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Automatic Transaxle - Service, Removal & Installation (FS5A-EL): Removal & Installation Mazda 3 BL

Automatic Trans 27 illustrations ~1830 words

AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FS5A-EL]

WARNINGWhen the transaxle and ATF are hot, they can badly burn you. Turn off the engine and wait until they are cool before changing the ATF.

Scheme 462

Scheme 462
Scheme 462
  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 drain plug. Tightening torque 29.4-41.2 N.m {3.0-4.2 kgf.m, 22-30 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) Draining ATF from drain plug: 3.0 L {3.2 US qt, 2.4 Imp qt} Overhauling ATX: 5.0 L {5.3 US qt, 4.4 Imp qt}
  6. Adjust the ATF amount to within the specified range according to the ATF inspection procedure. (See «AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [FS5A-EL]»(ref-345217-S26056264712009102000000) ). NOTE: The full amount of ATF for the ATX is as follows Capacity (approx. quantity) 8.14 L {8.6 US qt, 7.2 Imp qt}

Scheme 463

Scheme 463: Operating Inspection
Scheme 463: Operating Inspection
  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 [FS5A-EL]

WARNINGWhen the transaxle and ATF are hot, they can badly burn. Turn off the engine and wait until they are cool before replacing the ATF.
  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. Drain the ATF.
  5. Remove the oil pan.
  6. Remove the primary control valve body. (See «PRIMARY CONTROL VALVE BODY REMOVAL [FS5A-EL]»(ref-345217-S32739338962009102000000) ).
  7. Remove the coupler component.
  8. Install the coupler component.
  9. Install the primary control valve body. (See «PRIMARY CONTROL VALVE BODY REMOVAL [FS5A-EL]»(ref-345217-S32739338962009102000000) ).
  10. Install the oil pan. (See «PRIMARY CONTROL VALVE BODY REMOVAL [FS5A-EL]»(ref-345217-S32739338962009102000000) ).
  11. Install the under cover.
  12. Connect the negative battery cable.
  13. Install the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  14. Add ATF. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FS5A-EL]»(ref-345217-S10235626212009102000000) ).
  15. Perform the mechanical system test. (See «MECHANICAL SYSTEM TEST [FS5A-EL]»(ref-345217-S15912078622009102000000) .
  16. Perform the road test. (See «ROAD TEST [FS5A-EL]»(ref-345217-S11374157632009102000000) ).

OIL PRESSURE SWITCH REMOVAL/INSTALLATION [FS5A-EL]

WARNINGWhen the transaxle and ATF are hot, they can badly burn. Turn off the engine and wait until they are cool before replacing ATF.
  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 cord assembly connector.
  5. Remove the oil pressure switch.
  6. Install the oil pressure switch. Tightening torque 17.1-22.1 N.m {1.75-2.25 kgf.m, 13-16 ft.lbf}
  7. Connect the oil pressure switch connector.
  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) .)

INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION [FS5A-EL]

  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 battery, battery box and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  4. Remove the air cleaner component. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [LF, L3]»(ref-345212-S03134740962009102000000) .)
  5. Disconnect the input/turbine speed sensor connector.
  6. Remove the input/turbine speed sensor.
  7. Apply ATF to a new O-ring and install it on a new input/turbine speed sensor.
  8. Install the input/turbine speed sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
  9. Connect the input/turbine speed sensor connector.
  10. Install the air cleaner component. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [LF, L3]»(ref-345212-S03134740962009102000000) .)
  11. Install the battery, battery box and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  12. Connect the negative battery cable.
  13. Install the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)

INTERMEDIATE SENSOR REMOVAL/INSTALLATION [FS5A-EL]

CAUTIONWater or foreign objects entering the connector can cause a poor connection or corrosion. Be sure not to drop water or foreign objects on the connector when disconnecting it. If foreign materials are stuck to the intermediate sensor, disturbance by magnetic flux can cause sensor output to be abnormal and thereby negatively affect control. Make sure that foreign materials such as iron filings are not stuck to the intermediate sensor during installation.

Scheme 464

Scheme 464
Scheme 464
  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 battery, battery box and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  4. Disconnect the intermediate sensor connector.
  5. Remove the intermediate sensor.
  6. Apply ATF to a new O-ring and install it on a new intermediate sensor.
  7. Install the intermediate sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
  8. Connect the intermediate sensor connector.
  9. Install the battery, battery box and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  10. Connect the negative battery cable.
  11. Install the battery duct and battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)

VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [FS5A-EL]

CAUTIONWater or foreign objects entering the connector can cause a poor connection or corrosion. Be sure not to drop water or foreign objects on the connector when disconnecting it. If foreign materials are stuck to the VSS, disturbance by magnetic flux can cause sensor output to be abnormal and thereby negatively affect control. Make sure that foreign materials such as iron filings are not stuck to the VSS during installation.

Scheme 465

Scheme 465
Scheme 465
  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) .)

TCM REMOVAL/INSTALLATION [FS5A-EL]

CAUTIONDo not apply a shock to or touch the projection on the TCM, otherwise it may not operate normally.

Scheme 466

Scheme 466
Scheme 466
  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 battery, battery box and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  4. Remove in the order indicated in the table.
  5. Install in the reverse order of removal.

Scheme 467

Scheme 467: AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FS5A-EL]
Scheme 467: AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FS5A-EL]
  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 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.
  4. Drain the ATF. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FS5A-EL]»(ref-345217-S10235626212009102000000) ). 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.
  5. Remove in the order indicated in the table.
  6. Install in the reverse order of removal.
  7. Add ATF to the specified level. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FS5A-EL]»(ref-345217-S10235626212009102000000) ).
  8. Perform the following test. (See «MECHANICAL SYSTEM TEST [FS5A-EL]»(ref-345217-S15912078622009102000000) ). (See «ROAD TEST [FS5A-EL]»(ref-345217-S11374157632009102000000) ). 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 468

Scheme 468: Torque Converter Nuts Removal Note
Scheme 468: Torque Converter Nuts Removal Note

Scheme 469

Scheme 469
Scheme 469
  1. Hold the crankshaft pulley to prevent the drive plate from rotating.
  2. Remove the torque converter nuts from the starter installation hole.

Scheme 470

Scheme 470: No.4 Engine Mount Removal Note
Scheme 470: No.4 Engine Mount Removal Note

Scheme 471

Scheme 471
Scheme 471

Scheme 472

Scheme 472
Scheme 472

Scheme 473

Scheme 473
Scheme 473

Scheme 474

Scheme 474
Scheme 474
  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

WARNINGRemove the transaxle carefully, holding it steady. If the transmission falls it could be damaged or cause injury.
CAUTIONTo prevent the torque converter and transmission from separating, remove the transmission without tilting it toward the torque converter.

Scheme 475

Scheme 475
Scheme 475

Scheme 476

Scheme 476
Scheme 476
  1. Remove the clip A.
  2. Remove the clip B from the brake pipe (LF). NOTE: To prevent interference with the ATX, move the brake pipe (LF) and secure a space.
  3. Lean the engine toward the transaxle.
  4. Support the transaxle on a jack.
  5. Remove the transaxle mounting bolts.
  6. Remove the transaxle.

Transaxle Installation Note

WARNINGInstall the transaxle carefully, holding it steady. If the transmission falls it could be damaged or cause injury.
CAUTIONTo prevent the torque converter and transmission from separating, install the transmission without tilting it toward the torque converter.

Scheme 477

Scheme 477
Scheme 477
  1. Set the transaxle on a jack and lift it.
  2. Install the transaxle mounting bolts. Bolt length (measured from below the head) A: 50 mm {1.967 in} B: 65 mm {2.559 in} Tightening torque 37.3-52.0 N.m {3.8-5.3 kgf.m, 27.6-38.3 ft.lbf}
  3. Install the brake pipe (LF) to the clip B.
  4. Install the clip A.

Scheme 478

Scheme 478: No.1 Engine Mount and No.4 Engine Mount Installation Note
Scheme 478: No.1 Engine Mount and No.4 Engine Mount Installation Note

Scheme 479

Scheme 479
Scheme 479

Scheme 480

Scheme 480
Scheme 480

Scheme 481

Scheme 481
Scheme 481

Scheme 482

Scheme 482
Scheme 482
  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 over the No.4 engine mount bracket with the body stud bolts passing through the holes.
  5. Place the dynamic damper over the battery tray bracket with the body stud bolts passing through the holes, then tighten the bolts and nuts in the order shown in the figure.
  6. Remove the SST.
  7. Install the clip as shown in the figure.
  8. 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}

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 483

Scheme 483: Oil Pipe, Hose Clamp, Oil Hose Installation Note
Scheme 483: Oil Pipe, Hose Clamp, Oil Hose Installation Note

Scheme 484

Scheme 484
Scheme 484

Scheme 485

Scheme 485
Scheme 485
  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 486

Scheme 486: DRIVE PLATE REMOVAL/INSTALLATION [FS5A-EL]
Scheme 486: DRIVE PLATE REMOVAL/INSTALLATION [FS5A-EL]
  1. Remove the transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FS5A-EL]»(ref-345217-S34693716102009102000000) ).
  2. Remove in the order indicated in the table.
  3. Install in the reverse order of removal.

Scheme 487

Scheme 487: Drive Plate Mounting Bolts Removal Note
Scheme 487: Drive Plate Mounting Bolts Removal Note
  1. Set the SST or equivalent against the drive plate.
  2. Remove the bolts and the drive plate.

Drive Plate Installation Note

CAUTIONClean the crankshaft threads before tightening the bolts. The threads may be damaged if the bolts are tightened with any old sealant remaining.

Scheme 488

Scheme 488
Scheme 488
  1. Clean the crankshaft thread holes.
  2. Install the drive plate.
  3. Install the adapter.
  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 [FS5A-EL]»(ref-345217-S34693716102009102000000) ).

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