Removal & Installation - A/t: Removal & Installation Mazda Millenia I

Removal (1997 Models)

1. Disconnect negative battery cable. Raise and support vehicle. Drain transmission fluid. On 3.0L engines, remove lower converter cover. On all engines, remove starter. Remove torque converter bolts. Torque converter nuts on 2.3L and 4.0L engines are accessed through starter mounting opening.
2. On 2.3L engines, DO NOT rotate crankshaft counterclockwise. Engine damage may occur. On all engines, remove front exhaust pipe. Mark drive shaft(s) for reassembly reference, and remove drive shaft(s). Install plug in rear of transmission to prevent fluid leakage.
3. Remove vehicle speed sensor from transmission. Remove selector cable, transmission range sensor and solenoid valve connectors from transmission. Disconnect electrical connectors and oil cooler lines.
4. Support transmission using jack. Remove crossmember. Remove transfer case linkage (if equipped). Lower transmission slightly. Using another jack, slightly raise front of engine to access upper engine-to-transmission bolts, but DO NOT remove bolts yet.
5. Remove lower converter housing-to-engine bolts. Remove dipstick tube. Remove upper engine-to-transmission bolts. Slowly lower transmission.

1. To install transmission, reverse removal procedure. Ensure selector cable is adjusted correctly. Ensure torque converter is fully seated before installing transmission. Torque converter is correctly seated when distance between engine mating surface of converter housing and face of converter drive lug is .40-.57" (10.2-14.4 mm).
2. Tighten torque converter nuts to specification. See «TORQUE SPECIFICATIONS (B-SERIES)»(ref-2432-S24074779002000031800000) . Fill transmission with required amount of fluid, and check for external leaks.

Removal & Installation (1998 Models)

1. Disconnect negative battery cable. Raise and support vehicle. Drain transmission fluid. Remove transfer case (if equipped). Mark drive shaft(s) for reassembly reference, and remove drive shaft(s).
2. Remove starter. Remove torque converter bolts. Disconnect shift cable. Disconnect electrical connectors and harnesses. Remove catalytic converter. Remove transmission cooler lines. Remove rear transmission mount and crossmember.
3. Remove dipstick/filler tube. Remove bellhousing bolts. Install Torque Converter Holder (T97T-7902-A ). Remove transmission from vehicle. To install transmission, reverse removal procedure.

1. Disconnect negative battery cable. Raise and support vehicle. Drain transmission fluid. Remove shift rod and undercover. Remove front exhaust pipe. Mark drive shaft for reassembly reference and remove drive shaft. Install plug in rear of transmission to prevent fluid leakage.
2. Disconnect speedometer cable, vacuum hose and electrical connectors from transmission. Remove dipstick tube. Disconnect oil cooler lines from transmission. Disconnect wire harness from Power Plant Frame (PPF) connecting transmission to differential.
3. Support transmission using jack. Remove front and rear bolts from power plant frame, and pry out rear bolt spacer. Remove differential mounting spacer bolts, but leave spacers in place. CAUTION: DO NOT remove spacers from top rear of PPF. If spacers are removed, replace entire PPF unit as an assembly.
4. Screw bolt (M14 x 1.5) into rear sleeve (forward bolt hole). (Scheme 269) Twist and pull bolt downward to position sleeve in block. Install bolt (M6 x 1) in hole on side of power plant frame block to hold sleeve in place. Remove long bolt. Remove short bolt. Remove PPF.
5. Remove torque converter bolts and starter. Remove transmission mount bolts, and lower transmission. DO NOT shake transmission during removal or damage to crank angle sensor may result.

Scheme 269

Scheme 270

1. Install transmission, transmission mount and starter. Install torque converter bolts. Install Power Plant Frame (PPF) rear differential mounting spacer.
2. Support transmission until level. Position PPF and hand-tighten transmission side bolts. Ensure sleeve is installed in block. (Scheme 269) Install spacer and hand tighten bolts. Ensure reamer bolt goes in forward hole.
3. Tighten front, then rear PPF bolts to specification. See «TORQUE SPECIFICATIONS (MIATA)»(ref-2432-S30191723782000031800000). Remove jack. Ensure clearance between bottom of PPF and lowest point of body frame is 2.0-2.4" (51-61 mm). (Scheme 270)
4. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS (MIATA)»(ref-2432-S30191723782000031800000). Fill transmission with required amount of fluid, and check for external leaks.

Scheme 271

1. Disconnect negative and positive battery cables. Drain transmission fluid. Remove battery cover, battery and tray. Remove rear charge air cooler duct. Remove air cleaner assembly including resonance chamber.
2. Remove shift selector cable retaining clip. Disconnect shifter cable end at transaxle range switch lever. Remove connectors at output speed sensor, transaxle range switch and solenoid valves. Remove harness bracket and selector cable bracket. Remove rear intercooler. Remove bracket and starter
3. Disconnect VSS connector. Remove front intercooler and cooling fan. Raise and support vehicle. Remove front wheels. Remove left front hub lock nut. Remove splash shields. Remove fresh air duct and disconnect exhaust pipe ("Y" pipe). Unbolt lower ball joints from lower control arms.
4. Disconnect left upper lateral link and lower control arm. Remove right inner and outer drive shaft. Disconnect stabilizer control link. Remove left drive shaft. See appropriate AXLES SHAFTS article in AXLE SHAFTS & TRANSFER CASES.
5. Remove timing belt and accessory drive belts. Unbolt and set aside power steering pump and air conditioning compressor. DO NOT disconnect power steering or air conditioning lines. Disconnect shift selector rod. Remove dipstick tube. Support engine and loosen No. 3 engine mount bolt on fender. (Scheme 271) Remove No. 4 engine mount. Remove nut and damper from No. 1 engine mount. Remove No. 2 engine mount nut.
6. Gain access to torque converter. Rotate torque converter and remove torque converter nuts at flywheel. Remove No. 1 engine mount bolt and engine mount crossmember. Disconnect oil cooler hoses. Support transaxle with appropriate jack and remove bolts securing transaxle to engine. Remove transaxle from vehicle.

Removal - 2.5L

1. Disconnect negative and positive battery cables. Drain transmission fluid. Remove battery cover, battery and tray. Remove air cleaner assembly. Remove shift selector cable retaining clip. Disconnect shifter cable end at transaxle range switch lever. Disconnect transaxle range switch, turbine/output speed sensor and shift solenoid harness connectors. Unbolt electrical harness bracket and selector cable bracket. Disconnect No. 1 engine mount strut.
2. Remove starter. Disconnect vehicle speed sensor harness connector. Disconnect both oxygen sensor harness connectors. Raise and support vehicle. Remove front wheels. Remove all plastic splash shields and undercover panel. Unbolt and remove exhaust pipe ("Y" pipe). Disconnect and separate upper lateral link from left steering knuckle. Unbolt lower ball joints from lower control arms. Using a brass drift and hammer, drive off right side axle inner joint from joint shaft. Remove joint shaft. Insert differential side gear plug once joint axle is removed.
3. Install appropriate engine support and remove mount on rear of transaxle. Remove engine mount at bellhousing of transaxle. Remove lower mount and crossmember. Remove oil cooler line banjo bolts at transaxle. Remove remaining undercover panels. Remove lower access panel at bellhousing. Rotate torque converter and remove torque converter nuts at flywheel.
4. Separate left side axle from transaxle by prying with appropriate pry bar inserted between outer ring and transaxle case. Insert differential side gear plug once axle is removed. Remove bolts securing transaxle to engine. Support transaxle with appropriate jack and remove transaxle from vehicle.

Installation (2.3L & 2.5L)

To install transaxle, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS (MILLENIA) . Fill transaxle with required amount of fluid, and check for external leaks.