AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-G 2.5T)]

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Special Service Tool (SST)

1.  : Mazda SST number 2.  : Global SST number
1: 49 C017 5A0 2: –   Engine support set		1: 49 UN30 3050 2: 303–050   Engine lifting brackets		1: 49 L017 5A0 2: –   Support hanger

Caution

•  If the automatic transaxle has been replaced, perform TCM configuration. (See TCM CONFIGURATION [GW6A-EL, GW6AX-EL].)

•  If the automatic transaxle has been replaced, perform initial learning. (See INITIAL LEARNING [GW6A-EL, GW6AX-EL].)

•  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.

Removal

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

3.  Remove the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

4.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

5.  Remove the harness bracket installation bolts from the transaxle.

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6.  Remove the turbocharger air outlet pipe component installation nuts.

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7.  Remove the EGR pipe bracket installation bolts.

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8.  Remove the splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

9.  Disconnect the electric AT oil pump connector. (With i-stop)

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10.  Remove the bolts and set the wiring harness and wiring harness bracket in a place which does not interfere with servicing. (With i-stop)

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11.  Disconnect the control valve body connector.

Caution

•  Make sure that your hand does not touch the terminal as the connector terminal could be damaged.

•  Water or foreign matter entering the connector can cause a poor connection or corrosion. Be careful not to allow water droplets or foreign matter to get on the connector when disconnecting it.

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12.  Disconnect the ground cable.

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13.  Disconnect the selector cable from the transaxle. (See SELECTOR CABLE REMOVAL/INSTALLATION.)

14.  Remove the selector cable bracket.

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15.  Disconnect the breather hose from the transaxle.

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16.  Remove the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

17.  Disconnect the intermediate shaft from the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

18.  Remove the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

19.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

20.  Remove the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

21.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5T].)

22.  Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

23.  Disconnect the oil cooler from the transaxle with the hose connected. (Except Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-G 2.5T)].)

24.  Disconnect the water hose from the oil cooler. (Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-G 2.5T)].)

25.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

26.  Remove the blind cover.

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27.  Hold the crankshaft pulley to prevent drive plate from rotating.

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28.  Remove the torque converter nuts from the starter installation hole.

Note

•  There are six installation nuts.

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29.  Disconnect the front ABS wheel-speed sensors from the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

30.  Disconnect the clips securing the brake hose from the front shock absorbers. (See FRONT BRAKE HOSE REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)

31.  Disconnect the tie-rod end ball joints from the steering knuckles. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

32.  Disconnect the front lower arms from the steering knuckles. (See FRONT LOWER ARM REMOVAL/INSTALLATION.)

33.  Disconnect the front stabilizer control links from the front stabilizer. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

34.  Disconnect the front drive shaft (LH) from the transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

35.  Remove the front drive shaft (RH) from the transfer. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

36.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

37.  Remove the front crossmember component and No.1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

38.  Remove the transfer. (See TRANSFER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-G 2.5T)].)

39.  Remove the No.1 engine mounting bracket component.

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40.  Install the SST using the following procedures.

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Caution

•  Refer to the SST instruction manual for the basic handing procedure.

(1)  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

(2)  Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

(3)  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

(4)  Remove the keyless beeper. (with advanced keyless entry system) (See KEYLESS BEEPER REMOVAL/INSTALLATION.)

(5)  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

(6)  Protect the positions shown in the area using tape.

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(7)  To enable installation of the SST, remove the bolts and clip shown in the figure and set the wiring harness bracket aside.

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(8)  To enable installation of the SST, disconnect the clip shown in the figure from the protector and set the vacuum hose and the fuel hose aside.

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(9)  Install the SST using part number 99794 1025 or an M10—1.25, length 25 mm {0.98 in} bolt as shown in the figure.

Engine front side

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Tightening torque

38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

Engine rear side

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Tightening torque

38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

(10)  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber nuts.

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(11)  As shown in the figure, set the front shafts of the SST to the left and right bolts.

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(12)  Install the SST (49 L017 5A0) to the SST (49 C017 5A0) as shown in the figure.

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(13)  Install the SST (49 L017 5A0) to the SST (49 UN30 3050) with the hook of the SST (49 L017 5A0) facing outward.

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(14)  Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.

(15)  Apply tension to the chain to secure the engine.

41.  Remove in the order shown in the figure.

Warning

•  Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.

Caution

•  To prevent the torque converter and transaxle from separating, remove the transaxle without tilting it toward the torque converter.

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1	Transaxle mounting bolts (upper side)
2	No.4 engine mount bracket (See No.4 engine mount bracket removal note.)
3	Transaxle mounting bolts (lower side) (See No.4 engine mount bracket removal note.)
4	Transaxle (See No.4 engine mount bracket removal note.) (See Transaxle mounting bolt removal note.)

No.4 engine mount bracket removal note

Caution

•  A slot has been adopted for the No.4 engine mount bracket installation hole. If the No.4 engine mount bracket is deviated from the original position when installing the No.4 engine mount, engine noise or vibration could increase. When removing the No.4 engine mount, place alignment marks on the No.4 engine mount bracket so that they can be assembled to the same positions as before removal.

1.  Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal.

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Note

•  Paint so that the outline of the nut is framed on the bracket side.

2.  Remove the No.4 engine mount bracket.

Transaxle mounting bolt removal note

Warning

•  Remove the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Adjust the SST and lean the engine toward the transaxle.

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2.  Support the transaxle on a jack.

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3.  Remove the transaxle mounting bolts (lower side).

4.  Remove the transaxle.

Installation

Caution

•  Verify that the torque converter stud bolts are inserted into the drive plate bolt holes, and install the transaxle installation bolts. Otherwise, the drive plate could be damaged.

1.  Verify that the torque converter stud bolts are inserted into the drive plate bolt holes from the starter installation hole.

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2.  Install the transaxle mounting bolts.

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3.  Tighten the stud bolts for the transaxle.

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4.  Install the No.4 engine mount bracket to No.4 engine mount rubber, and temporarily tighten the installation bolt.

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5.  Lift up the transaxle using the SSTs, pass the transaxle stud bolts through the No.4 engine mount bracket, and temporarily tighten the No.4 engine mount bracket installation nuts.

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6.  Install the No.1 engine mount bracket component, and tighten the installation bolts in the order shown in the figure.

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7.  Install the transfer. (See TRANSFER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-G 2.5T)].)

8.  Install the front crossmember component and No.1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

9.  Temporarily tighten the No.1 engine mount rubber installation bolts.

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10.  Align the positions of the No.4 engine mount bracket installation nuts with the No.4 engine mount bracket.

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11.  Tighten the No.4 engine mount bracket installation nuts and bolt in the order shown in the figure.

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12.  Tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.

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13.  Install the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

14.  Remove the SSTs.

15.  Install the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

16.  Install the keyless beeper. (with advanced keyless entry system) (See KEYLESS BEEPER REMOVAL/INSTALLATION.)

17.  Install the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

18.  Install the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

19.  Install the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

20.  Connect the clip shown in the figure to the protector.

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21.  Install the bolts and clip shown in the figure.

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22.  Fix the crankshaft pulley to lock the torque converter against rotation.

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Caution

•  After temporarily tightening the torque converter installation nut uniformly, tighten it to the specified torque.

23.  Tighten the torque converter installation nut.

Note

•  There are six installation nuts.

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24.  Install the blind cover.

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25.  Install the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

26.  Install the front drive shaft (RH) to the transfer. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

27.  Connect the front drive shaft (LH) to the transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

28.  Connect the front stabilizer control links to the front stabilizer. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

29.  Connect the front lower arms to the steering knuckles. (See FRONT LOWER ARM REMOVAL/INSTALLATION)

30.  Connect the tie-rod end ball joints to the steering knuckles. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

31.  Connect the clips securing the brake hose to the front shock absorbers. (See FRONT BRAKE HOSE REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)

32.  Connect the front ABS wheel-speed sensors to the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

33.  Connect the water hose to the oil cooler. (Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-G 2.5T)].)

34.  Connect the oil cooler to the transaxle with the hose connected. (Except Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-G 2.5T)].)

35.  Install the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

36.  Install the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

37.  Install the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

38.  Connect the intermediate shaft to the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

39.  Install the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

40.  Connect the breather hose to the transaxle.

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41.  Install the selector cable bracket.

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42.  Connect the selector cable to the transaxle. (See SELECTOR CABLE REMOVAL/INSTALLATION.)

43.  Connect the ground cable as shown in the figure.

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44.  Connect the control valve body connector.

Caution

•  Make sure that your hand does not touch the terminal as the connector terminal could be damaged.

•  Verify that there is no fluid or foreign matter adhering to the connector before connecting the connector.

•  Insert the connector straight as the connector terminal could be damaged.

•  Rotate the connector lever until a click is heard.

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45.  Install the wiring harness bracket. (With i-stop)

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46.  Connect the electric AT oil pump connector. (With i-stop)

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47.  Install the splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

48.  Install the EGR pipe bracket installation bolts.

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49.  Install the turbocharger air outlet pipe component installation nuts.

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50.  Install the wiring harness bracket.

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51.  Tighten the wiring harness bracket installation bolts in the order shown in the figure.

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52.  Install the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

53.  Install the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

54.  Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

55.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5T].)

56.  Add the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

57.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

58.  Perform the “TCM configuration” (Automatic transaxle replacement). (See TCM CONFIGURATION [GW6A-EL, GW6AX-EL])

59.  Perform the “Initial Learning” (automatic transaxle replacement). (See INITIAL LEARNING [GW6A-EL, GW6AX-EL].)

60.  Perform the “Mechanical System Test”. (See MECHANICAL SYSTEM TEST [GW6A-EL, GW6AX-EL].)