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Axle Shaft: Reassembly

WARNING: This page is about a different car, the 2004 Mazda MPV, 2003 Mazda MPV, and 2002 Mazda MPV. However, it is still accessible from the selected car via links, so may be relevant.

Reassemble in the reverse order of disassembly.

NOTE: Does not apply to 2004 models, no Dynamic Damper.

Dynamic Damper Assembly Note

  1. Install the dynamic damper as shown in the illustration. See Fig 1 . Measure the distance shown ensure that is within specifications, see DYNAMIC DAMPER MEASUREMENTS  table.
  2. Install the new boot band onto the dynamic damper.
DYNAMIC DAMPER MEASUREMENTS

Length Application In. (mm)
2002 7.13-7.36 (181-187)
2003 10.66-10.89 (270.7-276.7)

ABS Sensor Rotor Assembly Note  Set a new ABS sensor rotor on the axle shaft and press it on using the Sensor Rotor Installer (49-B025-006A) and Sensor Rotor Installer Attachment (49-B025-009A), ensure that the measurement indicated in the illustration is 0.81" (20.7 mm). See Fig 2 .

Boot Assembly Note

  1. The wheel side and transaxle side boots are different.
  2. Fill the boot (wheel side) with the specified grease supplied in the boot kit.
    CAUTION: Do not touch grease with your hand. Apply it from the tube to prevent foreign matter entering the boot. The grease amount should be 4.59-5.29 oz. (0.135-0.156 L). Ensure that no foreign materials enter the boot.
  3. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
  4. Remove the tape.

Tripod Joint & Snap Ring Assembly Note

  1. Align the marks and install the tripod joint using a bar and a hammer. See Fig 3 .
    CAUTION: Do not damage the roller.
  2. Install the new snap ring using a snap-ring pliers.
    CAUTION: Be sure the snap ring engages correcting in the groove of the shaft.

Outer Ring Assembly Note

  1. Fill the outer ring and boot (transaxle side) with 6.36-7.06 oz. of specified grease supplied in the boot kit. See GREASE SPECIFICATIONS  table.
    CAUTION: Do not touch grease with your hand. Apply it from the tube to prevent foreign matter entering the boot.
  2. Install the outer ring.
  3. Set the axle shaft to the standard length. See AXLE SHAFT STANDARD LENGTH  table.
    GREASE SPECIFICATIONS

    Specifications Amount - ozs. (L)
    2002 4.59-5.29 (0.136-0.156)
    2003
    Left Side 6.36-7.06 (0.188-0.209)
    Right Side 6.71-7.41 (0.198-0.219)
    2004 7.06-7.76 (0.209-0.229)
    AXLE SHAFT STANDARD LENGTH

    Application In. (mm)
    2002
    Left Side 24.57-24.96 (624-634)
    Right Side 22.26-22.65 (565.4-575.4)
    2003
    Left Side 24.52-24.92 (622.9-632.9)
    Right Side 22.28-22.67 (565.9-575.9)
    2004
    Left Side 24.61-25.01 (625.2-635.2)
    Right Side 22.33-22.72 (567.2-577.2)
  4. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. See Fig 4 .
    CAUTION:
    • Do not let grease leak.
    • Do not damage the boot.
  5. Verify that the axle shaft length is within the standard.

Boot Band (Transaxle Side) Assembly Note  - Fold the band in the direction opposite to the forward revolving direction of the axle shaft and use pliers to pull it tight. See Fig 5 . Lock the end of the band by bending the locking clips.

CAUTION: Install the band into the groove securely.

Boot Band (Wheel Side) Assembly Note  - Letters in parenthesis in text reference letters in illustration. See Fig 6 .

  1. Adjust clearance (A) by turning the adjusting bolt of the Boot Clamp Crimper (49-T025-001). The correct clearance of (A) is 0.11" (2.9 mm).
  2. Crimp the wheel side small boot band using the boot clamp crimper. Verify that clearance (B) is within the specification. If clearance (B) is more than the specification, reduce clearance (A) of the boot clamp crimper and crimp the boot again. If clearance (B) is less than the specification, replace the boot band, increase clearance (A) of the boot clamp crimper, and crimp the new boot. The correct clearance of (B) is 0.095-0.110" (2.4-2.8 mm).
  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  2 and  3 .
  4. Fill the boot with the repair kit grease.
  5. Adjust clearance (A) by turning the adjusting bolt of the boot clamp crimper. The correct clearance of (A) is 0.13" (3.2 mm).
  6. Crimp the wheel side big boot band using the boot clamp crimper.
  7. Verify that clearance (B) is within the specification. If clearance (B) is more than the specification, reduce clearance (A) of the boot clamp crimper and crimp the boot again. If clearance (B) is less than the specification, replace the boot band, increase clearance (A) of the boot clamp crimper and crimp the new boot. The correct clearance of (B) is 0.095-0.110" (2.4-2.8 mm).
  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 .

Fig 1: Identifying Dynamic Damper
G00318579Courtesy of MAZDA MOTORS CORP.
Fig 2: Installing Sensor Rotor
G00318580Courtesy of MAZDA MOTORS CORP.
Fig 3: Assembling Tripod Joint
G00310659Courtesy of MAZDA MOTORS CORP.
Fig 4: Releasing Air From Boot
G00310660Courtesy of MAZDA MOTORS CORP.
Fig 5: Assembling Boot Band
G00310661Courtesy of MAZDA MOTORS CORP.
Fig 6: Identifying Boot Band Pliers
G00310662Courtesy of MAZDA MOTORS CORP.
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