bolt
(See M–22 WHEEL HUB BOLT REPLACEMENT)
2 Wheel hub, knuckle
(See M–22 WHEEL HUB, KNUCKLE REMOVAL/
INSTALLATION)
3 Joint shaft
(See M–29 JOINT SHAFT (MZR-CD (RF Turbo))
DISASSEMBLY/ASSEMBLY)
(See M–31 JOINT SHAFT (4WD) DISASSEMBLY/
ASSEMBLY)4 Front drive shaft
(See M–34 FRONT DRIVE SHAFT (MZR-CD (RF
Turbo)) DISASSEMBLY/ASSEMBLY)
(See M–39 FRONT DRIVE SHAFT (4WD)
DISASSEMBLY/ASSEMBLY)
5 Rear drive shaft
(See M–42 REAR DRIVE SHAFT
PRE-INSPECTION)
(See M–43 REAR DRIVE SHAFT REMOVAL/
INSTALLATION)
(See M–45 REAR DRIVE SHAFT DISASSEMBLY/
ASSEMBLY)

M–20
LOCATION INDEX
REAR DIFFERENTIAL/ELECTRONIC 4WD CONTROL SYSTEM LOCATION INDEXA6E630027100201
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8
7
5
4
3
6
1
2
8
7
5
4
3
6
1
2
L.H.D.
R.H.D.
A6J63002002
1 Differential oil
(See M–48 DIFFERENTIAL OIL INSPECTION)
(See M–48 DIFFERENTIAL OIL REPLACEMENT)
2 Oil seal (side gear)
(See M–49 OIL SEAL (SIDE GEAR)
REPLACEMENT)
3 Oil seal (companion flange)
(See M–49 OIL SEAL (COMPANION FLANGE)
REPLACEMENT)
4 Rear differential
(See M–51 REAR DIFFERENTIAL REMOVAL/
INSTALLATION)
(See M–52 REAR DIFFERENTIAL DISASSEMBLY)
(See M–56 REAR DIFFERENTIAL ASSEMBLY)5 Differential oil temperature sensor
(See M–65 DIFFERENTIAL OIL TEMPERATURE
SENSOR INSPECTION)
(See M–65 DIFFERENTIAL OIL TEMPERATURE
SENSOR REMOVAL/INSTALLATION)
6 4WD solenoid
(See M–66 4WD SOLENOID INSPECTION)
7 4WD control module
(See M–66 4WD CONTROL MODURE
INSPECTION)
(See M–67 4WD CONTROL MODURE REMOVAL/
INSTALLATION)
8 Coupling component
(See M–68 COUPLING COMPONENT REMOVAL/
INSTALLATION)
(See M–69 COUPLING COMPONENT
DISASSEMBLY)
(See M–72 COUPLING COMPONENT
ASSEMBLY)

GENERAL PROCEDURES
M–21
M
PRECAUTION (FRONT AND REAR AXLE)A6E631001018201Wheel and Tire Removal/Installation
1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a
wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}
Brake Line Disconnection/Connection
Caution
•Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut
tightening torque to allow for use of a torque wrench-SST combination.
2. If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
Suspension Arm Removal/Installation
1. Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and
unloaded.
Note
•Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools
are in designated position.
Connector Disconnection
1. Disconnect the negative (-) battery cable before disconnecting connectors.
Electronic Control 4WD System Parts
1. After servicing the electronic control 4WD system parts, verify that no DTC has been stored. Clear any DTCs
remaining in the memory.
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GENERAL PROCEDURES

M–22
REAR AXLE
WHEEL HUB BOLT REPLACEMENTA6E6314050002011. Remove the brake caliper component and the disc plate.
2. Remove the wheel hub bolt using the SST as
shown in the figure.
Note
•If the dust cover interferes with the wheel
hub bolt and the wheel hub bolt cannot be
removed, tap the part shown in the figure
with a chisel lightly and bend the process
back to the knuckle side.
3. Install a new wheel hub bolt into the wheel hub
and install a washer and hub nut on the hub bolt.
4. Tighten the hub nut while holding the wheel hub
using a brass bar.
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WHEEL HUB, KNUCKLE REMOVAL/INSTALLATIONA6E631405000202
Caution
•Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (wheel side) and fix it to an
appropriate place where the sensor will not be pulled by mistake while the vehicle is being
serviced.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
REAR AXLE
49 T028 3A0
BEND THIS PART
A6E0311W011
HUB BOLT
WHEEL
NUT WHEEL
NUT
WASHER
BRASS
BAR
A6E0311W012

REAR AXLE
M–23
M
.
93.2—131.4
{9.6—13.3,
68.8—96.9}
HHG
G
E
E
F
F
AB
A
B
C
C
D
D
86.2—116.6
{8.8—11.9, 63.6—85.9} 18.6—25.5
{1.90—2.63,
13.8—18.8}75.5—94.5
{7.7—9.6, 55.7—69.6}51.0—66.7
{5.3—6.8,
37.7—49.1}43.1—60.8
{4.4—6.1, 31.8—44.8}
235.2—318.5
{24.0—32.4,
173.5—234.9}
9
8
7
5
4
3
1
2
10
1918
17
15
16
14
13
11
12
20
6SST
SST
R
SST
R
R
R
R
75.5—94.5
{7.7—9.6,
55.7—69.6}
86.2—116.6
{8.8—11.9, 63.6—85.9}
86.2—116.6
{8.8—11.9, 63.6—85.9}
N·m {kgf·m, ft·lbf}
A6E63142101
1 ABS wheel-speed sensor
2 Parking brake cable
3 Locknut
(See M–24 Locknut Removal Note)
(See M–28 Locknut Installation Note)
4 Brake caliper component
5 Disc plate
6 Bolt (stabilizer control link (lower))
7 Bolt (rear lower arm (outer))
(See M–24 Bolt (Rear Lower Arm (Outer)) Removal
Note
8 Rear coil spring
(See M–28 Rear Coil Spring Installation Note)
9 Bolt (rear upper arm (outer))
10 Bolt (shock absorber (lower))
(See M–24 Bolt (Shock Absorber (Lower)) Removal
Note)11 Bolt (lateral link (outer))
(See M–24 Bolt (Lateral Link (Outer)) Removal
Note)
12 Bolt (trailing link (front))
(See M–25 Bolt (Trailing Link (Front)) Removal
Note)
(See M–28 Bolt (Trailing Link (Front)) Installation
Note)
13 Trailing link, knuckle component
14 Wheel hub, knuckle component
15 Wheel hub
(See M–25 Wheel Hub Removal Note)
(See M–27 Wheel Hub Installation Note)
16 Snap ring
17 Wheel bearing
(See M–25 Wheel Bearing Removal Note)
(See M–27 Wheel Bearing Installation Note)

M–24
REAR AXLE
Locknut Removal Note
1. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
2. Lock the hub by applying the brakes.
3. Remove the locknut.
Bolt (Rear Lower Arm (Outer)) Removal Note
1. Support the lower arm with a jack.
2. Loosen the lower arm bolts (inner).
3. Remove the lower arm bolts (outer).
4. Gradually lower the jack and separate the lower
arm (outer) from the knuckle.
Bolt (Shock Absorber (Lower)) Removal Note
1. Support the trailing link and the knuckle
component with a jack.
2. Remove the lower shock absorber bolts.
Bolt (Lateral Link (Outer)) Removal Note
1. Loosen the lateral link bolts (inner).
2. Remove the lateral link bolts (outer), and remove the lateral link (outer) from the knuckle.
18 Dust cover
(See M–26 Dust Cover Removal Note)
(See M–27 Dust Cover Installation Note)
19 Knuckle20 Wheel hub bolt
(See M–26 Wheel Hub Bolt Removal Note)
(See M–26 Wheel Hub Bolt Installation Note)
A6E0312W021
JACK
A6E63142102
JACK
A6E63142103

REAR AXLE
M–25
M
Bolt (Trailing Link (Front)) Removal Note
Warning
•Be sure that the trailing link and the knuckle component are supported securely with a jack.
Otherwise, the trailing link and/or the knuckle component may fall, causing death or injury, or
vehicle damage.
1. Verify that the trailing link and the knuckle
component are supported securely with a jack,
and remove the bolts at the trailing link front.
Wheel Hub Removal Note
1. Remove the wheel hub from the knuckle using
the SSTs.
2. If the bearing inner race remains on the wheel
hub, grind a section of the bearing inner race until
approx. 0.5 mm {0.02 in} remains. Then remove
it using a chisel.
Wheel Bearing Removal Note
1. Remove the wheel bearing from the knuckle
using the SSTs.
JACK
A6E63142103
49 G033 105
49 F026 103
49 G033 102
A6J63142104
A6E6312W002
49 F027 005
49 F026 103
49 G030 797
A6J63142105

M–26
REAR AXLE
Dust Cover Removal Note
Note
•The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and knuckle for proper
installation.
2. Remove the dust cover from the knuckle using a
chisel.
Wheel Hub Bolt Removal Note
Note
•The wheel hub bolts do not need to be removed unless they are being replaced.
1. Remove the wheel hub bolts from the wheel hub
using a press.
Wheel Hub Bolt Installation Note
1. Install the new wheel hub bolts to the wheel hub
using a press.
MARK
A6E63142104
A6E6312W003
A6E6312W004