Front Suspension: Removal & Installation Mazda 6 GG

REMOVAL/INSTALLATION

Scheme 9

1. Remove in the order indicated in the illustration.
2. Install in the reverse order of removal.

Bolt (Front Shock Absorber Lower Side) Removal Note

Support the knuckle with a jack to prevent it from falling.

Piston Rod Nut Removal Note

Scheme 10

1. Protect the coil spring using a piece of cloth, then set the SSTs.
2. Compress the coil spring using the SSTs, and remove the piston rod nut.

Scheme 11

Scheme 12

1. Temporarily install the coil spring, dust boot and mounting rubber on the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.
2. Mark the coil spring, dust boot and mounting rubber for proper installation as shown in the illustration.
3. Align the marks of the coil spring and dust boot. Protect the coil spring and dust boot using a piece of cloth, then set the SSTs.
4. Compress the coil spring using the SSTs.
5. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.
6. Make sure that the marks on the shock absorber and dust boot are aligned.
7. Install the mounting rubber and piston rod nut, then remove the SSTs. Piston rod nut tightening torque 29.0-39.0 ft. lbs. (39.2-52.9 N.m).

Front Shock Absorber and Coil Spring Installation Note

Install the stud bolts at a 27-33 degree angle from where the stabilizer control link is installed (center line), towards the inner side of the vehicle.

Scheme 13

Scheme 14

1. Align the gap of the damper fork with the projections of the damper.
2. Tighten the bolt.

Scheme 15

1. Remove in the order indicated in the illustration.
2. Install in the reverse order of removal.
3. Inspect the front wheel alignment. See «FRONT WHEEL ALIGNMENT»(ref-177890-S37902183632005060800000) .

Front Upper Arm Ball Joint Removal Note

1. Support the knuckle using the jack.
2. Separate the ball joint from the knuckle using the SST.

Scheme 16

Scheme 17

1. Remove the nuts (3 locations) from the upper part of the front shock absorber.
2. Pull the front shock absorber and coil spring out of the way, towards the outer side of the vehicle.
3. Remove the bolts.

Scheme 18

1. Wipe the grease off the ball stud.
2. Fill the inside of the new dust boot with grease.
3. Install the boot on the ball joint.
4. Install the new clip using the SST.
5. Verify that the clip is installed securely to the groove.
6. Wipe away the excess grease.

Note. Engine code AJ is for the 3.0L V6 engine.

Scheme 19

1. Remove the TWC (AJ) (only when removing/installing the right side front lower arm (front)). See EXHAUST SYSTEM REMOVAL/INSTALLATION [AJ].
2. Remove in the order indicated in the illustration.
3. Install in the reverse order of removal.

Front Lower Arm (Front) Ball Joint Removal Note

Separate the ball joint from the knuckle using the SSTs.

Scheme 20

Front Lower Arm (Front) Bushing (Inner Side) Removal Note

Press the bushing (inner side) out using the SSTs.

Scheme 21

Front Lower Arm (Front) Bushing (Outer Side) Removal Note

Press the bushing (outer side) out using the SSTs.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Mark the new bushing as shown in the figure.
2. Press the bushing in to the marking using the SSTs.
3. Verify that clearance distance A-B is 0.3445-0.4232" (8.75-10.75 mm).

Scheme 26

Scheme 27

Scheme 28

1. Mark the new bushing as shown in the illustration.
2. Press the bushing in to the marking using the SSTs.
3. Verify that clearance distance A-B is 0.5020-0.5807" (12.75-14.75 mm).

Clip Installation Note

1. Wipe the grease off the ball stud.
2. Fill the inside of the new dust boot with grease.
3. Install the boot on the ball joint.
4. Install the new clip using the SST. (Scheme 18)
5. Verify that the clip is installed securely to the groove.
6. Wipe away the excess grease.

1. Remove the under cover.
2. Remove the splash shield.
3. Remove the steering gear and linkage installation bolts, and pipe component installation bolts from the front crossmember, then suspend the steering gear and linkage with a cable. Tightening Torque Steering gear and linkage: 54.88-77.29 ft. lbs. (74.4-104.8 N.m). Pipe component: 69.1-95.5 inch lbs. (7.8-10.8 N.m).
4. Remove in the order indicated in the illustration.
5. Install in the reverse order of removal.
6. Inspect the front wheel alignment. See «WHEEL ALIGNMENT SPECIFICATIONS»(ref-163724-S18228060662004071200000) .

Scheme 29

Front Lower Arm (Rear) Ball Joint Removal Note

Separate the ball joint from the knuckle using the SSTs.

Scheme 30

Crossmember Bracket Removal Note

Scheme 31

1. Support the crossmember component with a jack and remove the nuts.
2. Remove the crossmember bracket.

Scheme 32

1. Loosen the front crossmember installation bolts (front side).
2. Lower the front crossmember, and remove the front lower arm bolt (inner side).
3. Remove the front lower arm (rear).

Scheme 33

1. Press the bushing out using the SSTs.
2. Remove the front lower arm (rear) from the press and tap the bushing out with a hammer.

Scheme 34

Scheme 35

Scheme 36

1. Mark the new bushing as shown in the illustration.
2. Press the bushing in to the marking using the SSTs.
3. Verify that clearance distance A-B is 0.936-1.013" (23.75-25.75 mm).

1. Wipe the grease off the ball stud.
2. Fill the inside of the new dust boot with grease.
3. Install the boot on the ball joint.
4. Install the new clip using the SST. (Scheme 18)
5. Verify that the clip is installed securely to the groove.
6. Wipe away the excess grease.

Front Lower Arm (Rear) Installation Note

Install the lower arm (rear) so that identification mark (L or R) faces toward the front of the vehicle.

1. Support the crossmember component with a jack and remove the nuts. (Scheme 31)
2. Remove the crossmember bracket.

Scheme 37

Scheme 38

1. Mark the crossmember as shown in the illustration (rear upper side only).
2. Remove the bushings using flathead screwdriver, being careful not to damage the front crossmember.

Scheme 39

Scheme 40

1. Set the bushings as shown in the illustration. NOTE: The bushings must be installed with correct orientation as shown below, or increased noise and vibration may result.
2. Install the bushing onto the crossmember using the SSTs.

Scheme 41

1. Remove the transverse member.
2. Install the transverse member.