AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6A-EL]

id0517i21172i1

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 bracket		1: 49 L017 5A0 2: –   Support hanger

Replacement Part

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 engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

4.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

6.  Disconnect the electric AT oil pump connector.

ac5wzw00009177

7.  Remove the bolts and set the wiring harness and wiring harness bracket in a place which does not interfere with servicing.

ac5wzw00010986

8.  Disconnect the control valve body connector.

ac5wzw00009179

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.

9.  Disconnect the ground cable.

ac5wzw00009180

10.  Disconnect the selector cable from the transaxle. (See SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION.)

11.  Remove the selector cable bracket.

ac5wzw00009182

12.  Disconnect the breather hose from the transaxle.

ac5wzw00009183

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

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

15.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

16.  Remove the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

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

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

21.  Disconnect the oil hoses from the transaxle. (With oil cooler No.2) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

ac5wzw00009497

22.  Remove the bolts shown in the figure and set the oil pipe component in a place which does not interfere with the servicing. (With oil cooler No.2) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

ac5wzw00009498

23.  Remove the bolts and set the wiring harness and wiring harness bracket in a place which does not interfere with servicing.

ac5wzw00010987

24.  Disconnect the oil cooler from the transaxle with the hose connected. (Except Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

25.  Disconnect the water hose from the oil cooler. (Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

26.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

27.  Remove the blind cover.

ac5wzw00009187

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

ac5jjw00003168

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

Note

•  There are six installation nuts.

ac5jjw00003050

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

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

32.  Disconnect the tie-rod ends from the steering knuckles. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

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

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

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

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

37.  Remove the seal rubber.

ac5wzw00004300

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

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

ac5wzw00009188

40.  Install the SST using the following procedures.

ac5wzw00009189

Caution

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

(1)  Install one front foot No.2 to each of the left and right front shafts of the SST.

(2)  Protect the positions shown in the figure using tape.

ac5wzw00009190

(3)  Remove the engine cover adapter.

ac5wzw00014478

(4)  Install the SST to the position shown in the figure using the following bolt and washer.

Engine front side

ac5wzw00009192

Bolt: part number 99794 1025 or an M10—1.25, length 25 mm {0.98 in}

Washer: approx. 3 mm {0.1 in}thickness

Tightening torque

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

Engine rear side

ac5wzw00009193

Bolt: part number 99794 1025 or an M10—1.25, length 25 mm {0.98 in}

Tightening torque

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

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

ac5wzw00009194

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

ac5wzw00012860

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

ac5jjw00010787

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

ac5jjw00010788

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

(10)  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.

ac5wzw00009196

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 Transaxle mounting bolt 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.

ac5wzw00009197

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.

ac5jjw00010787

2.  Support the transaxle on a jack.

ac5jjw00003179

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

4.  Remove the transaxle.

Installation

1.  If the transaxle is replaced with a new one, perform the following procedure.

(1)  Remove the shipping plug from the new transaxle.

(2)  Remove the plug from the transaxle removed from the vehicle.

(3)  Install the plug and washer that were removed to the new transaxle.

ac9uuw00011693

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.

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

ac5jjw00003065

3.  Install the transaxle mounting bolts.

ac5jjw00003066

4.  Tighten the stud bolts for the transaxle.

ac5wzw00009198

Note

•  If the No.4 engine mount bracket nut is loosened, tighten the stud bolts for the transaxle because they may be loosened.

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

ac5wzw00009199

6.  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.

ac5wzw00009200

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

ac5wzw00009201

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.

ac5wzw00009202

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

ac5wzw00009203

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

ac5wzw00009204

12.  Remove the SST (49 C017 5A0).

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

ac5wzw00009205

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

ac5jjw00003185

15.  Tighten the torque converter installation nut.

Caution

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

•  There are six installation nuts.

ac5jjw00003186

16.  Install the blind cover.

ac5wzw00009206

17.  Install the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

18.  Install the seal rubber.

ac5wzw00009622

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

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

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

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

23.  Connect the tie-rod ends to the steering knuckles. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

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

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

26.  Connect the water hose to the oil cooler. (Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

27.  Connect the oil cooler to the transaxle with the hose connected. (Except Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

28.  Install the wiring harness bracket.

ac5wzw00010988

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

ac5wzw00010989

30.  Install the oil pipe component. (With oil cooler No.2) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

ac5wzw00009499

31.  Connect the oil hose to the transaxle. (With oil cooler No.2) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)

ac5wzw00009500

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

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

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

35.  Install the engine cover adapter.

ac5wzw00014479

36.  Install the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

39.  Connect the breather hose to the transaxle.

ac5wzw00009183

40.  Install the selector cable bracket.

ac5wzw00011787

41.  Connect the selector cable to the transaxle. (See SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION.)

42.  Connect the ground cable to the No.4 engine mount bracket.

ac5wzw00009210

43.  Connect the control valve body connector.

ac5wzw00009212

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.

44.  Install the wiring harness bracket.

ac5wzw00010990

45.  Connect the electric AT oil pump connector.

ac5wzw00009177

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

47.  Install the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

48.  Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

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

50.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

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

52.  Install the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

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