Automatic Transaxle - Overhaul (FW6A-EL): Overhaul Mazda 3 BM

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 1099

Scheme 1100

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 1099): 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 1100): Identifying Control Valve Body Connector

Disassembly Procedure

Identifying TCM And Impact-Absorbing Material. Scheme 1101

Scheme 1102

Scheme 1103

Scheme 1104

Scheme 1105

Scheme 1106

Scheme 1107

Scheme 1108

Scheme 1109

Scheme 1110

Scheme 1111

Scheme 1112

Scheme 1113

Scheme 1114

Scheme 1115

Scheme 1116

Scheme 1117

Scheme 1118

Scheme 1119

Scheme 1120

Scheme 1121

1. Remove the coupler component using the following procedure. (Scheme 1102): 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 1103): Locating Connector (Scheme 1104): Disconnecting Connector Place the control valve body on an impact-absorbing material with the TCM side facing downward as shown in the figure. (Scheme 1105): 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 1106): Caution For Placing TCM Remove the bolts shown in the figure. (Scheme 1107): 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 1108): 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 1109): Locating Automatic Transaxle Connectors CAUTION: Be careful not to damage the connector using a precision flathead screwdriver. (Scheme 1110): Disconnecting Automatic Transaxle Connectors Using Flathead Screwdriver Remove the coupler component. (Scheme 1111): Identifying Coupler Component
2. Remove the ON/OFF solenoid using the following procedure: (Scheme 1112): Removal Procedure Of ON/OFF Solenoid Remove the bolt shown in the figure. (Scheme 1113): Locating ON/OFF Solenoid Bolt Remove the ON/OFF solenoid. (Scheme 1114): Identifying ON/OFF Solenoid
3. Remove oil pressure switch B using the following procedure: (Scheme 1115): Removal Procedure Of Oil Pressure Switch B Remove the bolts shown in the figure. (Scheme 1116): Locating Oil Pressure Switch B Mounting Bolts Remove oil pressure switch B. (Scheme 1117): Identifying Oil Pressure Switch B
4. Remove oil pressure switch A using the following procedure: (Scheme 1118): Removal Procedure Of Oil Pressure Switch A Remove the bolts shown in the figure. (Scheme 1119): Locating Oil Pressure Switch A Mounting Bolts Disengage oil pressure switch A tab. A: Tab (Scheme 1120): Identifying Oil Pressure Switch A Tab Remove oil pressure switch A. (Scheme 1121): Identifying Oil Pressure Switch A

Scheme 1122

Scheme 1123

1. Plug to the position shown in the figure with packing tape. (Scheme 1122): 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 1123): Identifying Plug (Packing Tape)

Scheme 1124

Scheme 1125

Scheme 1126

Scheme 1127

1. Prepare a clean oil receptacle. (Scheme 1124): 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 1125): Locating ATF In Torque Converter
3. Shake the torque converter to stir the ATF in the torque converter. (Scheme 1126): 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 1127): 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 1128

Scheme 1129

1. Plug to the position shown in the figure with packing tape. (Scheme 1128): 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 1129): Identifying Plug (Packing Tape)

Oil Cooler Flushing (Water Passage)

Scheme 1130

Scheme 1131

Scheme 1132

Scheme 1133

Scheme 1134

1. Plug the position (water passage) shown in the figure with packing tape. (Scheme 1130): 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 1131): Identifying Oil Receptacle
3. Add water to the oil cooler from the water passage shown in the figure. (Scheme 1132): 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 1133): 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 1134): Identifying Plug (Packing Tape)

Oil Cooler Flushing (Oil Passage)

Scheme 1135

Scheme 1136

Scheme 1137

Scheme 1138

1. Plug to the position (water passage) shown in the figure with packing tape. (Scheme 1135): 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 1136): 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 1137): 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 1138): Identifying Plug (Packing Tape)

Scheme 1139

Scheme 1140

Scheme 1141

Scheme 1142

Scheme 1143

Scheme 1144

Scheme 1145

Scheme 1146

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 1139): Locating Torque Converter Bushing Sliding Part Turbine shaft If there is a malfunction, replace the turbine shaft with a new one. (Scheme 1140): Locating Turbine Shaft Bearing Areas High clutch hub If there is a malfunction, replace the high clutch hub with a new one. (Scheme 1141): Locating High Clutch Hub Bearing Areas End cover If there is a malfunction, replace the end cover with a new one. (Scheme 1142): Locating End Cover Bearing Areas
3. Verify that there is no significant sliding trace on the following journal part. Ring gear and differential (Scheme 1143): 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 1144): 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 1145): Locating Sliding Trace On Drive Shaft (LH) Joint shaft If there is a malfunction, replace the joint shaft with a new one. (Scheme 1146): Locating Sliding Trace On Joint Shaft

Assembly Procedure

Scheme 1147

Scheme 1148

Scheme 1149

Scheme 1150

Scheme 1151

Scheme 1152

Scheme 1153

Scheme 1154

Scheme 1155

Scheme 1156

Scheme 1157

Scheme 1158

Scheme 1159

Scheme 1160

Scheme 1161

Scheme 1162

Scheme 1163

Scheme 1164

Scheme 1165

Scheme 1166

Scheme 1167

Scheme 1168

Scheme 1169

Scheme 1170

1. Place the control valve body with the TCM side pointing downward on an impact-absorbing material as shown in the figure. (Scheme 1147): 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 1148): 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 1149): Identifying Solenoid Pulling Direction If there is a malfunction, assemble the pin securing the solenoid to the malfunctioning part. (Scheme 1150): Locating Solenoid Securing Pin
3. Assemble the oil pressure switch A using the following procedure: (Scheme 1151): Identifying Oil Pressure Switch And Bolts Assemble the oil pressure switch A. (Scheme 1152): Identifying Oil Pressure Switch (Scheme 1153): 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 1154): Locating Valve Body Bolts
4. Assemble the oil pressure switch B using the following procedure: (Scheme 1155): Identifying Oil Pressure Switch And Bolts Assemble the oil pressure switch B. (Scheme 1156): Identifying Oil Pressure Switch (Scheme 1157): Identifying Oil Pressure Switch Installing Position Assemble and tighten the bolts shown in the figure. (Scheme 1158): 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 1159): Identifying ON/OFF Solenoid And Bolts Assemble the ON/OFF solenoid. (Scheme 1160): ON/OFF Solenoid Installing Location (Scheme 1161): 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 1162): Locating Valve Body Bolt
6. Assemble the coupler component using the following procedure: (Scheme 1163): Identifying Coupler Component And Bolt Assemble the coupler component. (Scheme 1164): Coupler Component Installing Location (Scheme 1165): 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 1166): Locating Coupler Component Connectors Assemble and tighten the bolts shown in the figure. (Scheme 1167): 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 1168): 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 1169): Caution For Connecting Connector
7. Place the assembled control valve body with the TCM side pointing upward on a workbench. (Scheme 1170): 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.