Mazda 6 2003 Reference manual

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CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2007 Mazda Motor of America, Inc.
Subject:
UNUSUAL NOISE FROM STEERING SHAFT WHEN TURNING STEERING WHEEL
Bulletin No: 06-001/07
Last Issued: 02/22/2007
Service Bulletin Mazda North American Operations
Irvine, CA 92618-2922
2003-2007 MAZDA6 - UNUSUAL NOISE FROM STEERING SHAFT WHEN TURNING STEERING WHEEL
APPLICABLE MODEL(S)/VINS
2003 - 2007 Mazda6
DESCRIPTION
On some vehicles, the steering shaft may make an unusual clunk noise during acceleration while the steering
wheel is turned. The intermediate shaft splines in the steering column may be lacking lubrication and causing
the clunk noise.
Customers having this concern should have their vehicle repaired using the following repair procedure.
SPLINE SLIDING LOCATION
1738a

Bulletin No: 06-001/07
© 2007 Mazda Motor of America, Inc. Last Issued: 02/22/2007
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REPAIR PROCEDURE
NOTE: Before performing this repair procedure, be sure to inform the customer that the new super grease is
very effective for noise, but it may change the steering and handling feel of their vehicle. Also, the
operation of the telescopic steering (if equipped) may feel slightly heavier after the repair.
1. Verify customer concern by changing steering column angle and length (telescoping only), then attempt to
duplicate clunk noise.
WARNING: Do not attempt to adjust the steering column angle or length while driving the vehicle. Be sure
to adjust the steering wheel only when the vehicle is stopped as you can lose control of the
vehicle if you change the steering tilt or position while driving.
2. Repeat Step 1 two (2) more times using different steering column angles and lengths (telescoping only),
then attempt to duplicate clunk noise.
- If clunk noise is gone, proceed to Step 3.
- If clunk noise is still present, do not proceed with this repair procedure. Troubleshoot other causes of
noise according to related sections of the Workshop Manual.
3. For telescopic equipped vehicle: Position steering shaft to most forward position.
4. Remove two (2) push-nuts securing joint cover.
5. Remove joint cover.
6. Remove pinch-bolt securing intermediate shaft.
7. Slide shaft toward A to remove from steering gear.
8. Slide shaft toward B to remove from tube.
JOINT
COVER
PUSH-NUT
TUBE
SHAFT
PINCH-BOLT
1738b
B
A
1738c

Bulletin No: 06-001/07
© 2007 Mazda Motor of America, Inc. Last Issued: 02/22/2007
Page 3 of 4
9. Wipe all grease off splines.
10.Apply approx. 5 cc of new super grease to splines and inside the tube.
11. Align marks and assemble tube and shaft.
12.Wipe off any extra grease.
13. Fit intermediate shaft to steering gear and tighten pinch bolt.
Tightening torque: 13.8 - 19.5 ft-lbf. (18.8 – 26.5 Nm, 1.9 - 2.7 kgfm)
14. Fit joint cover and reinstall two (2) push-nuts.
15.After reassembly, operate telescopic or tilt steering as follows:
- For vehicles equipped with tilt and telescopic: Operate telescopic three (3) times from front to rear. Oper-
ate tilt three (3) times from top to bottom, then return to original position.
- For vehicles equipped with tilt only: Operate tilt three (3) times from top to bottom, then return to original
position.
16. Verify repair.
1738e
REMOVE GREASE FROM SPLINES
APPLY NEW GREASE TO
SPLINES AND TUBE
MARKS
1738g

Bulletin No: 06-001/07
© 2007 Mazda Motor of America, Inc. Last Issued: 02/22/2007
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PART(S) INFORMATION
WARRANTY INFORMATION
NOTE: • This warranty information applies only to verified customer complaints on vehicles eligible for war-
ranty repair. Refer to the Warranty Wizard for warranty term information.
• Additional diagnostic time cannot be claimed for this repair.
Part Number Description Qty. Notes
0000-77-230E-01 Super Grease 1 1 oz. tube will repair 2 - 3 vehicles
Warranty Type A
Symptom Code 82
Damage Code 91
Part Number Main Cause 5555-07-008A
Quantity 0
Operation Number / Labor Hours: XXC024RX / 0.4 (includes cost of grease)