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

TORQUE CONVERTER INSPECTION

Scheme 338

Scheme 339

Scheme 340

Scheme 341

1. Assemble the turbine shaft to the torque converter. (Scheme 338): Identifying Turbine Shaft And Torque Converter (Scheme 339): Identifying Torque Converter Turbine Shaft Assembly
2. With the torque converter secured by hand, rotate the turbine shaft. (Scheme 340): Rotating Turbine Shaft Into Torque Converter NOTE: When rotating the turbine shaft, a little force is required depending on the amount of ATF in the torque converter. If the turbine shaft cannot be rotated, burning or seizure of the TCC clutch can be considered, therefore replace the torque converter with a new one.
3. Remove the turbine shaft. (Scheme 341): Identifying Turbine Shaft

Scheme 342

Scheme 343

1. Point the flat surface of the thrust needle bearing downward and place it on the surface plate. (Scheme 342): Identifying Surface Plate
2. With a load applied by hand to the thrust needle bearing, rotate the thrust needle bearing and verify that there is no malfunction (rotation sticking). If there is a malfunction, replace the thrust needle bearing with a new one. (Scheme 343): Checking Thrust Needle Bearing For Malfunction

Scheme 344

Scheme 345

1. Place the front planetary gear on a workbench as shown in the figure. (Scheme 344): Identifying Radial Needle Bearing
2. Rotate the pinion gears by hand and verify that there is no malfunction in the radial needle bearing in the pinion gear (rotation sticking). CAUTION: Verify for all the pinion gears. If there is a malfunction, replace the front planetary gear with a new one. (Scheme 345): Rotating Radial Needle Bearing

Scheme 346

Scheme 347

Scheme 348

1. Place the front planetary gear on a workbench as shown in the figure. see scheme 441: Identifying Thrust Needle Bearing
2. Assemble the front sun gear to the front planetary gear. (Scheme 346): Identifying Front Sun Gear And Front Planetary Gear (Scheme 347): Identifying Front Sun Gear To Front Planetary Gear Assembly
3. With a load applied by hand to the front sun gear, rotate the front sun gear and verify that there is no malfunction in the thrust needle bearing (rotation sticking). If there is a malfunction, replace the front planetary gear with a new one. (Scheme 348): Checking Front Planetary Gear For Malfunction
4. Remove the front sun gear. see scheme 445: Identifying Front Sun Gear

Scheme 349

1. Visually verify that all of the following washers are between the pinion gear and planetary carrier for one pinion gear. CAUTION: Verify for all the pinion gears. Copper washer (outer side): 2 Iron washer (inner side): 2 (Scheme 349): Identifying Copper Washer (Outer Side) And Iron Washer (Inner Side) Even if one of the washers is damaged, replace the front planetary gear with a new one.

Scheme 350

1. Place the front planetary gear on a workbench as shown in the figure. see scheme 447: Identifying Front Planetary Gear
2. Measure the gap between the pinion washer and planetary carrier. CAUTION: Measure for all the pinion gears. NOTE: Recommended measuring instrument: Thickness gauge Maximum: 0.879 mm {0.0346 in} (Scheme 350): Identifying Gap Between Pinion Washer And Planetary Carrier If it is more than the maximum specification, replace the front planetary gear with a new one.

Scheme 351

Scheme 352

1. Place the rear planetary gear with the front internal gear side pointing upward on a workbench. (Scheme 351): Identifying Rear Planetary Gear
2. Rotate the pinion gears by hand and verify that there is no malfunction in the radial needle bearing in the pinion gear (rotation sticking). CAUTION: Verify for all the pinion gears. If there is a malfunction, disassemble the rear planetary gear and replace the rear planetary carrier with a new one. (See «REAR PLANETARY GEAR DISASSEMBLY»(ref-537680-S22703105512013032500000).) (See «REAR PLANETARY GEAR ASSEMBLY»(ref-537680-S22006824812013032500000).) (Scheme 352): Rotating Pinion Gears

Scheme 353

Scheme 354

Scheme 355

Scheme 356

1. Place the rear planetary gear with the front internal gear side pointing upward on a workbench. see scheme 451: Identifying Rear Planetary Gear
2. Assemble the rear sun gear to the rear planetary gear. (Scheme 353): Identifying Rear Sun Gear (Scheme 354): Identifying Rear Sun Gear To Rear Planetary Gear Assembly
3. With a load applied by hand to the rear sun gear, rotate the rear sun gear and verify that there is no malfunction in the thrust needle bearing (rotation sticking). If there is a malfunction, disassemble the rear planetary gear and replace the rear planetary carrier with a new one. (See «REAR PLANETARY GEAR DISASSEMBLY»(ref-537680-S22703105512013032500000).) (See «REAR PLANETARY GEAR ASSEMBLY»(ref-537680-S22006824812013032500000).) (Scheme 355): Checking Rear Sun Gear For Malfunction
4. Remove the rear sun gear. (Scheme 356): Identifying Rear Sun Gear

Scheme 357

1. Visually verify that all of the following washers are between the pinion gear and planetary carrier for one pinion gear. CAUTION: Verify for all the pinion gears. Copper washer (outer side): 2 Iron washer (inner side): 2 (Scheme 357): Identifying Copper Washer (Outer Side) And Iron Washer (Inner Side) Even if one of the washers is damaged, disassemble the rear planetary gear and replace the rear planetary carrier with a new one. (See «REAR PLANETARY GEAR DISASSEMBLY»(ref-537680-S22703105512013032500000).) (See «REAR PLANETARY GEAR ASSEMBLY»(ref-537680-S22006824812013032500000).)

Scheme 358

Scheme 359

1. Place the rear planetary gear with the front internal gear side pointing downward on a workbench. (Scheme 358): Identifying Rear Planetary Gear
2. Measure the gap between the pinion washer and planetary carrier. CAUTION: Measure for all the pinion gears. NOTE: Recommended measuring instrument: Thickness gauge Maximum: 0.879 mm {0.0346 in} (Scheme 359): Identifying Gap Between Pinion Washer And Planetary Carrier If it is more than the maximum specification, disassemble the rear planetary gear and replace the rear planetary carrier with a new one. (See «REAR PLANETARY GEAR DISASSEMBLY»(ref-537680-S22703105512013032500000).) (See «REAR PLANETARY GEAR ASSEMBLY»(ref-537680-S22006824812013032500000).)

Scheme 360

Scheme 361

1. Place the reduction planetary gear with the rear internal gear side pointing downward on a workbench. (Scheme 360): Identifying Reduction Planetary Gear
2. Rotate the pinion gears by hand and verify that there is no malfunction in the radial needle bearing in the pinion gear (rotation sticking). CAUTION: Verify for all the pinion gears. If there is a malfunction, disassemble the reduction planetary gear and replace the reduction planetary carrier with a new one. (See «REDUCTION PLANETARY GEAR DISASSEMBLY»(ref-537680-S09422845562013032500000).) (See «REDUCTION PLANETARY GEAR ASSEMBLY»(ref-537680-S41760707712013032500000).) (Scheme 361): Rotating Pinion Gears

Scheme 362

1. Visually verify that all of the following washers are between the pinion gear and planetary carrier for one pinion gear. CAUTION: Verify for all the pinion gears. Copper washer: 2 (Scheme 362): Identifying Copper Washers Even if one of the washers are damaged, disassemble the reduction planetary gear and replace the reduction planetary carrier with a new one. (See «REDUCTION PLANETARY GEAR DISASSEMBLY»(ref-537680-S09422845562013032500000).) (See «REDUCTION PLANETARY GEAR ASSEMBLY»(ref-537680-S41760707712013032500000).)

Scheme 363

1. Place the reduction planetary gear with the rear internal gear side pointing downward on a workbench. see scheme 462: Identifying Reduction Planetary Gear
2. Measure the gap between the pinion washer and planetary carrier. CAUTION: Measure for all the pinion gears. NOTE: Recommended measuring instrument: Thickness gauge Maximum: 0.820 mm {0.0322 in} (Scheme 363): Identifying Gap Between Pinion Washer And Planetary Carrier If it is more than the maximum specification, disassemble the reduction planetary gear and replace the reduction planetary carrier with a new one. (See «REDUCTION PLANETARY GEAR DISASSEMBLY»(ref-537680-S09422845562013032500000).) (See «REDUCTION PLANETARY GEAR ASSEMBLY»(ref-537680-S41760707712013032500000).)

Scheme 364

1. Measure the inner diameter of the bush shown in the figure. NOTE: When measuring, measure near the center of the bush avoiding the oil groove, and then calculate the average value of the X and Y directions as shown in the figure. Recommended measuring instrument: Cylinder gauge or caliper gauge (Scheme 364): Identifying Bush Inner Diameter Maximum: 35.095 mm {1.3816 in} If it is more than the maximum specification, disassemble the reduction planetary gear and replace the reduction planetary carrier with a new one. (See «REDUCTION PLANETARY GEAR DISASSEMBLY»(ref-537680-S09422845562013032500000).) (See «REDUCTION PLANETARY GEAR ASSEMBLY»(ref-537680-S41760707712013032500000).)

Scheme 365

Scheme 366

Scheme 367

Scheme 368

Scheme 369

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

1. Place the secondary gear and output gear with the output gear side pointing upward on a workbench. (Scheme 365): Identifying Secondary Gear And Output Gear
2. Assemble the bearing race to the secondary gear and output gear. NOTE: Bearing race size: Outer diameter approx. 75 mm {3.0 in} (Scheme 366): Identifying Bearing Race (Scheme 367): Identifying Bearing Race Assembled With Secondary Gear And Output Gear
3. With a load applied by hand to the bearing race, rotate the bearing race and verify that there is no malfunction in the taper roller bearing (rotation sticking). If there is a malfunction, disassemble the secondary gear and output gear and replace the taper roller bearing with a new one. (See «SECONDARY GEAR AND OUTPUT GEAR DISASSEMBLY»(ref-537680-S17909404632013032500000).) (See «SECONDARY GEAR AND OUTPUT GEAR ASSEMBLY»(ref-537680-S05448670962013032500000).) (Scheme 368): Checking Taper Roller Bearing For Malfunction
4. Remove the bearing race. (Scheme 369): Identifying Bearing Race
5. Place the secondary gear and output gear with the output gear side pointing downward on a workbench. (Scheme 370): Identifying Secondary Gear And Output Gear
6. Assemble the bearing race to the secondary gear and output gear. NOTE: Bearing race size: Outer diameter approx. 70 mm {2.8 in} (Scheme 371): Identifying Bearing Race (Scheme 372): Identifying Bearing Race Assembled With Secondary Gear And Output Gear
7. With a load applied by hand to the bearing race, rotate the bearing race and verify that there is no malfunction in the taper roller bearing (rotation sticking). If there is a malfunction, disassemble the secondary gear and output gear and replace the taper roller bearing with a new one. (See «SECONDARY GEAR AND OUTPUT GEAR DISASSEMBLY»(ref-537680-S17909404632013032500000).) (See «SECONDARY GEAR AND OUTPUT GEAR ASSEMBLY»(ref-537680-S05448670962013032500000).) (Scheme 373): Checking Taper Roller Bearing For Malfunction
8. Remove the bearing race. (Scheme 374): Identifying Bearing Race

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

1. Place the ring gear and differential with the ring gear side pointing upward on a workbench. (Scheme 375): Identifying Ring Gear And Differential
2. Assemble the bearing race to the ring gear and differential. NOTE: Bearing race size: Outer diameter approx. 80 mm {3.1 in} (Scheme 376): Identifying Bearing Race (Scheme 377): Identifying Bearing Race Assembled With Ring Gear And Differential
3. With a load applied by hand to the bearing race, rotate the bearing race and verify that there is no malfunction in the taper roller bearing (rotation sticking). If there is a malfunction, disassemble the ring gear and differential and replace the taper roller bearing with a new one. (See «RING GEAR AND DIFFERENTIAL DISASSEMBLY»(ref-537680-S12512712582013032500000).) (See «RING GEAR AND DIFFERENTIAL ASSEMBLY»(ref-537680-S28398192182013032500000).) (Scheme 378): Checking Taper Roller Bearing For Malfunction
4. Remove the bearing race. (Scheme 379): Identifying Bearing Race
5. Place the ring gear and differential with the ring gear side pointing downward on a workbench. (Scheme 380): Identifying Ring Gear And Differential
6. Assemble the bearing race to the ring gear and differential. NOTE: Bearing race size: Outer diameter approx. 80 mm {3.1 in} (Scheme 381): Identifying Bearing Race (Scheme 382): Identifying Bearing Race Assembled With Ring Gear And Differential
7. With a load applied by hand to the bearing race, rotate the bearing race and verify that there is no malfunction in the taper roller bearing (rotation sticking). If there is a malfunction, disassemble the ring gear and differential and replace the taper roller bearing with a new one. (See «RING GEAR AND DIFFERENTIAL DISASSEMBLY»(ref-537680-S12512712582013032500000).) (See «RING GEAR AND DIFFERENTIAL ASSEMBLY»(ref-537680-S28398192182013032500000).) (Scheme 383): Checking Taper Roller Bearing For Malfunction
8. Remove the bearing race. (Scheme 384): Identifying Bearing Race

Scheme 385

Scheme 386

1. Measure the inner diameter of the journal (front side) shown in the figure. NOTE: When measuring, measure near the center of the journal avoiding the oil groove, and then calculate the average value of the X and Y directions as shown in the figure. Recommended measuring instrument: Cylinder gauge or caliper gauge Maximum: 30.046 mm {1.1829 in} (Scheme 385): Identifying Inner Diameter Of Differential Journal (Front Side) If it is more than the maximum specification, 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).)
2. Measure the inner diameter of the journal (rear side) shown in the figure. NOTE: When measuring, measure near the center of the journal avoiding the oil groove, and then calculate the average value of the X and Y directions as shown in the figure. Recommended measuring instrument: Cylinder gauge or caliper gauge Maximum: 30.046 mm {1.1829 in} (Scheme 386): Identifying Inner Diameter Of Differential Journal (Rear Side) If it is more than the maximum specification, 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).)