Front Crossmember Removal/Installation: Notes

Special Service Tool (SST)

49 T028 3A0
Ball joint puller set

Courtesy of MAZDA MOTORS CORP.

CAUTION:

Performing the following procedures could cause an open circuit in the front ABS wheel-speed sensor wiring harness if it is pulled by mistake. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.
Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

Remove the wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
Remove the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
Disconnect the intermediate shaft from the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
Disconnect the front ABS wheel-speed sensor wiring harness installed to the steering knuckle and set it aside. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION .)

Fig 1: Locating Front ABS Wheel-Speed Sensor Wiring Harness Clip With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Remove the front under cover No. 2. (See FRONT UNDER COVER NO. 2 REMOVAL/INSTALLATION .)
Remove the front under cover No. 1. (See FRONT UNDER COVER NO. 1 REMOVAL/INSTALLATION .)
Remove the front splash shield. (See FRONT SPLASH SHIELD REMOVAL/INSTALLATION .)
Remove the fasteners and clips shown in the figure and partially peel back the front over fender.

Fig 2: Front Over Fender Fasteners And Clips
Courtesy of MAZDA MOTORS CORP.
Remove the screws and the fasteners shown in the figure and set the front mudguard aside.

Fig 3: Front Mudguard Fasteners And Screws
Courtesy of MAZDA MOTORS CORP.
Remove the front crossmember extension.

Fig 4: Front Crossmember Extension With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Disconnect the front stabilizer control link (front stabilizer side).

Fig 5: Disconnecting Front Stabilizer Control Link With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Remove the snap pin from the tie-rod end.

Fig 6: Tie-Rod End And Snap Pin
Courtesy of MAZDA MOTORS CORP.
Loosen the locknut of the tie-rod end.

Fig 7: Tie-Rod End And Locknut
Courtesy of MAZDA MOTORS CORP.

Tightening torque

47-59 N.m {4.8-6.0 kgf.m, 35-43 ft.lbf}
Using the SST, disconnect the steering knuckle and tie-rod end.

Fig 8: Disconnect Steering Knuckle And Tie-Rod End Using SST
Courtesy of MAZDA MOTORS CORP.
Remove the locknut from the tie-rod end.

Fig 9: Tie-Rod End And Locknut
Courtesy of MAZDA MOTORS CORP.
Disconnect the front lower arm ball joint. (See FRONT LOWER ARM BALL JOINT INSTALLATION NOTE .)

Fig 10: Disconnecting Front Lower Arm Ball Joint With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Remove the bracket plate (No. 1). (2WD)

Fig 11: Bracket Plate (No. 1) With Bolts
Courtesy of MAZDA MOTORS CORP.
Remove the deadweight and bracket plate. (AWD)

Fig 12: Deadweight, Bracket Plate And Bolts (AWD)
Courtesy of MAZDA MOTORS CORP.
Remove the plate.

Fig 13: Plate, Fasteners And Bolts With Torque Specifications (2WD And AWD)
Courtesy of MAZDA MOTORS CORP.
Disconnect the hanger rubber from the front crossmember and set it aside.

Fig 14: Front Crossmember And Hanger Rubber
Courtesy of MAZDA MOTORS CORP.
Remove in the order indicated in the table.
Install in the reverse order of removal. (See SUSPENSION LINKS INSTALLATION NOTE .)

When replacing the front crossmember, inspect the wheel alignment and adjust it if necessary. (See FRONT WHEEL ALIGNMENT .)

Fig 15: Front Crossmember Components With Torque Specification

Courtesy of MAZDA MOTORS CORP.

COMPONENT DESCRIPTION

1	Front crossmember component (See Front Crossmember Component Removal Note .) (See No. 1 Engine Mount Rubber and Front Crossmember Component Installation Note .)
2	Front stabilizer insulator (See FRONT STABILIZER REMOVAL .) (See FRONT STABILIZER INSTALLATION .)
3	Front stabilizer (See FRONT STABILIZER REMOVAL .) (See FRONT STABILIZER INSTALLATION .)
4	Steering gear and linkage (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION .)
5	Front lower arm (See FRONT LOWER ARM REMOVAL/INSTALLATION .)
6	No. 1 engine mount rubber (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY .) (See No. 1 Engine Mount Rubber and Front Crossmember Component Installation Note .)
7	Front crossmember