Front Suspension: Removal & Installation Mazda 6 GH

FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION

Scheme 2

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

Bolt (Front Shock Absorber Lower Side) Removal Note

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

Scheme 3

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

Scheme 4

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

Piston Rod Nut Removal Note

Scheme 5

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 6

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 figure.
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

39.2-52.9 N.m {4.00-5.39 kgf.m, 29.0-39.0 ft.lbf}

Scheme 7

FRONT UPPER ARM REMOVAL/INSTALLATION

Scheme 8

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-288818-S02823078962008062500000) ).

Scheme 9

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

Scheme 10

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 11

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.

Scheme 12

1. Remove the upper arm from the vehicle. (See «FRONT UPPER ARM REMOVAL/INSTALLATION»(ref-288767-S16226474612008062500000) ).
2. Inspect for damage, cracks, and bending.
3. Inspect the ball joint rotational torque. Rotate the ball joint five times. Measure the rotational torque using a suitable alien socket and a torque wrench. If not within the specification, replace the lower arm component. Front upper arm ball joint rotation torque 1.5 N.m {15.0 kgf.cm, 13.2 in.lbf} max.

Scheme 13

1. Remove the lower arm (front) from the vehicle. (See «FRONT LOWER ARM (FRONT) REMOVAL/INSTALLATION»(ref-288767-S02036920302008062500000) ).
2. Inspect for damage, cracks, and bending.
3. Inspect the ball joint rotational torque. Rotate the ball joint five times. Measure the rotational torque using a suitable Allen socket and a torque wrench. If not within the specification, replace the lower arm component. Front lower arm (front) ball joint rotation torque 1.18-2.23 N.m {12.1-22.7 kgf.cm, 10.5-19.7 in.lbf}

Scheme 14

1. Remove the TWC (AJ) (only when removing/installing the right side front lower arm - front). (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [AJ]»(ref-288789-S14623219872008062500000) ).
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Front Lower Arm (Front) Ball Joint Removal Note

Scheme 15

Scheme 16

1. Insert a washer between the SST and the nut to prevent damage to the locknut.
2. Disconnect the ball joint using the SST.
3. If the ball joint cannot be disconnected in Step 2 , tap the SST from the bottom using a copper hammer.

Scheme 17

Scheme 18

Scheme 19

1. With the steering knuckle bushing installed to the ball joint, remove the front lower arm (front) from the steering knuckle.
2. Install the nut to the front lower arm (front) ball joint and remove the steering knuckle bushing using the SST . At this time, insert a washer between the SST and the locknut to prevent damage to the locknut.
3. If the steering knuckle bushing cannot be removed in Step 2 , tap the steering knuckle bushing with a hammer and remove the steering knuckle bushing. CAUTION: If you tap the steering knuckle bushing with a hammer to remove it, replace the steering knuckle bushing with a new one to avoid excessive play.

Scheme 20

Scheme 21

1. Install the steering knuckle bushing to the steering knuckle using a multi-purpose bolt and nut, and washers. CAUTION: Press-in the steering knuckle bushing vertically to the steering knuckle. When pressing the steering knuckle bushing in the steering knuckle, be careful not to damage the steering knuckle bushing upper surface where it contacts the dust boot. NOTE: Bolt diameter: 16 mm {0.63 in} Bolt stem length: 65 mm {2.56 in} or more Washer outer diameter: Approx. 45 mm {1.77 in} Washer thickness: Approx. 3 mm {0.12 in}
2. Tighten the bolt and nut to press-in the steering knuckle bushing to the steering knuckle.

Scheme 22

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

Scheme 23

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

Scheme 24

Scheme 25

Scheme 26

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 8.75 mm-10.75 mm {0.3445 in-0.4232 in}.

Scheme 27

Scheme 28

Scheme 29

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 12.75 mm-14.75 mm {0.5020 in-0.5807 in}.

Scheme 30

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.

Scheme 31

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: 74.4-104.8 N.m {7.857-10.68 kgf.m, 54.88-77.29 ft.lbf} Pipe component: 7.8-10.8 N.m {79.6-110.0 kgf.cm, 69.1-95.5 in.lbf}
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-288818-S02823078962008062500000) ).

Crossmember Bracket Removal Note

Scheme 32

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

Scheme 33

1. Support the crossmember component with a jack.
2. Loosen the crossmember component installation bolts (front side). (Do not remove the bolts completely).
3. Remove the crossmember component installation bolts (rear side).
4. Remove the front lower arm (rear).

Scheme 34

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 35

Scheme 36

Scheme 37

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 23.75-25.75 mm {0.936-1.013 in}.

Scheme 38

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.

Front Lower Arm (Rear) Installation Note

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

Scheme 39

1. Remove the lower arm (rear) from the vehicle. (See «FRONT LOWER ARM (REAR) REMOVAL/INSTALLATION»(ref-288767-S26792818932008062500000) ).
2. Inspect for damage, cracks, and bending.
3. Inspect the ball joint rotational torque. Rotate the ball joint five times. Measure the rotational torque using a suitable alien socket and a torque wrench. If not within the specification, replace the lower arm component. Front lower arm (rear) ball joint rotation torque 1.00-2.22 N.m {10.2-22.6 kgf.cm, 8.86-19.6 in.lbf}

Scheme 40

1. Remove the front crossmember component. (See «FRONT CROSSMEMBER REMOVAL/INSTALLATION»(ref-288767-S18504899432008062500000) ).
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-288818-S02823078962008062500000) ).

Scheme 41

1. Apply rubber grease to the inside surface of the stabilizer bushing.
2. Align the bushing with the inside of positioning plate on the stabilizer bar.
3. Install the stabilizer bracket.

Scheme 42

1. Remove the stabilizer control link from the vehicle. (See «FRONT STABILIZER REMOVAL/INSTALLATION»(ref-288767-S18220915472008062500000) ).
2. Inspect for bending and damage.
3. Measure the ball joint starting torque. Rock the ball joint stud side to side 10 times. Rotate the ball joint stud 10 times. Measure the starting torque using a suitable alien socket and a torque wrench. Front stabilizer control link ball joint starting torque 0.2-0.8 N.m {2.1-8.1 kgf.cm, 1.8-7.0 in.lbf}

Scheme 43

1. Remove the under cover.
2. Remove the splash shield.
3. Remove the transverse member. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-288767-S37098920042008062500000) ).
4. Remove the steering gear and linkage, 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: 74.4-104.8 N.m {7.857-10.68 kgf.m, 54.88-77.29 ft.lbf} Pipe component: 7.8-10.8 N.m {79.6-110.0 kgf.cm, 69.1-95.5 in.lbf}
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-288818-S02823078962008062500000) ).

Scheme 44

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

Scheme 45

Scheme 46

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

Scheme 47

Scheme 48

Scheme 49

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

Scheme 50

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