General notes — Part 1 Mazda 6 GG facelift

General notes

1. The oil pan could contain small chips, shavings, and other particles which may be helpful in inspecting the condition of the transaxle and diagnosing certain problems. To ensure that all foreign particles stay in the oil pan, make sure that the transaxle is never tipped completely over while the oil pan is still installed. Disassemble the transaxle in a clean area (dustproof work space) to prevent entry of dust into the mechanisms. Inspect the individual transaxle components in accordance with the QUICK DIAGNOSIS CHART during disassembly. Use only plastic hammers when applying force to separate the light alloy case joints. Never use rags during disassembly; they may leave particles that can clog fluid passage. Several parts resemble one another; arrange them so that they do not get mixed up. Disassemble the control valve component and thoroughly clean it when the clutch or brake band has burned or when the ATF has degenerated. WARNING: Although the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.

Scheme 918

Scheme 919

Scheme 920

Scheme 921

Scheme 922

Scheme 923

Scheme 924

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Scheme 927

Scheme 928

Scheme 929

Scheme 930

Scheme 931

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Scheme 942

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Scheme 945

Scheme 946

Scheme 947

Scheme 948

Scheme 949

Scheme 950

Scheme 951

Scheme 952

Scheme 953

Scheme 954

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Scheme 956

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Scheme 958

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Scheme 961

Scheme 962

Scheme 963

Scheme 964

Scheme 965

Scheme 966

1. Remove the torque converter, and immediately turn it so that the hole faces upward This will help to keep any remaining fluid from spilling.
2. Remove the ATF dipstick and oil filler tube.
3. Remove the O-ring from the oil filler tube.
4. Remove the breather hose.
5. Assemble the SST.
6. Lift the transaxle and mount it on the SST.
7. Remove the input/turbine speed sensor.
8. Remove the O-ring from the input/turbine speed sensor.
9. Remove the oil pressure switch.
10. Remove the transaxle range switch.
11. Remove the vehicle speed sensor.
12. Remove the O-ring from the vehicle speed sensor.
13. Remove the intermediate sensor.
14. Remove the O-ring from the intermediate sensor.
15. Remove the connector pipe, connector bolt and oil pipe. WARNING: Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil cover, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil cover, and clean with cleaning fluids.
16. Remove the oil cover. Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause. Clutch facing material Drive plate and brake band wear Steel (magnetic) Bearing, gear, and driven plate wear Aluminum (nonmagnetic) Aluminum part wear
17. Disconnect the solenoid valve connector.
18. Remove the bolts as shown in the figure.
19. Remove the secondary control valve body.
20. Remove the coupler component.
21. Remove the O-rings and tubular pins from the transaxle case. WARNING: Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil pan, and clean with cleaning fluids.
22. Remove the oil pan. Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause. Clutch facing material Drive plate and brake band wear Steel (magnetic) Bearing, gear, and driven plate wear Aluminum (nonmagnetic) Aluminum part wear
23. Disconnect the solenoid valve connector, ground, and TFT sensor.
24. Remove the oil strainer.
25. Remove the O-ring from the oil strainer.
26. Remove the bolts as shown in the figure. NOTE: Remove the control valve body by removing the head of the manual valve from the port of the parking assist lever component.
27. Remove the Primary control valve body.
28. Remove the coupler component.
29. Remove the accumulator component.
30. Remove the manual shaft. Remove the roll pin using a pin punch. Remove the manual shaft. Remove the O-ring from the manual shaft.
31. Remove the parking rod lever component.
32. Remove the band servo component.
33. Remove the oil pump.
34. Remove the converter housing by tapping lightly with a plastic hammer.
35. Remove the forward clutch component.
36. Remove the differential.
37. Remove the actuator plate.
38. Remove the support actuator.
39. Pull out the parking pawl shaft.
40. Remove the parking pawl.
41. Remove the pawl return spring.
42. Remove the Output gear component.
43. Remove the Secondary sun gear.
44. Remove the direct clutch component and one-way clutch No.2.
45. Remove the Needle bearing, seal rings and spacer.
46. Remove the reduction brake.(See «REDUCTION BRAKE DISASSEMBLY/ ASSEMBLY»(ref-277058-S30044060012008011500000) .)
47. Remove the end cover.
48. Remove the O-rings from the transaxle case.
49. Remove the band strut.
50. Remove the 2-4 brake band, and hold it together using a piece of wire as shown in the figure.
51. Remove the clutch component.
52. Remove the snap ring.
53. Remove the rear planetary gear component.
54. Remove the front sun gear by tapping its end with a flathead screwdriver or similar tool, as shown in the figure.
55. Remove the forward clutch hub.
56. Remove the front planetary gear component.
57. Remove the front internal gear and one-way clutch component.
58. Remove the locknut. Knock the crimped portion of the locknut outward by using a small chisel and a hammer. Install the SST to the primary gear in the order shown. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf} Install the SST to the locknut in the order shown. Remove the locknut.
59. Remove the primary gear by tapping it with a flathead screwdriver, etc. as shown in the figure.
60. Remove the bearing and distance piece. CAUTION: Removing the bearing race using a flathead screwdriver can damage the inside of the bearing race. Handle the flathead screwdriver carefully.
61. Remove torx screws from the converter housing side.
62. Remove the bearing race.
63. Remove the bearing race using the SST as shown in the figure.
64. Remove the bearing using the SST as shown in the figure.

Scheme 967

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Scheme 968

Scheme 969

1. Measure the spring free length. Accumulator spring (standard) ACCUMULATOR SPRING SPECIFICATIONS 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} If not as specified, replace the spring.
2. Install the forward accumulator small spring, forward accumulator large spring and forward accumulator.
3. Install the servo apply accumulator small spring, servo apply accumulator large spring and servo apply accumulator.

1. Select the adjustment shims, referring to Bearing Preload.
2. If the drive plates or 2-4 brake band are replaced with new ones, soak the new part in ATF for at least two hours before installation.
3. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
4. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
5. Use petroleum jelly, not grease, when assembling again.
6. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
7. Assemble the housing within 10 minutes after applying sealant, and allow it to cure for at least 30 minutes after assembly before filling the transaxle with ATF.

Scheme 970

Note. The bearing and race at locations 3, 4, 5, 6 and 7 are one-piece units.

Outer diameter of bearing and race

OUTER DIAMETER OF BEARING AND RACE

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Scheme 981