Front Suspension: Removal & Installation Mazda RX-8 I

REMOVAL/INSTALLATION

1. Remove the front suspension tower bar. See «FRONT SUSPENSION TOWER BAR»(ref-170063-S10851823732004122800000) REMOVAL/INSTALLATION.
2. Remove in the order indicated in the illustration.
3. Install in the reverse order of removal.

Scheme 4

Piston Rod Nut Removal Note

1. Protect the coil spring from scratches using a piece of cloth and install the SSTs.
2. Compress the coil spring using the SSTs and remove the piston rod nut.

Scheme 5

Scheme 6

1. Protect the coil spring from scratches using a piece of cloth and install the SSTs.
2. Compress the coil spring using the SSTs.
3. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.

Scheme 7

Scheme 8

1. Align the mark on the upper spring seat with the dust boot projection.
2. Install the upper spring seat so that the upper spring seat stud is at a 27-33 degree angle to the shock absorber installation shaft (lower side).

Scheme 9

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-178181-S26941813692005061300000) .

Caliper & Mounting Support Removal Note

Remove the caliper and mounting support from the steering knuckle and suspend it with a cable in a location out of the way.

Shock Absorber Lower Bolt & Nut Removal Note

1. Loosen the shock absorber upper nuts.
2. Remove the front shock absorber lower bolt and nut.

Front Upper Arm Ball Joint Removal Note

Remove the front upper arm ball joint from the steering knuckle using the SST.

Scheme 10

Front Upper Arm Removal Note

1. Remove the front upper arm bolts.
2. Push down the front lower arm, and then remove the front upper arm from the gap between the shock absorber lower end and the front lower arm.

Scheme 11

Scheme 12

1. Cut off 0.12-0.15" (3-4 mm) from each side of the bushing knob using a hacksaw.
2. Remove the bushing using the SSTs and a press.

Bushing Installation Note

Press the bushing in using the SST and a press.

Scheme 13

Scheme 14

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

Scheme 15

1. Remove the front suspension tower bar. See «FRONT SUSPENSION TOWER BAR»(ref-170063-S10851823732004122800000) REMOVAL/INSTALLATION.
2. Remove in the order indicated in the illustration.
3. Install in the reverse order of removal.

Remove the caliper and mounting support from the steering knuckle and suspend it with a cable in a location out of the way.

Front Lower Arm Ball Joint Removal Note

Disconnect the front lower arm ball joint from the steering knuckle using the SST.

Scheme 16

Note. When removing the front lower arm ball joint, the steering knuckle bushing may also come off. If it comes off, replace the steering knuckle.

Upper Arm Ball Joint Removal Note

1. Loosen the bolts on the vehicle side.
2. Disconnect the upper arm ball joint using the SST.

Scheme 17

Scheme 18

Scheme 19

1. Mark the front upper arm as shown in the illustration.
2. Remove the bushing using the SSTs.

Scheme 20

Scheme 21

1. Cut off the stopper plate rubber using a razor.
2. Cut off 0.20-0.23" (5-6 mm) from each side of the knob end of the bushing using a hacksaw.

Bushing (Shock Absorber Lower Side Connecting Part) Removal Note

Remove the bushing using the SSTs.

Scheme 22

Bushing (Shock Absorber Lower Side Connecting Part) Installation Note

Compress the bushing using the SSTs.

Scheme 23

Scheme 24

Scheme 25

1. Press the bushing in using the SSTs.
2. Insert the stopper plate rubber into the inner pipe of the bushing (front side).

Scheme 26

Scheme 27

1. Align the marks placed during removal and install the bushing.
2. Press the bushing in using the SSTs.

Scheme 28

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

Scheme 29

1. Remove the front lower arm from the vehicle.
2. Inspect the front lower arm for bending or damage. If there is any malfunction, replace it.
3. Inspect the ball joint for excessive play. If there is any malfunction, replace the front lower arm.
4. Rotate the ball joint 5 times.
5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench. Front lower arm ball joint rotational torque. 4-25 inch lbs. (0.4-2.9 N.m) If not within the specification, replace the front lower arm.

Scheme 30

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

Stabilizer Bracket Installation Note

1. Apply rubber grease to the inner side of the stabilizer bushing.
2. Align the outer side of the stabilizer slide stopper with the stabilizer bushing.
3. Install the stabilizer bracket.

Scheme 31

1. Remove the front suspension tower bar. See «FRONT SUSPENSION TOWER BAR»(ref-170063-S10851823732004122800000) REMOVAL/INSTALLATION.
2. Remove in the order indicated in the illustration.
3. Install in the reverse order of removal.
4. Inspect the front wheel alignment. See «FRONT WHEEL ALIGNMENT»(ref-178181-S26941813692005061300000) .
5. Set the EPS system to the neutral position. See EPS SYSTEM NEUTRAL POSITION SETTING. CAUTION: After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction.

Scheme 32

Axle & Hub Component Removal Note

1. Loosen the front upper arm inner bolts.
2. Remove the axle and hub component.

Scheme 33

Scheme 34

1. Suspend the engine using the SSTs.
2. Support the front crossmember using a jack. WARNING: Verify that the crossmember component is securely supported by a jack. If the crossmember component falls, it could cause serious injury or death, or damage to the vehicle.
3. Remove the transverse member.
4. Remove the mounting rubber while gradually lowering the front crossmember.

Scheme 35

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

Scheme 36

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

Plate Installation Note

Install the plates with the identification marks facing upward.

Scheme 37