NHTSA ID Number: 10145249
Manufacturer Communication Number: 03-003-18-3519
TSB/Document Date: 2018-10-09
Summary
Some vehicles may exhibit an oil leak from the companion flange area (A) of the transfer unit. This concern may be caused by companion flange oil seal wear. The oil seal has been improved to increase the wear resistance.
Technical
Service Bulletin
Mazda
North American Operations
Irvine, CA 92618-2922
Subject:
OIL LEAK FROM COMPANION FLANGE AREA OF TRANSFER UNIT
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted in Red text.
Previous TSBs: Date(s) Issued:
03-002/17
11/20/2017
DESCRIPTION
APPLICABLE MODEL(S)/VINS
2013-2016 CX-5 AWD vehicles with VINs lower than JM3KE******878977 (produced before October 5,
2016)
Some vehicles may exhibit an oil leak from the companion flange area (A) of the transfer unit. This concern
may be caused by companion flange oil seal wear. The oil seal has been improved to increase the wear
resistance.
Customers having this concern should have their vehicle repaired using the following repair procedure.
Page 1 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
REPAIR PROCEDURE
1. Verify the customer concern.
NOTE: First try to replace the oil seal without disassembling the transfer unit. If this is not applicable or
effective, disassemble the transfer unit.
Companion Flange Oil Seal Replacement Procedure without disassembling the Transfer Unit
(Without replacing Collapsible Spacer):
IMPORTANT:
This procedure can only be used one time because the collapsible spacer will already be collapsed
and its function will be lost.
This procedure requires precise measurement of the bearing preload. Carefully read through the
procedure and understand the work flow and required skills before starting to work.
Page 2 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
Part Description
Notes
A
Lock Nut (*)
REUSE
B
Washer (*)
REUSE
C Companion Flange Component (*)
REUSE
D
REPLACE
E
Collapsable Spacer
DO NOT REMOVE
F
Pinion Shaft
DO NOT REMOVE
G
DO NOT REMOVE
(*) Reinstall lock nut, washer and companion flange component after replacing the oil seal, in the original
position, so that the same bearing preload value can be assured before disassembly and after assembly.
2. Verify that this is the first time replacing the oil seal using this procedure.
NOTE: Confirm it by checking the vehicle repair history and/or existence of position marks on the
companion flange, lock nut and pinion shaft during the previous oil seal replacement.
If the oil seal has been previously replaced using this procedure, this procedure must not be used
again. Replace the oil seal by disassembling the transfer unit. Go to “Companion Flange Oil Seal
Replacement Procedure by Disassembling Transfer Unit”.
If this is the first time replacing the oil seal using this procedure, go to next step.
3. Prepare vehicle for lift, move the gear selector to the neutral position and raise vehicle.
4. Remove the propeller shaft according to the instructions on MGSS online (PROPELLER SHAFT
REMOVAL/INSTALLATION).
5. Measure the bearing (A) preload by turning the pinion shaft (B) within the backlash range of the hypoid
gear (C).
Page 3 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
6. Record the measured value.
NOTE: If the backlash of hypoid gear is too small, it may be difficult to measure the bearing preload. In this
case, this procedure is not effective. Disassemble the transfer unit to replace the oil seal. Go to
“Companion Flange Oil Seal Replacement Procedure by Disassembling Transfer Unit”.
When measured with a torque wrench (A) or spring scale (B).
Upper Limit Value of Bearing Preload:
Method
Upper Limit Value
A. When measured with a torque wrench 1.44 Nm {14kgf-cm, 12 in-lbf｝
B. When measured with a spring scale
2.83 kg
Page 4 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
- If the preload is less thanthe upper limit value, go to next step.
- If the preload is greater thanthe upper limit value, the collapsible spacer needs to be replaced to adjust
the preload and so this procedure must not be used. Disassemble the transfer unit to replace the oil seal.
Go to “Companion Flange Oil Seal Replacement Procedure by Disassembling Transfer Unit”.
7. Put a position mark (A) over the companion flange (B), lock nut (C) and pinion shaft (D) as shown below.
NOTE: Be sure to put the mark clearly so that all three (3) parts can be reassembled in the same position.
8. Secure the companion flange using the SST and remove the locknut.
9. Remove the washer.
10. Remove the companion flange using the SST.
Page 5 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
11. Remove the oil seal using a tape-wrapped flathead screwdriver.
12. Install the modified oil seal using the SST.
NOTE: Place the B stamped side of the SST onto the oil seal side.
Page 6 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
13. Apply grease to the area of the companion flange where it contacts the bearing inner race (rear).
14. Install the companion flange to the drive pinion gear component, aligning the position marks (A) on the
companion flange and the pinion shaft.
15. Install the washer, facing it in the same direction as when it was removed.
NOTE: If the direction of washer has changed, the drive pinion preload will change.
16. After applying transfer oil to the threaded area of the old locknut, temporarily tighten it.
NOTE: If the locknut cannot be installed, assemble the companion flange by lightly tapping it with a plastic
hammer to start threading on the drive pinion gear.
Page 7 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
17. While checking the tightening torque with a torque wrench (A), tighten the lock nut (B) until the position
mark (C) on the lock nut aligns with the position mark (D) on the companion flange.
18. Record the locknut tightening torque value when it is tightened to the alignment mark.
- If the tightening torque is within the maximum specification, it is OK, go to next step.
Tightening Torque Specification:
80 - 284 Nm {8.2 - 28 kgf-m, 60 - 209 ft-lbf}
- If the tightening torque has exceeded the maximum specification, some internal problems are possible and
this procedure is not effective. Disassemble the transfer unit to replace the oil seal. Go to “Companion
Flange Oil Seal Replacement Procedure by Disassembling Transfer Unit”.
19. Measure the bearing preload using the same procedure as shown above, then compare it with the
specifications below.
Page 8 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
Bearing Preload Specification:
No.
Method
Limit Value
Specification
1
Torque
wrench
Upper Limit Value
(Value measured in above step) + 0.29 Nm (*)
2
Torque
wrench
Lower Limit Value
(Value measured in above step) + 0.06 Nm (*)
3
Torque
wrench
Upper Limit Value
in
Workshop Manual
1.44 Nm
1
Spring scale
Upper Limit Value
Upper Limit Value (Value measured in above step) + 0.57 Kg
(*)
2
Spring scale
Lower Limit Value
(Value measured in above step) + 0.12 Kg (*)
Spring scale
Upper Limit Value
in
Workshop Manual
2.83 Kg
3
NOTE (*): This value is a tolerance plus a value that is increased by resistance of the new oil seal installed.
If the preload is within all three (3) limit values (above), it is ok, go to next step.
If the preload is outside one or more of the three (3) limit values (above), the procedure is not
effective. Disassemble the transfer unit to replace the oil seal. Go to “Companion Flange Oil Seal
Replacement Procedure by Disassembling Transfer Unit”.
20. Reinstall the propeller shaft according to the instructions on MGSS online (PROPELLER SHAFT
REMOVAL/INSTALLATION).
Companion Flange Oil Seal Replacement Procedure by Disassembling Transfer Unit:
Replace the oil seal according to the instructions on MGSS online (TRANSFER REMOVAL/INSTALLATION
[FW6AX-EL]) and the applicable Transmission/Transaxle workshop manual (TRANSFER
DISASSEMBLY/ASSEMBLY).
21. Verify the repair.
PARTS INFORMATION
1. When the companion flange oil seal is replaced withoutdisassembling the transfer unit.
Page 9 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
Part Number Description Qty.
KN01-27-165A
1
Notes
(REPLACE) Illustration No. 10
2. When the companion flange oil seal is replaced withdisassembling the transfer unit.
Transfer, Remove & Install:
Part Number
Description
Qty.
Notes
PEB4-13-460
Gasket, Exhaust Manifold
1
(REPLACE) For PE Engine only
PY01-13-460
Gasket, Exhaust Manifold
1
(REPLACE) For PY Engine only
PE23-40-305
Gasket
1
(REPLACE) For PE/PY Engine only
9994-61-000
Nut, Exhaust Manifold
2
(REPLACE) For PE/PY Engine only
B455-32-099B
Bolt, Intermediate Shaft
1
(REPLACE)
D651-33-042A
Lock Nut, Drive Shaft
1
(REPLACE)
T060-26-169A
Snap Pin, Ball Joint
1
(REPLACE)
9956-41-800
2
(REPLACE) For MTX
9956-41-400
1
(REPLACE) For ATX
Use applicable No.
AT Fluid
---
For topping it up
Transfer, Overhaul:
Page 10 of 18
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.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 03-003/18
Last Issued: 09/20/2018
Part Number
Description
Qty.
Notes
0730-26-060
Breather
1
(REPLACE) Illustration No. 1
KN01-27-326
Baffle plate
1
(REPLACE) Illustration No. 2
CN01-27-397
1
(REPLACE) Illustration No. 3
KN01-27-398
1
(REPLACE) Illustration No. 4
KN01-27-514
1
(REPLACE) Illustration No. 5
KN01-27-238
1
(REPLACE) Illustration No. 6
KN01-27-171
Collapsible spacer
1
(REPLACE) Illustration No. 7
9956-41-800
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