AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6AX-EL]

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

Replacement Part

Caution

•  If the automatic transaxle has been replaced, perform TCM configuration. (See TCM CONFIGURATION [FW6A-EL, FW6AX-EL].)

•  If the automatic transaxle has been replaced, perform initial learning. (See INITIAL LEARNING [FW6A-EL, FW6AX-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 2.5].)

3.  Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

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

5.  Remove the PCM component. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

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

8.  Disconnect the electric AT oil pump connector.

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

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10.  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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11.  Remove the wiring harness clip and bolts, and set the wiring harnesses and wiring harness brackets in a place which does not interfere with servicing.

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12.  Disconnect the ground cable.

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13.  Disconnect the selector cable from the transaxle. (See SELECTOR LEVER COMPONENT 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 2.5].)

22.  Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL, FW6AX-EL].)

23.  Remove the oil cooler and water hose component as a single unit. (Except Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [FW6A-EL, FW6AX-EL].)

24.  Remove the water hose component. (Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [FW6A-EL, FW6AX-EL].)

25.  Remove the lower radiator hose component. (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

27.  Remove the blind cover.

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

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

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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.)

32.  Disconnect the tie-rod end from the steering knuckle. (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.)

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

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

37.  Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

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

40.  Remove the exhaust manifold (WU-TWC). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

41.  Remove the transfer. (See TRANSFER REMOVAL/INSTALLATION [FW6AX-EL].)

42.  Loosen the bolt shown in the figure.

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43.  Remove the bracket.

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44.  Remove the No.1 engine mounting bracket.

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45.  Install the SST using the following procedures.

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

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

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

(5)  Remove the keyless beeper. (See KEYLESS BEEPER REMOVAL/INSTALLATION.)

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

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

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(8)  To enable installation of the SST, disconnect the clip shown in the figure and set the wiring harness aside.

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

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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 front 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)  To prevent interference of the SST with the hose when assembling the SST (49 L017 5A0), disconnect the hose clip from the bracket shown in the figure and set the fuel hose and vacuum hose aside.

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

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

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

46.  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

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.

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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.

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3.  Install the transaxle mounting bolts.

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4.  Tighten the stud bolts for the transaxle.

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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.

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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.

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

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8.  Install the bracket to the transaxle and tighten the bolts in the order shown in the figure.

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9.  Tighten the bolt shown in the figure.

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10.  Install the transfer. (See TRANSFER REMOVAL/INSTALLATION [FW6AX-EL].)

11.  Install the exhaust manifold (WU-TWC). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

13.  Temporarily tighten the No.1 engine mount rubber, deadweight, and bracket plate installation bolts.

Caution

•  Assemble the deadweight with the deadweight rotation lock contacting the bracket plate to prevent abnormal noise from occurring.

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

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

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16.  Tighten the No.1 engine mount rubber, deadweight, and bracket plate installation bolts.

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

18.  Install the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

19.  Remove the SST (49 C017 5A0, 49 L017 5A0).

20.  Connect the hose clip to the bracket shown in the figure.

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21.  Connect the clip shown in the figure.

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

23.  Install the keyless beeper. (See KEYLESS BEEPER REMOVAL/INSTALLATION.)

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

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

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

27.  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.

28.  Tighten the torque converter installation nut.

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29.  Install the blind cover.

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

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

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

33.  Connect the front stabilizer control links to the front stabilizer. (See FRONT STABILIZER INSTALLATION.)

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

35.  Connect the tie-rod end to the steering knuckle. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

36.  Connect the clips securing the brake hose to the front shock absorbers. (See FRONT BRAKE HOSE REMOVAL/INSTALLATION.)

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

38.  Install the lower radiator hose component. (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

39.  Install the water hose component. (Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [FW6A-EL, FW6AX-EL].)

40.  Install the oil cooler and water hose component as a single unit. (Except Automatic Transaxle Replacement) (See OIL COOLER REMOVAL/INSTALLATION [FW6A-EL, FW6AX-EL].)

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

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

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

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

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

46.  Connect the breather hose to the transaxle.

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47.  Install the selector cable bracket.

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

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

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50.  Install the wiring harness clip and 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.  Connect the control valve body connector.

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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.

53.  Install the wiring harness bracket.

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54.  Connect the electric AT oil pump connector.

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

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

57.  Install the PCM component. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

58.  Install the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

59.  Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

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

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

62.  Add the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL, FW6AX-EL].)

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

64.  Perform the “TCM configuration” (Automatic transaxle replacement). (See TCM CONFIGURATION [FW6A-EL, FW6AX-EL].)

65.  Perform the “Initial Learning” (Automatic transaxle Replacement). (See INITIAL LEARNING [FW6A-EL, FW6AX-EL].)

66.  Perform the “Mechanical System Test”. (See MECHANICAL SYSTEM TEST [FW6A-EL, FW6AX-EL].)