2014 - Mazda6 - DriveLine/Axle

FRONT DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

1	Boot band (See Boot Band (Transaxle Side (Large Diameter)) Disassembly Note.) (See Boot Band (Transaxle Side (Large Diameter)) Assembly Note.)
2	Boot band (See Boot Band (Transaxle Side (Small Diameter)) Disassembly Note.) (See Boot Band (Transaxle Side (Small Diameter)) Assembly Note.)
3	Outer ring (See Outer Ring Disassembly Note.) (See Outer Ring Assembly Note.)
4	Dust cover (if equipped) (See Dust Cover Disassembly Note.) (See Dust Cover Assembly Note.)
5	Bearing (See Bearing Disassembly Note.) (See Bearing Assembly Note.)
6	Snap ring (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
7	Tripod joint (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
8	Boot (See Boot Disassembly Note.) (See Boot Assembly Note.)
9	Boot band (See Boot Band (Wheel Side) Disassembly Note.) (See Boot Band (Wheel Side) Assembly Note.)
10	Boot (See Boot Disassembly Note.) (See Boot Assembly Note.)
11	Shaft and ball joint component

Boot Band (Transaxle Side (Large Diameter)) Disassembly Note

NOTE:

• Remove the boot band only if there is a malfunction.

1. Pry up the boot band at the points indicated in the figure using pliers and remove the band.

Boot Band (Transaxle Side (Small Diameter)) Disassembly Note

NOTE:

• Remove the boot band only if there is a malfunction.

1. Remove the boot band using end clamp pliers.

Outer Ring Disassembly Note

1. Mark the outer ring and the shaft for proper assembly.

2. Secure the drive shaft using a vise.

3. Tap the outer ring slightly using a hammer and urethane bar or equivalent, and remove the outer ring from the drive shaft.

CAUTION:

• Lightly tap the outer ring carefully, otherwise the tripod joint rollers could be damaged.

Dust Cover Disassembly Note

1. Disassemble the dust cover using the press and the SST.

Bearing Disassembly Note

1. Disassemble the bearing using the press and the SST.

Snap Ring, Tripod Joint Disassembly Note

1. Place an alignment mark on the shaft and tripod joint.

2. Remove the snap ring using snap ring pliers.

3. Remove the tripod joint from the shaft.

CAUTION:

• Do not try to remove the tripod joint by hitting it with a hammer. The tripod joint could be damaged.

Boot Disassembly Note

NOTE:

• Remove the wheel side boot only if there is any malfunction.

1. Wrap the shaft splines with tape.

2. Remove the boot.

Boot Band (Wheel Side) Disassembly Note

NOTE:

• Remove the boot band only if there is a malfunction.

1. Remove the boot band using end clamp pliers.

Boot Assembly Note

NOTE:

• The boot shapes on the wheel side and the differential side are different. Do not install the wrong boot by mistake.

1. Fill the inside of the new dust boot (wheel side) with grease.

NOTE:

• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

Grease amount

• 96—106 g {3.4—3.7 oz}

2. Install the boot with the drive shaft spline still wrapped with vinyl tape.

3. Remove the vinyl tape.

Boot Band (Wheel Side) Assembly Note

1. Adjust clearance A by turning the adjusting bolt of the SST.

Clearance A

• Large diameter side: 3.2 mm {0.13 in}

• Small diameter side: 2.9 mm {0.11 in}

2. Crimp the wheel side boot band using the SST. Verify that clearance B is within the specification.

Large diameter side

Small diameter side

Clearance B

• Large diameter side: 1.2 mm {0.047 in} or less

• Small diameter side: 1.0 mm {0.039 in} or less

• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot band again.

3. Verify that the boot band does not protrude from the boot band installation area.

• If it does, replace the boot band and repeat Steps 1 and 2.

Tripod Joint, Snap Ring Assembly Note

1. While aligning the marks on the shaft and the tripod joint, insert the tripod joint using a bar and a hammer.

2. Insert a new snap ring using snap ring pliers.

3. Verify that the snap ring is engaged correctly in the groove of the shaft.

Bearing Assembly Note

1. Using the SST, install a new bearing.

Dust Cover Assembly Note

1. Using the SST, install a new dust cover.

Outer Ring Assembly Note

1. Fill the outer ring and boot (transaxle side) with the specified grease.

NOTE:

• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

Grease amount

• 89—99 g {3.2—3.4 oz}

2. Secure the outer ring using a vise.

CAUTION:

• Carefully perform the work when securing the outer ring to the vise, otherwise the oil seal could be deformed.

3. Align the roller with the outer ring, tap the roller slightly using a hammer and urethane bar or equivalent, and install the drive shaft to the outer ring while keeping the drive shaft vertical.

CAUTION:

• Be careful that no foreign matter such as dust or dirt gets into the outer ring, otherwise the drive shaft could be damaged.

4. Set the drive shaft to the standard length.

Front drive shaft standard length (ATX)

• LH

• 675.5—685.5 mm {26.60—26.98 in}

• RH

• 1040.95—1050.95 mm {40.9824—41.3760 in}

5. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.

NOTE:

• Verify that there is no grease leak while being careful not to damage the boot.

• If the boot is damaged, it may not be possible to perform the full-length adjustment of the drive shaft.

6. Verify that the drive shaft length is within the specification under atmospheric pressure inside the boot.

• If not within the specification, repeat from Step 3.

Boot Band (Transaxle Side (Small Diameter)) Assembly Note

1. Adjust clearance C by turning the adjusting bolt of the SST.

Clearance C

• 2.9 mm {0.11 in}

2. Crimp the transaxle side small boot band using the SST. Verify that clearance D is within the specification.

Clearance D

• 0.8 mm {0.031 in} or less

• If clearance D is more than the specification, reduce clearance C of the SST and crimp the boot band again.

3. Verify that the boot band does not protrude from the boot band installation area.

• If it does, replace the boot band and repeat Steps 1 and 2.

Boot Band (Transaxle Side (Large Diameter)) Assembly Note

1. Pry up the boot band at the points indicated in the figure using pliers and tighten the boot band.

2. Verify that the boot band is installed to the boot slot securely.