Automatic Transaxle - Service, Removal & Installation (FN4A-EL): Removal & Installation Mazda 3 BL

AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FN4A-EL]

Scheme 368

1. Remove the oil dipstick.
2. Remove the oil drain plug and washer.
3. Drain the ATF into a container.
4. Install a new washer and the drain plug. Tightening torque 29.4-41.2 N.m {3.0-4.2 kgf.m, 21.7-30.3 ft.lbf}
5. Add the specified ATF until ATF level reaches lower notch of dipstick type of ATF through the oil filler tube. ATF type ATF M-V Capacity (Approx. quantity) 7.2 L {7.6 US qt, 6.3 lmp qt}
6. Ensure that the ATF level is in the HOT range (65°C {149°F}). Add ATF to the specified level as necessary.

Scheme 369

1. Verify that the starter operates only when the ignition switch is turned to the START position with the selector lever in P or N position. If there is any malfunction, adjust the TR switch.
2. Verify that the back-up lights illuminate when shifted to R position with the ignition switch at the ON position. If there is any malfunction, adjust the TR switch.
3. Verify that the positions of the selector lever and the indicator are aligned. If there is any malfunction, adjust the TR switch.

TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION [FN4A-EL]

Scheme 370

1. Remove the oil pan. (See «CONTROL VALVE BODY REMOVAL [FN4A-EL]»(ref-345215-S12219400902009102000000) ).
2. Remove the control valve body. (See «CONTROL VALVE BODY REMOVAL [FN4A-EL]»(ref-345215-S12219400902009102000000) ).
3. Remove the coupler component.
4. Install a coupler component.
5. Install the control valve body. (See «CONTROL VALVE BODY INSTALLATION [FN4A-EL]»(ref-345215-S38753903942009102000000) ).
6. Install the oil pan. (See «CONTROL VALVE BODY INSTALLATION [FN4A-EL]»(ref-345215-S38753903942009102000000) ).
7. Perform the mechanical system test. (See «MECHANICAL SYSTEM TEST [FN4A-EL]»(ref-345215-S31925879532009102000000) ).

INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION [FN4A-EL]

1. Remove the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
2. Remove the battery, battery box and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
3. Disconnect the input/turbine speed sensor connector.
4. Remove the input/turbine speed sensor.
5. Apply ATF to a new O-ring and install it on a new input/turbine speed sensor.
6. Install the input/turbine speed sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
7. Connect the input/turbine speed sensor connector.
8. Install the battery, battery box and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
9. Install the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)

VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [FN4A-EL]

Scheme 371

1. Remove the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Disconnect the VSS connector.
5. Remove the VSS.
6. Apply ATF to a new O-ring and install it on a new VSS.
7. Install the VSS. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
8. Connect the VSS connector.
9. Install the under cover.
10. Connect the negative battery cable.
11. Install the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)

PCM REMOVAL/INSTALLATION [FN4A-EL]

1. Remove and install the PCM. (See «PCM REMOVAL/INSTALLATION [LF, L3]»(ref-345210-S40556685212009102000000) .)

Scheme 372

1. Remove the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
2. Remove the following parts. Battery, battery tray and battery box. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .) Air cleaner component. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [LF, L3]»(ref-345212-S03134740962009102000000) .) Exhaust manifold insulator. Front tires and splash shield. Under cover.
3. Drain the ATF. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FN4A-EL]»(ref-345215-S24754048372009102000000) ). 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.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Add ATF to the specified level. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FN4A-EL]»(ref-345215-S24754048372009102000000) ).
7. Perform the following test. (See «MECHANICAL SYSTEM TEST [FN4A-EL]»(ref-345215-S31925879532009102000000) ).(See «ROAD TEST [FN4A-EL]»(ref-345215-S33947189042009102000000) ). SERVICE ITEM CHART Service item Test item Line pressure test Stall test Time lag test Road test ATX replacement X ATX overhaul X X X X Torque converter replacement X X Oil pump replacement X Clutch system replacement X X X X: Test to be performed after the service work

Scheme 373

Scheme 374

1. Hold the crankshaft pulley to prevent the drive plate from rotating.
2. Remove the torque converter nuts from the starter installation hole.

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

1. To install the front shaft (RH) of the SST (49 C017 5A0), remove the clip shown in the figure.
2. Install the SST using the following procedure. CAUTION: Refer to the SST instruction manual for the basic handing procedure. Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure. Install the left rear shaft of the SST to the bolt of the left shock absorber (identical position to right side). Install front foot No.2 to the left/right front shaft of the SST , then align the groove of the front shaft of the SST with the folded up part of the vehicle as shown in the figure. Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal. Make sure each joint is securely tightened.
3. Suspend the engine using the SST .
4. Remove the battery tray bracket, No.4 engine mount rubber and bracket.

Transaxle Removal Note

Scheme 380

1. 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

Scheme 381

1. Set the transaxle on a jack and lift it.
2. Install the transaxle mounting bolts. Tightening torque 37.3-52.0 N.m {3.8-5.3 kgf.m, 27.6-38.3 ft.lbf}

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

1. Install the No.4 engine mount bracket on the transaxle case and tighten nuts.
2. Install the No.1 engine mount rubber to the crossmember and temporarily tighten bolts.
3. Place the No.4 engine mount rubber with the body stud bolts passing through the holes and tighten the bolt as shown in the figure.
4. Place the battery tray bracket on the No.4 engine mount rubber with body stud bolts passing through the holes and tighten bolts and nuts in the order as shown in the figure.
5. Remove the SST .
6. Install the clip as shown in the figure.
7. Fully tighten the bolts CAUTION: Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly. Tighten the bolts while being careful of their length to prevent interference between the steering gear housing and bolt. Bolt length (measured from below the head) Front crossmember side: 62 mm {2.441 in} No.1 engine mount bracket side: 65 mm {2.559 in} Tightening torque A type: 72.6-90.9 N.m {7.5-9.2 kgf.m, 53.6-67.0 ft.lbf} B type: 93.1-116.6 N.m {9.5-11.8 kgf.m, 68.7-85.9 ft.lbf}

Scheme 387

1. Hold the crankshaft pulley to prevent the drive plate from rotating. CAUTION: Loosely and equally tighten the torque converter nuts, then further tighten them to the specified tightening torque.
2. Tighten the torque converter mounting nuts. Tightening torque 40.5-54.7 N.m {4.2-5.5 kgf.m, 29.9-40.3 ft.lbf}

Scheme 388

1. Drain the ATF. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FN4A-EL]»(ref-345215-S24754048372009102000000) ). CAUTION: The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines contact the oil seal.
2. Remove the drive shaft and joint shaft. (See «DRIVE SHAFT REMOVAL/INSTALLATION»(ref-345220-S15798404382009102000000) .) (See «JOINT SHAFT REMOVAL/INSTALLATION [LF]»(ref-345220-S26930526422009102000000) .)
3. Remove the oil seal.
4. Using the SST and a hammer, tap a new oil seal in evenly until the SST contacts the transaxle case.
5. Coat the lip of the oil seal with transaxle oil.
6. Install the drive shaft and joint shaft. (See «DRIVE SHAFT REMOVAL/INSTALLATION»(ref-345220-S15798404382009102000000) .) (See «JOINT SHAFT REMOVAL/INSTALLATION [LF]»(ref-345220-S26930526422009102000000) .)
7. Add ATF to the specified level. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FN4A-EL]»(ref-345215-S24754048372009102000000) ).
8. Perform the mechanical system test. (See «MECHANICAL SYSTEM TEST [FN4A-EL]»(ref-345215-S31925879532009102000000) ).

On-Vehicle Removal

Scheme 389

Scheme 390

Scheme 391

1. Remove the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
2. Disconnect the negative battery cable.
3. Drain the ATF into a separate suitable container. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FN4A-EL]»(ref-345215-S24754048372009102000000) ).
4. Remove the under cover.
5. Remove the oil pan.
6. Disconnect the solenoid connectors and GND.
7. Remove the oil strainer.
8. Remove the control valve body installation bolts as shown in the figure, then remove the control valve body component as shown in the figure.
9. Remove the accumulators and accumulator springs.

Scheme 392

Scheme 393

Scheme 394

Scheme 395

1. Install the accumulator springs and accumulators into the transaxle case. ACCUMULATOR SPRINGS AND ACCUMULATORS SPECIFICATION Spring Outer diameter (mm {in}) Free Length (mm {in}) No. of coils Wire diameter (mm {in}) Servo apply accumulator large spring 21.0 {0.827} 67.8 {2.669} 10.3 3.5 {0.138} Servo apply accumulator small spring 13.0 {0.512} 67.8 {2.669} 17.1 2.2 {0.087} Forward accumulator large spring 21.0 {0.827} 75.0 {2.953} 10.7 2.3 {0.091} Forward accumulator small spring 15.6 {0.614} 49.0 {1.929} 7.7 2.4 {0.094}
2. Install the control valve body component. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf} Bolt length (measured from below the head) Mark B: 40 mm {1.575 in} No mark: 70 mm {2.756 in}
3. Install the oil strainer.
4. Match the harness colors, then connect the solenoid connectors and GND, and install the TFT sensor. SPRING SPECIFICATION Spring Color of connector (harness side) Pressure control solenoid Black Shift solenoid A White Shift solenoid B Blue Shift solenoid C Green Shift solenoid D White Shift solenoid E Black
5. Install the GND. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
6. Apply a light coat of silicon sealant to the contact surfaces of the oil pan and transaxle case.
7. Install the oil pan. Tightening torque 6-8 N.m {62-81 kgf.cm, 53-70 in.lbf}
8. Install the under cover.
9. Connect the negative battery cable.
10. Install the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
11. Add ATF and with the engine idling, inspect the ATF level. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FN4A-EL]»(ref-345215-S24754048372009102000000) ).
12. Perform the mechanical system test. (See «MECHANICAL SYSTEM TEST [FN4A-EL]»(ref-345215-S31925879532009102000000) ).

Oil Cooler Installation Note

1. The automatic transaxle oil cooler flushing must be performed whenever a transaxle is removed for service because the existing fluid may be contaminated, and to prevent contamination of new fluid. NOTE: Flushing must be performed after installation of the overhauled or replaced transaxle.
2. Follow the instructions in the manufacturer's publication for flushing operation.

Scheme 396

Scheme 397

Scheme 398

1. Apply compressed air to the cooler-side opening, and blow any remaining grime and foreign material from the cooler pipes. Compressed air should be applied for no less than 1 min.
2. Align the marks, and slide the oil hose onto the oil pipe until it is fully seated as shown. NOTE: If reusing the hose, install the new hose clamp exactly on the mark left by the previous hose clamp. Then apply force to the hose clamp in the direction of the arrow in order to fit the clamp in place.
3. Install the new hose clamp onto the hose.
4. Verify that the hose clamp does not interfere with any other components.

Scheme 399

1. Remove the transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FN4A-EL]»(ref-345215-S36780265692009102000000) ).
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal. DIAGNOSIS PROCEDURE 1 Drive plate mounting bolts (See «DRIVE PLATE MOUNTING BOLTS REMOVAL NOTE»(ref-345215-S14014022032009102000000) ). 2 Backing plate 3 Drive plate (See «DRIVE PLATE INSTALLATION NOTE»(ref-345215-S12050547032009102000000) ).

Scheme 400

1. Set the SST or equivalent against the drive plate.
2. Remove the bolts and the drive plate.

Scheme 401

1. Remove the sealant from bolt holes in the crankshaft and from the drive plate mounting bolts.
2. Install the drive plate.
3. Install the backing plate.
4. Set the SST or equivalent against the drive plate.
5. Tighten the drive plate mounting bolts in two or three steps in the order as shown in the figure. Tightening torque 108-116 N.m {11.0-11.8 kgf.m, 79.7-85.5 ft.lbf}
6. Install the transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FN4A-EL]»(ref-345215-S36780265692009102000000) ).