Transmission removal (MVL)

1. Component views

Transmission (RZ4E, 2WD models)

Part name

  1. Starter motor
  2. Transmission
  3. Bolt
  4. Bolt
  5. Shift knob
  6. Insulator
  7. Shift lever
  8. Nut
  9. Grommet
  10. Bolt
  11. Nut
  12. Transmission crossmember
  13. Nut
  14. Cushion rubber
  15. Nut
  16. Bolt
  17. Slave cylinder
  18. Bolt
  19. Bolt

Tightening torque

3: 76 N・m { 7.7 kgf・m / 56 lb・ft } Engine-Transmission fixing bolt

4: 19 N・m { 1.9 kgf・m / 14 lb・ft }

8: 7 N・m { 0.7 kgf・m / 62 lb・in }

10: 9 N・m { 0.9 kgf・m / 80 lb・in }

11: 67 N・m { 6.8 kgf・m / 593 lb・in }

13: 140 N・m { 14.3 kgf・m / 103 lb・ft }

15: 97 N・m { 9.9 kgf・m / 72 lb・ft }

16: 43 N・m { 4.4 kgf・m / 32 lb・ft }

18: 25 N・m { 2.5 kgf・m / 18 lb・ft }

19: 97 N・m { 9.9 kgf・m / 72 lb・ft } Starter fixing bolt

Transmission (RZ4E, 4WD models)

Part name

  1. Starter motor
  2. Transmission
  3. Bolt
  4. Bolt
  5. Shift knob
  6. Insulator
  7. Shift lever
  8. Nut
  9. Grommet
  10. Bolt
  11. Nut
  12. Transmission crossmember
  13. Nut
  14. Cushion rubber
  15. Nut
  16. Bolt
  17. Slave cylinder
  18. Bolt
  19. Bolt

Tightening torque

3: 76 N・m { 7.7 kgf・m / 56 lb・ft } Engine-Transmission fixing bolt

4: 19 N・m { 1.9 kgf・m / 14 lb・ft }

8: 7 N・m { 0.7 kgf・m / 62 lb・in }

10: 9 N・m { 0.9 kgf・m / 80 lb・in }

11: 67 N・m { 6.8 kgf・m / 593 lb・in }

13: 140 N・m { 14.3 kgf・m / 103 lb・ft }

15: 115 N・m { 11.7 kgf・m / 85 lb・ft }

16: 43 N・m { 4.4 kgf・m / 32 lb・ft }

18: 25 N・m { 2.5 kgf・m / 18 lb・ft }

19: 97 N・m { 9.9 kgf・m / 72 lb・ft } Starter fixing bolt

Transmission (4JJ3, 2WD models)

Part name

  1. Starter motor
  2. Transmission
  3. Bolt
  4. Bolt
  5. Shift knob
  6. Insulator
  7. Shift lever
  8. Nut
  9. Grommet
  10. Bolt
  11. Nut
  12. Transmission crossmember
  13. Nut
  14. Cushion rubber
  15. Nut
  16. Orifice
  17. Slave cylinder
  18. Bolt
  19. Bolt
  20. Bolt

Tightening torque

3: 76 N・m { 7.7 kgf・m / 56 lb・ft } Engine-Transmission fixing bolt

4: 19 N・m { 1.9 kgf・m / 14 lb・ft }

8: 7 N・m { 0.7 kgf・m / 62 lb・in }

10: 9 N・m { 0.9 kgf・m / 80 lb・in }

11: 67 N・m { 6.8 kgf・m / 49 lb・ft }

13: 140 N・m { 14.3 kgf・m / 103 lb・ft }

15: 97 N・m { 9.9 kgf・m / 72 lb・ft }

18: 25 N・m { 2.5 kgf・m / 18 lb・ft }

19: 43 N・m { 4.4 kgf・m / 32 lb・ft }

20: 97 N・m { 9.9 kgf・m / 72 lb・ft } Starter fixing bolt

Transmission (4JJ3, 4WD models)

Part name

  1. Starter motor
  2. Transmission
  3. Bolt
  4. Bolt
  5. Shift knob
  6. Insulator
  7. Shift lever
  8. Nut
  9. Grommet
  10. Bolt
  11. Nut
  12. Transmission crossmember
  13. Nut
  14. Cushion rubber
  15. Nut
  16. Orifice
  17. Slave cylinder
  18. Bolt
  19. Bolt
  20. Bolt

Tightening torque

3: 76 N・m { 7.7 kgf・m / 56 lb・ft } Engine-Transmission fixing bolt

4: 19 N・m { 1.9 kgf・m / 14 lb・ft }

8: 7 N・m { 0.7 kgf・m / 62 lb・in }

10: 9 N・m { 0.9 kgf・m / 80 lb・in }

11: 67 N・m { 6.8 kgf・m / 593 lb・in }

13: 140 N・m { 14.3 kgf・m / 103 lb・ft }

15: 115 N・m { 11.7 kgf・m / 85 lb・ft }

18: 25 N・m { 2.5 kgf・m / 18 lb・ft }

19: 43 N・m { 4.4 kgf・m / 32 lb・ft }

20: 97 N・m { 9.9 kgf・m / 72 lb・ft } Starter fixing bolt

2. Transmission safety information

Caution

  • Be careful not to cause any damage.
  • Because damage to the rib especially decreases the case strength, even greater caution is necessary when handling the rib sections.

Warning

  • When performing work on heavy items such as the case and gears, take care to prevent injury.

3. Transfer preparation

1. 4WD models

1) Change the transfer mode to 2WD using the 2-4 switch.

Caution

  • Before removing the transfer assembly from the vehicle, change the transfer mode to 2WD.

4. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

5. Transmission air deflector removal

1) Remove the transmission air deflector from the frame.

Legend

  1. Transmission air deflector
  2. Bolt

6. Transmission oil drain

1) Start the engine and warm up the transmission body sufficiently.

2) Stop the engine.

3) Remove the transmission drain plug and O-ring, and drain the transmission oil.

Warning

  • When the engine temperature is high, take care not to burn yourself.

7. Driver seat removal

1. Bench seat or console tray specifications

Refer to "9.Body, Cab, Accessories 9I.Seats driver seat removal".

8. Passenger seat removal

1. Bench seat or console tray specifications

Refer to "9.Body, Cab, Accessories 9I.Seats passenger seat removal".

9. Rear seat removal

1. Bench seat or console tray specifications (Crew cab)

Refer to "9.Body, Cab, Accessories 9I.Seats rear seat removal".

10. Front sill plate removal

1. Bench seat or console tray specifications

1) Remove the front sill plate from the floor.

Regular cab, crew cab

Legend

  1. Front sill plate
  2. Clip
  3. Claw section

Extend cab

Legend

  1. Front sill plate
  2. Clip
  3. Claw section

11. Front door finisher removal

1. Bench seat or console tray specifications

1) Remove the front door finisher from the body.

12. Rear sill plate removal

1. Bench seat or console tray specifications (Crew cab)

1) Remove the rear sill plate from the floor.

Legend

  1. Rear sill plate
  2. Clip
  3. Claw section

13. Rear door finisher removal

1. Bench seat or console tray specifications (Crew cab)

1) Remove the rear door finisher from the body.

14. Rear end upper trim cover removal

1. Bench seat or console tray specifications (Regular cab)

1) Remove the rear end upper trim cover from the body panel.

Legend

  1. Claw section
  2. Rear end upper trim cover
  3. Clip
  4. Hook

2. Bench seat or console tray specifications (Crew cab)

1) Remove the rear end upper trim cover from the body panel.

Caution

  • For models with center top tethers (bracket type), disengage the clips and claws, and then pull upward while bending the end of the rear end upper trim to an extent that it will not get damaged.

Models with center top tethers (bracket type)

Legend

  1. Seat belt guide cover
  2. Rear end upper trim cover
  3. Clip
  4. Claw section
  5. Hook
  6. Bend the end of the rear end upper trim cover.
  7. Pull out the rear end upper trim upward.
  8. Center top tether (Bracket type)

Models without center top tethers (bracket type)

Legend

  1. Seat belt guide cover
  2. Rear end upper trim cover
  3. Clip
  4. Claw section
  5. Hook

15. Rear pillar trim cover removal

1. Bench seat or console tray specifications (Regular cab)

1) Remove the seat belt lower anchor bolt from the rear pillar.

Legend

  1. Seat belt lower anchor bolt

2) Remove the rear pillar lower trim cover from the rear pillar.

Legend

  1. Claw section
  2. Rear pillar lower trim cover
  3. Clip

2. Bench seat or console tray specifications (Crew cab)

1) Remove the rear pillar lower trim cover from the rear pillar.

Legend

  1. Claw section
  2. Rear pillar lower trim cover
  3. Clip

3. Bench seat or console tray specifications (Extend cab)

1) Remove the rear end trim cover from the body panel.

Note

  • Pull out the push clip while holding it in the direction of the arrow.

Extend cab

Legend

  1. Rear end trim cover
  2. Clip
  3. Hook
  4. Claw section

2) Remove the seat belt lower anchor bolt from the floor panel.

Legend

  1. Seat belt lower anchor bolt

3) Remove the rear pillar lower trim cover from the rear pillar.

Legend

  1. Claw section
  2. Rear pillar lower trim cover
  3. Clip

4) Remove the seat belt upper anchor bolt from the rear pillar.

Legend

  1. Seat belt upper anchor bolt

5) Remove the rear upper trim cover from the rear pillar.

Legend

  1. Rear pillar upper trim cover
  2. Clip
  3. Hook

16. Rear end trim cover removal

1. Bench seat or console tray specifications (Except extend cab)

1) Remove the rear end trim cover from the body panel.

Note

  • Pull out the push clip while holding it in the direction of the arrow.

Regular cab

Legend

  1. Rear end trim cover
  2. Hook hole
  3. Push clip

Crew cab

Legend

  1. Rear end trim cover
  2. Hook hole
  3. Push clip

17. Dash side trim pad removal

1. Bench seat or console tray specifications

1) Remove the dash side trim pad from the body.

Right side

Legend

  1. Dash side trim pad
  2. Retainer
  3. Clip

Left side

Legend

  1. Dash side trim pad
  2. Retainer
  3. Clip

18. Center pillar lower trim cover removal

1. Bench seat or console tray specifications (Crew cab)

1) Remove the seat belt lower anchor bolt from the center pillar.

Legend

  1. Seat belt lower anchor bolt

2) Remove the center pillar lower trim cover from the center pillar.

Legend

  1. Clip
  2. Center pillar lower trim cover
  3. Claw section

19. Parking brake cover removal

1. Bench seat specifications

1) Remove the parking brake cover from the floor mat.

20. Center console removal

1. Bench seat or console tray specifications

1) Remove the extension from the center console and floor.

Legend

  1. Center console
  2. Extension

21. Console box removal

1. Except bench seat specifications

Refer to "9.Body, Cab, Accessories 9L.Exterior, Interior Trim console box removal".

22. Floor mat removal

1. Bench seat or console tray specifications (Vinyl floor mat specifications)

1) Remove the floor mat from the body.

23. Floor carpet removal

1. Bench seat or console tray specifications (Except vinyl floor mat specifications)

1) Remove the floor carpet from the body.

24. Grommet removal

1) Remove the grommet from the floor panel.

2) Remove the insulator from the shift lever.

Legend

  1. Nut
  2. Grommet
  3. Bolt
  4. Slit
  5. Insulator
  6. Floor panel

25. Shift lever removal

1) Remove the shift lever from the transmission.

RZ4E

4JJ3

26. Engine hood removal

1) Open the engine hood.

Note

  • Before removing the hinge from the engine hood, put a marking of the hinge location for putting the hinge back in place.

2) Remove the hinge bolt from the engine hood.

27. Engine cover removal

1) Remove the engine cover from the engine.

RZ4E

Legend

  1. Engine cover

4JJ3

Legend

  1. Engine cover

28. Wiper linkage removal

Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage removal".

29. Cowl panel removal

1) Remove the cowl panel from vehicle.

30. Transmission preparation

1) Raise the vehicle using a jack.

2) Use a suitable stand to support the vehicle.

31. Rear propeller shaft removal

Refer to "3.Driveline, Axle 3C.Drive Shaft System rear propeller shaft removal".

32. Front propeller shaft removal

1. 4WD models

Refer to "3.Driveline, Axle 3C.Drive Shaft System front propeller shaft removal".

33. Engine harness disconnect

1. 2WD models

1) Disconnect the engine harness from the connectors of the following parts.

  • Neutral switch connector
  • Backup light switch connector
  • Vehicle speed sensor connector (Models without ABS)

2WD models (Models without ABS)

Legend

  1. Harness clip
  2. Backup light switch connector
  3. Neutral switch connector
  4. Vehicle speed sensor connector

2WD models (Models with ABS)

Legend

  1. Harness clip
  2. Backup light switch connector
  3. Neutral switch connector

2) Remove the harness clip from the transmission and harness bracket.

2. 4WD models

1) Disconnect the engine harness from the connectors of the following parts.

  • Transmission side neutral switch
  • Backup light switch
  • Actuator
  • 2-4 switch
  • Transfer side neutral switch
  • Vehicle speed sensor (Models without ABS)

2) Remove the harness clip from the transmission and harness bracket.

Transmission side (RZ4E)

Legend

  1. Clip
  2. Neutral switch connector
  3. Backup light switch connector

Transmission side (4JJ3)

Legend

  1. Clip
  2. Neutral switch connector
  3. Backup light switch connector

Transfer side

Legend

  1. Neutral switch connector
  2. 2-4 switch connector
  3. Actuator connector
  4. Vehicle speed sensor connector (Models without ABS)

34. Slave cylinder disconnect

1. RZ4E

1) Remove the slave cylinder from the transmission.

2) Remove the oil pipe and band clip from the transmission.

3) Disconnect the oil hose and oil hose bracket as a set from the transmission.

Legend

  1. Oil hose
  2. Oil hose bracket
  3. Bushing
  4. Band clip
  5. Oil pipe
  6. Slave cylinder

2. 4JJ3

1) Remove the slave cylinder from the transmission.

2) Remove the oil pipe and band clip from the transmission.

3) Disconnect the oil hose and oil hose bracket as a set from the transmission.

Legend

  1. Oil hose
  2. Oil hose bracket
  3. Bushing
  4. Orifice
  5. Band clip
  6. Slave cylinder
  7. Oil pipe

35. Transfer removal

1. 4WD models

1) Remove the transfer from the transmission.

36. Transmission crossmember removal

1. 2WD models

1) Install special tool to the engine.

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) engine removal".

Refer to "1.Engine 1B.Mechanical(4JJ3 without DPD) engine removal".

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) engine removal".

2) Install the wire to the engine hanger and hoist.

Note

  • Hold up the engine as high as not to be lifted up.

3) Support the transmission using a transmission jack.

4) Remove the engine rear mounting nuts on the transmission cross member side.

5) Remove the transmission crossmember from the frame.

6) Remove the cushion rubber from the transmission.

Note

  • Remove the transmission side engine rear mounting bolts.

Legend

  1. Cushion rubber

2. 4WD models

1) Install special tool to the engine.

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) engine removal".

Refer to "1.Engine 1B.Mechanical(4JJ3 without DPD) engine removal".

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) engine removal".

2) Install the wire to the engine hanger and hoist.

Note

  • Hold up the engine as high as not to be lifted up.

3) Support the transmission using a transmission jack.

4) Remove the engine rear mounting nuts on the transmission cross member side.

RZ4E

4JJ3

5) Remove the transmission crossmember from the frame.

6) Remove the cushion rubber from the transmission.

Note

  • Remove the transmission side engine rear mounting nuts.

Legend

  1. Cushion rubber

37. Starter motor removal

Refer to "1.Engine 1J.Electrical(RZ4E-TC) starter motor removal".

Refer to "1.Engine 1J.Electrical(4JJ3 without DPD) starter motor removal".

Refer to "1.Engine 1J.Electrical(4JJ3 with DPD) starter motor removal".

38. Transmission removal

1) Remove the transmission from the engine.

Note

  • To prevent the clutch housing starter motor installation section from interfering with the floor panel, turn the transmission counterclockwise and remove.
Copyright Mazda Motor Corporation. All rights reserved.