2002 MAZDA 6 Workshop Manual Suplement

REAR DRIVE SHAFT
M–43
M
REAR DRIVE SHAFT REMOVAL/INSTALLATIONA6E631725500202
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. Drain the rear differential oil into a container. (See M–48 DIFFERENTIAL OIL REPLACEMENT.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
.
SST
R
R
R
OILOIL
4
3
1
2
235.2—318.5
{24.0—32.4,
173.5—234.9}
N·m {kgf·m, ft·lbf}
A6J63172001
1 Trailing link, knuckle component
(See M–22 WHEEL HUB, KNUCKLE REMOVAL/
INSTALLATION)
2 Rear drive shaft
(See M–44 Rear Drive Shaft Removal Note)3Oil seal
(See M–49 OIL SEAL (SIDE GEAR)
REPLACEMENT)
4Clip
(See M–44 Clip Installation Note)

M–44
REAR DRIVE SHAFT
Rear Drive Shaft Removal Note
1. Deform the metal cover of the oil seal using a bar,
and disengage the drive shaft.
Note
•Oil seal cannot be reused. Always replace
the oil seal with a new one.
Clip Installation Note
1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does
not exceed the specification on installation.
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Steps 1—2
using a new clip.
Outer diameter specification
26.0 mm {1.02 in} max.
End Of Sie
A6J63172201
OUTER
DIAMETER OPENING
CLIP
A6E0313W021

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

M–46
REAR DRIVE SHAFT
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.
Snap Ring Disassembly Note
1. Mark the drive shaft end and inner ring for proper
reassembly.
Caution
•Mark with paint; do not use a punch.
2. Remove the snap ring using snap-ring pliers.
Balls, Inner Ring, Cage Disassembly Note
1. Mark the inner ring and cage for proper reassembly.
Caution
•Mark with paint; do not use a punch.
2. Turn the cage approximately 30 degrees and
pull the cage and balls from the inner ring.
ABS Sensor Rotor Assembly Note
1. Install the ABS sensor rotor to the drive shaft
using the SSTs.
MARK
A6E6316W010
MARK
A6E63172005
30°
A6J63172006
49 B025 006A20.7 mm
{0.81 in}
49 B025 009AABS SENSOR
ROTOR
A6E63172008

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

REAR DIFFERENTIAL
M–49
M
End Of SieOIL SEAL (SIDE GEAR) REPLACEMENTA6E6319271002051. Remove the drain plug and the drain differential oil into a container.
2. Install a new washer and the drain plug, and tighten.
3. Remove the rear drive shaft. (See M–43 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
4. Remove the clip from the drive shaft.
Caution
•Wrap the end of a screwdriver with cloth to prevent scratches to the inside of the differential
casing.
5. Remove the oil seal from the differential casing
using a screwdriver.
6. Apply differential oil to the new oil seal lip.
7. Install the new oil seal to the differential carrier
using the SSTs.
8. After installing the new clip onto the drive shaft,
insert the drive shaft into the differential. (See M–
43 REAR DRIVE SHAFT REMOVAL/
INSTALLATION.)
9. Verify that the drive shaft cannot be pulled out.
10. Add the specified differential oil.
11. fter adding the oil, perform an oil level inspection.
(See M–48 DIFFERENTIAL OIL INSPECTION.)
12. Install a new washer and the oil 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 Sie
OIL SEAL (COMPANION FLANGE) REPLACEMENTA6E6319271002061. Drain the differential oil into a container.
2. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the locknut using the SST.
4. Support the differential using a jack.
A6A63192003
49 G030 79649 G030 797
A6A63192004
49 S120 710
A6A63192005

M–50
REAR DIFFERENTIAL
5. After removing the front side of the differential
mount, gradually lower the jack and tilt the front
side of the differential downward.
6. Pull the companion flange off using the SST.
7. Remove the oil seal from the differential carrier
using a screwdriver or similar tool.
8. Apply differential oil to the new oil seal lip.
9. Install the new oil seal to the differential carrier
using the SST.
10. Install the companion flange to the drive pinion.
11. Jack up the differential and install the front side of
the differential mount.
Tightening torque
74.5—104.9 N·m {7.6—10.7 kgf·m, 55.0—77.3
ft·lbf}
12. Install the washer and a new locknut.
13. Tighten the locknut to the specified torque using
the SST.
Tightening torque
167—226 N·m {17.1—23.0 kgf·m, 124—166
ft·lbf}
14. Install the propeller shaft. (See L–5 PROPELLER
SHAFT REMOVAL/INSTALLATION)
15. Add the specified differential oil from the filler
plug. (See M–48 DIFFERENTIAL OIL
REPLACEMENT)
End Of Sie
JACK
DIFFERENTIAL
A6E63192042
49 0839 425C
A6A63192043
49 W011 102
A6A63192006
49 S120 710
A6A63192007