Mazda 3 Service Manual: Automatic Transaxle Removal/Installation [Fw6 A EL]

CAUTION:

• 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.

1. Remove the battery cover..

2. Disconnect the negative battery cable..

3. Remove the aerodynamic under cover No.2 and the splash shield as a single unit..

4. Drain the ATF..

5. Disconnect and/or remove the following parts in the engine compartment.

a. Remove the battery component (ex: battery, battery tray and PCM component)..

b. Remove the air cleaner component..

c. Disconnect the selector cable from the transaxle.

d. Disconnect the connectors and GND wiring harness from the transaxle.

e. Remove the bracket from the transaxle.

f. Disconnect the oil cooler from the transaxle with the hose connected. (Except Automatic Transaxle Replacement).

g. Disconnect the water hose from the oil cooler. (Automatic Transaxle Replacement).

h. Remove the starter..

6. Disconnect and/or remove the following parts related to the suspension and axle.

a. Remove the front tires..

b. Disconnect the ABS wheel-speed sensors from the steering knuckles..

c. Disconnect the clip securing the brake hose (LH) from the front shock absorber..

d. Disconnect the brake hose (LH) from the front shock absorber..

e. Disconnect the tie-rod end ball joints from the steering knuckles..

f. Disconnect the front lower arms from the steering knuckles..

g. Disconnect the front stabilizer control links from the front shock absorbers..

h. Disconnect the drive shaft (LH) from the transaxle..

i. Disconnect the drive shaft (RH) from the joint shaft..

j. Remove the joint shaft..

7. Install the SST using the following procedures.

CAUTION:

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

a. Remove the windshield wiper arm and blade..

b. Remove the front fender molding..

c. Remove the cowl grille..

d. Remove the cowl panel..

e. Protect the windshield using tape.

f. Replace the hood stay to the position shown in the figure.

NOTE:

• The hood opening angle is increased by placing the hood stay to the position shown in the figure. A space for installing the SST

  can be secured by increasing the hood opening angle.

i. Disconnect the washer tank and set it aside.

ii. Tilt the hood stay in the direction of the arrow shown in the figure.

iii. Pull out the hood stay in the direction of the arrow shown in the figure.

iv. Rotate the hood stay at the pivot fulcrum shown in the figure.

v. Remove the hood stay.

vi. Install the hood stay as shown in the figure.

CAUTION:

• If the hood stay is not hooked to the hood hole, the hood may fall down. Lightly shake the hood to verify that the hood stay is hooked securely.

g. To enable to install the SST

, disconnect the clip shown in the figure and set the wiring harness aside.

h. 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

Tightening torque

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

Engine rear side

Tightening torque

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

i. Align the bolt of the front shock absorber (RH) shown in the figure with the rear shaft hole for the right side of the SST

.

j. Align the bolt of the front shock absorber (LH) shown in the figure with the rear shaft hole for the left side of the SST

.

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

, and then align the holes of the SST

front shafts with the bolt on the left and right side of each front side frame.

l. Install the SST

(49 L017 5A0) to the SST

(49 C017 5A0) as shown in the figure.

m. Install the SST

(49 L017 5A0) to the SST

(49 UN30 3050) with the hook of the SST

(49 L017 5A0) facing outward.

CAUTION:

• Install the SST (49 L017 5A0) so that it does not interfere with parts such as the fuel pipe. If the SST (49 L017 5A0) interferes, parts such as the fuel pipe could be damaged.

  

  
  

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

.

o. Apply tension to the chain to secure the engine.

8. Remove in the order indicated in the table.

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.

9. Install in the reverse order of removal.

10. Add the ATF..

11. Perform the “Mechanical System Test”..

Torque Converter Installation Nuts Removal Note

1. Remove the blind cover.

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

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

Transaxle Removal Note

1. Adjust the SST

(49 C017 5A0) and lean the engine toward the transaxle.

2. Support the transaxle on a jack.

3. Remove the transaxle mounting bolts.

4. Remove the transaxle.

Transaxle Installation Note

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.

2. Install the transaxle mounting bolts.

No.1 Engine Mount and No.4 Engine Mount Installation Note

1. Install the No.4 engine mount bracket to the transaxle case, and then tighten the nuts.

Tightening torque

• 94—116 N·m {9.6—11 kgf·m, 70—85 ft·lbf}

2. Install the No.1 engine mount bracket to the converter housing, and then tighten the bolts.

Tightening torque

• 94—112 N·m {9.6—11 kgf·m, 70—82 ft·lbf}

3. Install the No.1 engine mount rubber to the front crossmember, and then temporarily tighten the bolts.

CAUTION:

• Tighten the bolts while being careful of their length to prevent interference between the steering gear housing and bolt.

Bolt stem length

• Front crossmember side: 62 mm {2.4 in}

• No.1 engine mount bracket side: 65 mm {2.6 in}

4. Align the No.4 engine mount rubber installation hole to the stud bolts on the body.

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

Tightening torque

• 94—152 N·m {9.6—15 kgf·m, 70—112 ft·lbf}

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

Tightening torque

• 73—90 N·m {7.5—9.1 kgf·m, 54—66 ft·lbf}

7. Align the battery tray bracket installation hole to the stud bolts on the body.

8. Install the battery tray bracket to the No.4 engine mount rubber, and then tighten the nuts.

Tightening torque

• 44—61 N·m {4.5—6.2 kgf·m, 33—44 ft·lbf}

9. Remove the SSTs

.

Torque Converter Installation Nut Installation Note

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

CAUTION:

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

2. Tighten the torque converter installation nut

Tightening torque

• 41—54 N·m {4.2—5.5 kgf·m, 31—39 ft·lbf}

3. Instal the blind cover.