Axle shaft repair (Mazda Capella GD)

The outer joint of the axle shaft cannot be repaired and the entire axle must be replaced if excessive play is detected. The inner ball joint should only be disassembled for cleaning or replacement of the rubber seal. If the shaft has been removed, the retaining ring on the inner end must always be replaced, as must any other work on the axle.

The design of the internal constant velocity joint is different for manual and automatic transmissions and work must be carried out accordingly.

13.2.1. With the stepped transmission installed

Clamp the drive shaft in a vice (using soft metal pads). Lift the bent edges of the clamp bracket with a screwdriver and then pull out the edges of the bracket with pliers. Remove the clips from both cuffs and pull the cuffs inward.

Using a screwdriver, remove the safety ring from the groove of the hinge housing, as shown in Figure 176.



Remove the hinge housing from the drive shaft and clean the released ball bearing separator from excess grease. Using snap ring pliers, remove the snap ring from the shaft end as shown in Figure 177. Before removing the ring, mark the relative positions of the shaft end and the inner ring.

• Remove the complete ball joint from the shaft.
• Remove both seals from the shaft.
• Press the balls out of the holes one by one using a small screwdriver. Turn the separator slightly until it can be released from the outer ring.

Clean all parts thoroughly. If necessary, completely replace the loose joint. Bent shafts also need to be replaced. If the joint still looks good, do not remove the grease from the separator and do not use any cleaning agents, such as gasoline, for cleaning. Figure 178 shows an assembly diagram of the shaft with the location of the individual components.





If the balls, cage, or outer ring have rust spots, scratches, or other defects, a new ball joint must be installed.

Always replace rubber seals with holes or tears to prevent dirt from getting into the hinge. Repair kits with seals and prescribed lubricant are available.

Reassemble the hinge in reverse order. The rubber seals for the inner and outer hinges are different and cannot be confused. You need to proceed as follows:

• Use the grease supplied with the repair kit and press the balls into the separator one by one.
• Wrap some tape around the threaded end of the shaft and place both cuffs on the shaft. Fill the ball joint on the gear side with grease and place the rubber seals through the joint housing so that the rim fits into the groove on the outer side.
• Place the separator and the inner rotating ring over the shaft (with markings along one line) and install a spring retaining ring on the end of the shaft.
• Fill the inner side of the ball joint completely with grease and carefully slide the outer housing with the toothed shaft through the joint. Insert the large safety ring into the inside of the housing (figure 176). Check that the ring fits properly.
• Fill the inner side of the ball joint completely with grease and carefully push the outer housing with the toothed shaft through the joint. Take the large safety ring on the inside onto the springs (figure 176). Check that the ring fits perfectly around the circumference.
• Clean the outer side of the outer casing and shaft grooves from dirt and put on rubber seals. Check that the rim fits correctly in the grooves of the housing and shaft.
• Place new clamps around the rubber cuffs.
• The clamping brackets must be installed against the direction of shaft rotation. The edge of the staple is bent back while it is held with pliers and bent. After this, bend the safety plate with a screwdriver.
• Immediately insert a new retaining ring into the groove at the end of the shaft.
• Before installing the shaft, wipe off all grease from the outside of the shaft and seals.

13.2.2. In the installed automatic transmission

• Figure 179 shows the installation drawing of this drive shaft. When compared with Figure 178, the difference in the design of constant velocity joints can be established.

• Clamp the drive shaft in a vice with soft metal pads.
• Lift the bent edges of the clamp bracket with a screwdriver and then gouge out the edges of the bracket with pliers. Remove the clamps and pull the cuffs inward.
• Remove the housing cap from the three-star joint.
• Using thrust ring pliers as shown in Figure 180, remove the retaining ring from the axle shaft groove and remove the joint sprocket from the shaft. Before this, it is necessary to mark the relative position of the sprocket and shaft.

• Remove both seals from the shaft.

Clean all parts thoroughly. If the bearing on the sprocket journal is loose, the parts need to be replaced. Bent shafts also need to be replaced.

If the joint still looks good, do not remove the grease from the separator and do not use any degreasing cleaners such as gasoline.

Always replace rubber seals with holes or tears to prevent dirt from getting into the hinge. Repair kits with seals and prescribed lubricant are available.

Reassemble the hinge in reverse order. The rubber seals for the inner and outer hinges are different and cannot be confused.

After inserting the three-star joint, insert the safety ring into the shaft according to the marking.

Wrap some tape around the shaft thread and place both sleeves on the shaft. Fill the ball joint on the gear side with grease and place the rubber seals through the joint casing so that the rim fits into the groove on the outer side. Place new clamps around the rubber cuffs. The clamping brackets must be installed against the direction of shaft rotation. The edge of the staple is bent back while it is held with pliers and bent. After this, bend the safety plate with a screwdriver.