Automatic Transaxle - Overhaul (FW6A-EL): Overhaul Mazda 3 BL рестайлинг

Cleaning After Disassembly

1. Clean the torque converter. (See «TORQUE CONVERTER CLEANING»(ref-537680-S05942292462013032500000) .) CAUTION: To prevent damage to the parts, do not clean the inside of the torque converter using degreaser.
2. Clean the oil cooler. (See «OIL COOLER CLEANING»(ref-537680-S32814902912013032500000) .) CAUTION: To prevent damage to the parts, do not clean the inside of the oil cooler using degreaser.
3. Flush dirt on the surface of the drive plate with ATF (ATF FZ). CAUTION: To prevent damage to the parts, do not clean the drive plate using degreaser.
4. Clean the disassembled parts using degreaser and dry them using an air compressor. In addition, clean the oil passage using the air compressor. WARNING: Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes. CAUTION: To prevent damage to parts, do not clean aluminum and rubber parts using alkaline agent. To prevent damage to parts, do not clean rubber parts using white gasoline and kerosene.

Scheme 1465

Scheme 1466

1. Remove the ATF or foreign matter adhering to the outside of the transaxle using degreaser or the air compressor. WARNING: Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes. CAUTION: If foreign matter, water, or degreaser penetrates the transaxle and connector, it could cause a malfunction. Before cleaning the outside of the transaxle, plug the position shown in the figure with the packing tape. (Scheme 1465): Identifying Breather Pipe, Control Valve Body Connector, Oil Cooler And Seal
2. Verify that there is no ATF or foreign matter on the connector shown in the figure. Control valve body connector If there is ATF or foreign matter on the connector shown in the figure, remove it. (Scheme 1466): Identifying Control Valve Body Connector

Disassembly Procedure

Identifying TCM And Impact-Absorbing Material. Scheme 1467

Scheme 1468

Scheme 1469

Scheme 1470

Scheme 1471

Scheme 1472

Scheme 1473

Scheme 1474

Scheme 1475

Scheme 1476

Scheme 1477

Scheme 1478

Scheme 1479

Scheme 1480

Scheme 1481

Scheme 1482

Scheme 1483

Scheme 1484

Scheme 1485

Scheme 1486

Scheme 1487

1. Remove the coupler component using the following procedure. (Scheme 1468): Removal Procedure Of Coupler Components Disconnect the connector shown in the figure. CAUTION: If a connector is disconnected, do not pull the wiring harness. Pull the connector at a straight after releasing the lock. (Scheme 1469): Locating Connector (Scheme 1470): Disconnecting Connector Place the control valve body on an impact-absorbing material with the TCM side facing downward as shown in the figure. (Scheme 1471): Identifying TCM And Impact-Absorbing Material CAUTION: Placing the TCM side pointed downward on a workbench directly could damage the TCM. If the TCM side is placed pointed downward, place the control valve body on an impact-absorbing material so that the TCM does not contact the workbench directly. After removing the coupler component, if the control valve body is placed on the workbench with the TCM side facing upward, the pins securing the solenoids shown in the figure could fall off and become lost. If the solenoid installation position shown in the figure is changed, it will cause a malfunction. To prevent the pin securing the solenoid from falling, always place the control valve body on an impact-absorbing material with the TCM side facing downward after removing the coupler component. (Scheme 1472): Caution For Placing TCM Remove the bolts shown in the figure. (Scheme 1473): Locating Automatic Transaxle Mounting Bolts Disconnect the connectors shown in the figure. CAUTION: If a connector is disconnected, do not pull the wiring harness. Pull the connector at a straight after releasing the lock. (Scheme 1474): Locating Automatic Transaxle Connectors CAUTION: For the connector shown in the figure, pull the connector at a straight after releasing the lock using a precision flathead screwdriver. (Scheme 1475): Locating Automatic Transaxle Connectors CAUTION: Be careful not to damage the connector using a precision flathead screwdriver. (Scheme 1476): Disconnecting Automatic Transaxle Connectors Using Flathead Screwdriver Remove the coupler component. (Scheme 1477): Identifying Coupler Component
2. Remove the ON/OFF solenoid using the following procedure: (Scheme 1478): Removal Procedure Of ON/OFF Solenoid Remove the bolt shown in the figure. (Scheme 1479): Locating ON/OFF Solenoid Bolt Remove the ON/OFF solenoid. (Scheme 1480): Identifying ON/OFF Solenoid
3. Remove oil pressure switch B using the following procedure: (Scheme 1481): Removal Procedure Of Oil Pressure Switch B Remove the bolts shown in the figure. (Scheme 1482): Locating Oil Pressure Switch B Mounting Bolts Remove oil pressure switch B. (Scheme 1483): Identifying Oil Pressure Switch B
4. Remove oil pressure switch A using the following procedure: (Scheme 1484): Removal Procedure Of Oil Pressure Switch A Remove the bolts shown in the figure. (Scheme 1485): Locating Oil Pressure Switch A Mounting Bolts Disengage oil pressure switch A tab. A: Tab (Scheme 1486): Identifying Oil Pressure Switch A Tab Remove oil pressure switch A. (Scheme 1487): Identifying Oil Pressure Switch A

Scheme 1488

Scheme 1489

1. Plug to the position shown in the figure with packing tape. (Scheme 1488): Identifying Plug (Packing Tape) Outside Of Torque Converter CAUTION: If foreign matter penetrates the torque converter, it could cause a malfunction. Therefore, when cleaning the outside of the torque converter, plug the position shown in the figure with packing tape.
2. Wipe off any dirt or foreign matter adhering to the outside of the torque converter using a rag. Clean depending on the condition using degreaser and dry them using an air compressor. WARNING: Always wear protective eye wear when using the air compressor. Otherwise, degreaser or dirt particles blown off by the air compressor could get into the eyes.
3. Clean away the used packing tape as a plug. (Scheme 1489): Identifying Plug (Packing Tape)

Scheme 1490

Scheme 1491

Scheme 1492

Scheme 1493

1. Prepare a clean oil receptacle. (Scheme 1490): Identifying Oil Receptacle
2. Add new ATF (ATF FZ) to the torque converter from the position shown in the figure. NOTE: Because the ATF in the torque converter needs to be well stirred, when adding ATF do not completely fill the torque converter. Fill only about halfway. (Scheme 1491): Locating ATF In Torque Converter
3. Shake the torque converter to stir the ATF in the torque converter. (Scheme 1492): Shaking Torque Converter
4. Drain the ATF in the torque converter into the clean oil receptacle. NOTE: While shaking the torque converter, drain as much of the ATF in the torque converter as possible. (Scheme 1493): Draining ATF In Torque Converter Into Oil Receptacle
5. Verify that none of the following foreign material is mixed in with the ATF drained from the torque converter: Large metal fragments of ø 0.5 mm {0.02 in} or more that cannot pass through the oil strainer Fibrous clutch or brake facing
6. Dispose of the ATF in the oil receptacle and clean the oil receptacle.
7. Perform Steps 2 - 6 three times. If metal fragments and facing material continue to appear in the drained ATF from the torque converter after it is flushed repeatedly, replace the torque converter with a new one.

Scheme 1494

Scheme 1495

1. Plug to the position shown in the figure with packing tape. (Scheme 1494): Identifying Oil Cooler And Plug (Packing Tape) CAUTION: If foreign matter penetrates the oil cooler, it could cause a malfunction. Therefore, when cleaning the outside of the oil cooler, plug the position shown in the figure with packing tape.
2. Wipe off any dirt or foreign matter adhering to the outside of the oil cooler using a rag. Clean depending on the condition using degreaser and dry them using an air compressor. WARNING: Always wear protective eye wear when using the air compressor. Otherwise, degreaser or dirt particles blown off by the air compressor could get into the eyes.
3. Clean away the used packing tape as a plug. A: Plug (packing tape) (Scheme 1495): Identifying Plug (Packing Tape)

Oil Cooler Flushing (Water Passage)

Scheme 1496

Scheme 1497

Scheme 1498

Scheme 1499

Scheme 1500

1. Plug the position (water passage) shown in the figure with packing tape. (Scheme 1496): Identifying Oil Cooler And Plug (Packing Tape) CAUTION: If engine coolant or water penetrates the oil cooler (in oil passage), it could cause a malfunction. Therefore, when flushing the oil cooler (water passage), plug the position (oil passage) shown in the figure with packing tape.
2. Prepare a clean oil receptacle. (Scheme 1497): Identifying Oil Receptacle
3. Add water to the oil cooler from the water passage shown in the figure. (Scheme 1498): Locating Water Passage To Oil Cooler
4. Blow compressed air into the water passage shown in the figure and drain the engine coolant and water in the oil cooler. (Scheme 1499): Blowing Compressed Air From Oil Cooler Water Passage WARNING: Always wear protective eye wear when using the air compressor. Otherwise, engine coolant, water, or dirt particles blown off by the air compressor could get into the eyes. CAUTION: Perform the work at a position where the engine coolant and water in the oil cooler can be drained into a clean oil receptacle. To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure. Compressed air pressure 150-200 kPa {1.53-2.03 kgf/cm 2, 21.8-29.0 psi}
5. Verify that none of the following foreign material is mixed in with the engine coolant and water drained from the oil cooler. Rust or water stain due to deterioration of engine coolant Engine oil Fragments of cooling system parts (plastic, metal, or rubber fragments)
6. Dispose of the engine coolant and water in the oil receptacle and clean the oil receptacle.
7. Perform Steps 3 - 6 three times. If foreign material remains even after the oil cooler is flushed repeatedly, replace the oil cooler with a new one and inspect the cooling system part. NOTE: For the cooling system part inspection, verify the Workshop Manual.
8. Clean away the used packing tape as a plug. A: Plug (packing tape) (Scheme 1500): Identifying Plug (Packing Tape)

Oil Cooler Flushing (Oil Passage)

Scheme 1501

Scheme 1502

Scheme 1503

Scheme 1504

1. Plug to the position (water passage) shown in the figure with packing tape. (Scheme 1501): Identifying Oil Cooler And Plug (Packing Tape) CAUTION: If ATF penetrates the oil cooler (in water passage), it could cause a malfunction. Therefore, when flushing the oil cooler (oil passage), plug the position (water passage) shown in the figure with packing tape.
2. Prepare a clean oil receptacle. see scheme 421: Identifying Oil Receptacle
3. Add new ATF (ATF FZ) to the oil cooler from the oil passage shown in the figure. (Scheme 1502): Locating Oil Cooler Air Passage
4. Blow compressed air into the oil passage shown in the figure and drain the ATF in the oil cooler. WARNING: Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes. (Scheme 1503): Blowing Compressed Air From Oil Passage CAUTION: Perform the work at a position where the ATF in the oil cooler can be drained into a clean oil receptacle. To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure. Compressed air pressure 491-882 kPa {5.01-8.99 kgf/cm 2, 71.3-127.0 psi}
5. Verify that none of the following foreign material is mixed in with the ATF drained from the oil cooler. Large metal fragments of ø 0.5 mm {0.02 in} or more that cannot pass through the oil strainer Fibrous clutch or brake facing
6. Dispose of the ATF in the oil receptacle and clean the oil receptacle.
7. Perform Steps 3 - 6 three times. If foreign material such as metal fragments or facing remain even after the oil cooler is flushed repeatedly, replace the oil cooler with a new one.
8. Clean away the used packing tape used as the (Scheme 1504): Identifying Plug (Packing Tape)

Scheme 1505

Scheme 1506

Scheme 1507

Scheme 1508

Scheme 1509

Scheme 1510

Scheme 1511

Scheme 1512

1. Visually inspect the parts according to the following table and replace a malfunctioning part with a new one. NOTE: Check the color depending on the condition to specify the malfunctioning part. Part name (mechanism name) Inspection item Gear Missing teeth or tooth loss Peeling on tooth surface Other damage (cracks, wear, impact, deformation, burning or seizure) Tapered roller bearing Peeling on sliding surface Cage deformation Discoloration due to burning (temper color) Other damage (cracks, wear, impact, deformation, burning or seizure) Thrust needle bearing Peeling on sliding surface Discoloration due to burning (temper color) Other damage (cracks, wear, impact, deformation, burning or seizure) Radial needle bearing Peeling on sliding surface Cage deformation Discoloration due to burning (temper color) Other damage (cracks, wear, impact, deformation, burning or seizure) Clutch (brake) drive plate Facing peeling Discoloration due to burning (temper color) Other damage (cracks, wear, impact, deformation, burning or seizure) Clutch (brake) piston and seal plate Lip (rubber) tear or wear Other damage (cracks, impact, deformation) Clutch (brake) springs and retainer component Spring removal Spring deformation (significant attitude) Retainer deformation Other damage (cracks, wear, impact) Parts other than the above External appearance damage (cracks, wear, impact, deformation, burning or seizure)
2. Verify that there is no bushing adhesion trace or significant sliding trace on the following bushing sliding part. Torque converter If there is a malfunction, replace the torque converter with a new one. (Scheme 1505): Locating Torque Converter Bushing Sliding Part Turbine shaft If there is a malfunction, replace the turbine shaft with a new one. (Scheme 1506): Locating Turbine Shaft Bearing Areas High clutch hub If there is a malfunction, replace the high clutch hub with a new one. (Scheme 1507): Locating High Clutch Hub Bearing Areas End cover If there is a malfunction, replace the end cover with a new one. (Scheme 1508): Locating End Cover Bearing Areas
3. Verify that there is no significant sliding trace on the following journal part. Ring gear and differential (Scheme 1509): Locating Sliding Trace On Ring Gear And Differential Journal Part If there is a malfunction, disassemble the ring gear and differential and replace the differential gear case with a new one. (See «RING GEAR AND DIFFERENTIAL DISASSEMBLY»(ref-537680-S12512712582013032500000).) (See «RING GEAR AND DIFFERENTIAL ASSEMBLY»(ref-537680-S28398192182013032500000).) (Scheme 1510): Locating Sliding Trace On Ring Gear And Differential Assembly Journal Part Drive shaft (LH) If there is a malfunction, disassemble the drive shaft (LH) and replace the outer ring with a new one. NOTE: For the drive shaft disassembly/assembly procedure, verify the Workshop Manual. (Scheme 1511): Locating Sliding Trace On Drive Shaft (LH) Joint shaft If there is a malfunction, replace the joint shaft with a new one. (Scheme 1512): Locating Sliding Trace On Joint Shaft

Assembly Procedure

Scheme 1513

Scheme 1514

Scheme 1515

Scheme 1516

Scheme 1517

Scheme 1518

Scheme 1519

Scheme 1520

Scheme 1521

Scheme 1522

Scheme 1523

Scheme 1524

Scheme 1525

Scheme 1526

Scheme 1527

Scheme 1528

Scheme 1529

Scheme 1530

Scheme 1531

Scheme 1532

Scheme 1533

Scheme 1534

Scheme 1535

Scheme 1536

1. Place the control valve body with the TCM side pointing downward on an impact-absorbing material as shown in the figure. (Scheme 1513): Placing Control Valve Body With TCM Side Pointing Downward On Impact-Absorbing Material CAUTION: Placing the TCM side pointed downward on a workbench directly could damage the TCM. If the TCM side is placed pointed downward, place the control valve body on an impact-absorbing material so that the TCM does not contact the workbench directly. If the control valve body is placed on the workbench with the TCM side pointing upward, the pins securing the solenoids shown in the figure could fall off and become lost. If the solenoid installation position shown in the figure is changed, it will cause a malfunction. To prevent the pin securing the solenoid from falling, always place the control valve body on an impact-absorbing material with the TCM side pointing downward until the coupler component is assembled. (Scheme 1514): Caution For Placing TCM
2. Verify that the pins securing the pressure control solenoid, TCC control valve, and each shift solenoid are not removed using the following procedure: Pull each solenoid in the direction of the arrow shown in the figure and verify that it is secured. (Scheme 1515): Identifying Solenoid Pulling Direction If there is a malfunction, assemble the pin securing the solenoid to the malfunctioning part. (Scheme 1516): Locating Solenoid Securing Pin
3. Assemble the oil pressure switch A using the following procedure: (Scheme 1517): Identifying Oil Pressure Switch And Bolts Assemble the oil pressure switch A. (Scheme 1518): Identifying Oil Pressure Switch (Scheme 1519): Identifying Oil Pressure Switch Installing Position Assemble and tighten the bolts shown in the figure. NOTE: Bolt size: M6x1.0 bolt, length to approx. 60 mm {2.4 in} Tightening torque 9-10 N.m {92-101 kgf.cm, 80-88 in.lbf} (Scheme 1520): Locating Valve Body Bolts
4. Assemble the oil pressure switch B using the following procedure: (Scheme 1521): Identifying Oil Pressure Switch And Bolts Assemble the oil pressure switch B. (Scheme 1522): Identifying Oil Pressure Switch (Scheme 1523): Identifying Oil Pressure Switch Installing Position Assemble and tighten the bolts shown in the figure. (Scheme 1524): Identifying Valve Body Bolts (A And B) Tightening torque 9-10 N.m {92-101 kgf.cm, 80-88 in.lbf}
5. Assemble the ON/OFF solenoid using the following procedure: (Scheme 1525): Identifying ON/OFF Solenoid And Bolts Assemble the ON/OFF solenoid. (Scheme 1526): ON/OFF Solenoid Installing Location (Scheme 1527): Identifying ON/OFF Solenoid Installing Position Assemble and tighten the bolt shown in the figure. NOTE: Bolt size: M6x1.0 bolt, length to approx. 16 mm {0.63 in} Tightening torque 9-10 N.m {92-101 kgf.cm, 80-88 in.lbf} (Scheme 1528): Locating Valve Body Bolt
6. Assemble the coupler component using the following procedure: (Scheme 1529): Identifying Coupler Component And Bolt Assemble the coupler component. (Scheme 1530): Coupler Component Installing Location (Scheme 1531): Identifying Coupler Component Installing Position Connect the connectors shown in the figure. CAUTION: When connecting a connector, insert it straight until it is securely locked. (Scheme 1532): Locating Coupler Component Connectors Assemble and tighten the bolts shown in the figure. (Scheme 1533): Locating Bolts (A, B And C) CAUTION: Tighten the bolts while pressing the coupler component so that the bolt hole shown in the figure and coupler component hole do not shift. Tightening torque 9-10 N.m {92-101 kgf.cm, 80-88 in.lbf} (Scheme 1534): Caution For Tightening Coupler Component Bolt Connect the connector shown in the figure. CAUTION: When connecting a connector, insert it at a straight angle until it is securely locked. (Scheme 1535): Caution For Connecting Connector
7. Place the assembled control valve body with the TCM side pointing upward on a workbench. (Scheme 1536): Caution For Placed Assembled Control Valve Body With TCM Side Pointing Downward On Workbench CAUTION: Place the assembled control valve body with the TCM side pointing upward on a workbench. If it is placed with the TCM side pointing downward on the workbench, the TCM could be damaged.