Automatic Transaxle - Overhaul (FW6A-EL): Specifications Mazda CX-5 I

TORQUE CONVERTER INSPECTION

Scheme 1

Scheme 2

Scheme 3

Scheme 4

1. Assemble the turbine shaft to the torque converter. (Scheme 1): Identifying Turbine Shaft And Torque Converter (Scheme 2): Identifying Torque Converter Turbine Shaft Assembly
2. With the torque converter secured by hand, rotate the turbine shaft. (Scheme 3): 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 4): Identifying Turbine Shaft

Scheme 5

Scheme 6

1. Point the flat surface of the thrust needle bearing downward and place it on the surface plate. (Scheme 5): 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 6): Checking Thrust Needle Bearing For Malfunction

Scheme 7

Scheme 8

1. Place the front planetary gear on a workbench as shown in the figure. (Scheme 7): 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 8): Rotating Radial Needle Bearing

Scheme 9

Scheme 10

Scheme 11

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 9): Identifying Front Sun Gear And Front Planetary Gear (Scheme 10): 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 11): Checking Front Planetary Gear For Malfunction
4. Remove the front sun gear. see scheme 445: Identifying Front Sun Gear

Scheme 12

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 12): 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 13

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 13): 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 14

Scheme 15

1. Place the rear planetary gear with the front internal gear side pointing upward on a workbench. (Scheme 14): 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 15): Rotating Pinion Gears

Scheme 16

Scheme 17

Scheme 18

Scheme 19

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 16): Identifying Rear Sun Gear (Scheme 17): 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 18): Checking Rear Sun Gear For Malfunction
4. Remove the rear sun gear. (Scheme 19): Identifying Rear Sun Gear

Scheme 20

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 20): 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 21

Scheme 22

1. Place the rear planetary gear with the front internal gear side pointing downward on a workbench. (Scheme 21): 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 22): 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 23

Scheme 24

1. Place the reduction planetary gear with the rear internal gear side pointing downward on a workbench. (Scheme 23): 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 24): Rotating Pinion Gears

Scheme 25

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 25): 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 26

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 26): 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 27

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 27): 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 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Place the secondary gear and output gear with the output gear side pointing upward on a workbench. (Scheme 28): 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 29): Identifying Bearing Race (Scheme 30): 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 31): Checking Taper Roller Bearing For Malfunction
4. Remove the bearing race. (Scheme 32): Identifying Bearing Race
5. Place the secondary gear and output gear with the output gear side pointing downward on a workbench. (Scheme 33): 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 34): Identifying Bearing Race (Scheme 35): 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 36): Checking Taper Roller Bearing For Malfunction
8. Remove the bearing race. (Scheme 37): Identifying Bearing Race

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Place the ring gear and differential with the ring gear side pointing upward on a workbench. (Scheme 38): 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 39): Identifying Bearing Race (Scheme 40): 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 41): Checking Taper Roller Bearing For Malfunction
4. Remove the bearing race. (Scheme 42): Identifying Bearing Race
5. Place the ring gear and differential with the ring gear side pointing downward on a workbench. (Scheme 43): 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 44): Identifying Bearing Race (Scheme 45): 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 46): Checking Taper Roller Bearing For Malfunction
8. Remove the bearing race. (Scheme 47): Identifying Bearing Race

Scheme 48

Scheme 49

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 48): 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 49): 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).)