Disassembly and assembly of the front drive shaft with constant velocity ball joint (Mazda CX-5KE)

Note:

: replace the part with a new one after each removal.

: use a special tool or device.

: apply lubricant.

1. Using pliers, pry up the boot clamp at the points shown in the figure and remove the large diameter clamp from the boot on the gearbox side.

Note: The small diameter boot clamp is removed only if it is damaged.

2. Remove the small diameter boot clamp using special pliers.



3. Mark the relative positions of the drive shaft and outer ring for correct assembly later.

Caution: Apply marks with paint. Do not use punching.

4. Remove the retaining ring.



5. Remove the outer ring from the drive shaft.

6. If equipped, remove the dust ring using a press and a special tool.



7. Remove the bearing from the drive shaft using a press and a special tool.



8. Apply alignment marks to the end of the drive shaft and the inner ring for correct assembly later.

Caution: Apply marks with paint. Do not use punching.

(The original article is available on: MAZBOOK.RU)

9. Remove the retaining ring using special pliers.

10. Remove the cage with balls and separator from the shaft.

Note: Remove the wheel side boot only if faulty.

11. Wrap the shaft splines with electrical tape.



12. Remove the clamps and remove the boot from the wheel side of the shaft.

Note: The drive shaft boots on the wheel side and the gearbox side are different. Be careful not to mix up the boots when installing.

13. Place grease inside the new boot on the wheel side.

Note: Do not touch the grease with your hands. Apply grease with a grease gun to prevent foreign materials from entering the boot.

Amount of grease:

• SKYACTIV-G 2.0 petrol engine: 95-115 g.
• Diesel engine SKYACTIV-D 2.2: 125-145 g.

14. After making sure that the shaft splines are still covered with electrical tape, install the boot onto the drive shaft.

15. Remove the electrical tape from the shaft splines.

16. Adjust the gap A to 2.9 mm by turning the adjusting screw of the special crimping tool.



17. Tighten the small clamp of the boot on the wheel side using a special tool. Make sure that the gap B is within the norm (2.4-2.8 mm). If the gap B exceeds the permissible range, reduce the gap A on the crimping tool and crimp the clamp again. If the gap B is less than the norm, replace the boot clamp with a new one, increase the gap A on the crimping tool and crimp the new clamp.





18. Make sure that the boot clamp does not protrude beyond the boot mounting areas. If the clamp is not installed where it should be, replace the boot clamp with a new one, repeating the operations described above.

19. Adjust the gap C to 3.2 mm by turning the adjusting screw of the special crimping tool.



20. Tighten the large clamp of the boot on the wheel side using a special tool. Make sure that the clearance D is within the norm (2.4-2.8 mm). If the gap D exceeds the permissible range, reduce the gap C on the crimping tool and crimp the clamp again. If the gap D is less than the norm, replace the boot clamp with a new one, increase the gap C on the crimping tool and crimp the new clamp.



21. Make sure that the boot clamp does not protrude beyond the boot mounting areas. If the clamp is not installed where it should be, replace the boot clamp with a new one, repeating the operations described above.



22. Having aligned the marks, install the balls with the separator on the inner race.

Caution: Install the collar so that its outside diameter matches the groove of the retaining ring. If installed incorrectly, the drive shaft may come apart.

23. After aligning the marks, install the inner race onto the shaft.

24. Install a new retaining ring.

25. Place in outer ring with dust cover (from the gearbox side) necessary lubrication.

Note: Do not touch the grease with your hands. Apply grease with a grease gun to prevent foreign materials from entering the boot.

Amount of grease:

• SKYACTIV-G 2.0 petrol engine: 85-105 g.
• Diesel engine SKYACTIV-D 2.2: 100-120 g.

26. Install the outer ring on the shaft.

27. Install the boot.

28. Adjust the length of the drive shaft to the standard value (see section "Service data" at the beginning of the chapter).

29. Bleed all the air out of the boots by carefully lifting the small diameter edges of each boot with a flat screwdriver wrapped in cloth.

Attention.

• Be careful to avoid grease leaks.
• Be careful not to damage the boot.

30. Make sure that the drive shaft length is within the standard.



31. Using pliers, pry up the large diameter boot clamp at the points shown in the figure and tighten the clamp.



32. Make sure the clamp is securely installed on the boot.