Removal & Installation - A/t: Removal & Installation Mazda MPV II

Installation (2.3L & 2.5L)

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

1. Disconnect negative battery cable. Remove battery, battery tray and battery carrier. Remove air cleaner assembly. Raise and support vehicle. Remove front wheels. Remove splash shield and starter. Drain transmission fluid into proper container. Disconnect speedometer cable. Disconnect solenoid valve, transmission range switch, input/turbine speed sensor connections, and remove harness bracket.
2. Remove engine mount and transaxle crossmembers. Disconnect vehicle speed sensor. Using Special Tool (49-TO28-3AO), separate tie rod end from lower control arm. Remove lower control arm and axle shaft. Remove shift linkage or selector cable. Remove torque converter undercover and torque converter bolts. Disconnect transmission oil cooler lines.
3. Support transmission using appropriate jack. Remove transmission mounting bolts, and slowly remove transmission. To install transmission, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151370-S01099208872002121600000) . Fill transmission with required amount of fluid, and check for external leaks.

Scheme 263

1. Disconnect negative battery cable. Remove battery and battery tray. Disconnect ground connections at transaxle. Remove fresh air duct. Remove air cleaner assembly. Raise and support vehicle. Remove front wheels. Remove splash shields. Drain transmission fluid into proper container. Remove harness brackets. Disconnect connectors from valve body solenoids, transaxle range switch and turbine shaft speed sensor. Disconnect dipstick tube and fuel filter mounting nut.
2. Disconnect shift control cable. Remove No. 1 engine mount nut, isolator and stay bracket. (Scheme 263) Support engine, and remove No. 4 engine mount. Remove crossmember.
3. Disconnect vehicle speed sensor connector. Mark position of front bushings for reassembly reference and remove longitudinal engine mount crossmember. Disconnect tie rod end and stabilizer end link. Remove lower control arm. Remove left axle shaft. See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER CASES. Remove right inner axle shaft.
4. Remove intake manifold bracket and starter. Gain access to torque converter and remove torque converter-to-flywheel nuts. Remove No. 5 engine mount bracket. Disconnect No. 2 engine mount. Disconnect oil cooler hoses. Lower engine and lean engine toward transaxle. Support transaxle by using appropriate jack. Remove transaxle-to-engine bolts and lower transaxle.

Removal - 2.5L (GF4A-EL)

1. Disconnect negative battery cable. Remove battery and battery tray. Remove fresh air duct. Remove air cleaner assembly. Raise and support vehicle. Drain transmission fluid into proper container. Remove front wheels, engine undercover and splash shields. Disconnect shift selector cable.
2. Remove bolts securing transaxle harness brackets. Disconnect transmission range switch, shift solenoid valve, turbine shaft speed sensor and vehicle speed sensor harness connectors. Disconnect all ground cable connections from transaxle. Disconnect starter harness. Remove No. 1 engine mount stay bracket. (Scheme 263) Unbolt fuel filter, and wire aside.
3. Drain fluid, and disconnect oil cooler outlet and inlet lines. Disconnect breather hose. Disconnect tie rod ends from knuckles, and remove stabilizer bar control links.
4. Remove bolts and nuts at left and right lower control arm ball joints. Pull lower arms downward to separate from knuckles. DO NOT damage ball joint dust boots. Separate left axle shaft from transaxle using pry bar inserted between shaft and case. DO NOT damage oil seal.
5. Remove engine mount transverse crossmember. Remove joint shaft bracket, and remove right drive shaft with joint shaft. Install Differential Side Gear Holder (49 G030 455) into differential side gear opening (to prevent side gears from becoming misaligned).
6. Support engine from above using proper engine support assembly, and take up weight of engine. Remove No. 5 engine mount bracket. Remove No. 1 engine mount bolts and engine mount crossmember. Mark front crossmember bushings for reassembly reference. Remove torque converter access cover and torque converter nuts. Remove starter.
7. Disconnect and remove No. 4 engine mount. Lower engine assembly slightly. Support transaxle using transmission jack from below. Remove transaxle-to-engine mounting bolts, and remove transaxle from vehicle.

Installation (2.0L & 2.5L)

To install transaxle, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. On 2.0L, refer to illustration for transaxle-to-engine mounting bolt identification. (Scheme 264) On all models, install NEW clips on axle ends before installing axle shafts. Fill transaxle with required amount of fluid, and check for external leaks.

Scheme 264

1. Disconnect negative battery cable. Remove battery and battery tray. Raise and support vehicle. Remove wheels and splash shields. Disconnect air hose, and remove air cleaner and resonance chamber. Drain transmission fluid into proper container. Remove EGR pipe and front exhaust
2. Disconnect throttle cable assembly from transaxle. Disconnect transaxle range switch, speed sensor and solenoid valve connectors. Disconnect and remove selector cable. Remove dipstick and filler tube. Disconnect and plug oil cooler lines.
3. Support engine from above using engine support assembly. Remove engine mounts. Remove crossmember member. Disconnect tie rod ends from knuckles. Remove lower ball joint cinch bolts and pry lower control arms from knuckle. Remove lower control arm.
4. Separate left axle shaft from transaxle using pry bar inserted between axle shaft and case. DO NOT damage oil seal. Separate right axle shaft or intermediate shaft from transaxle. Remove starter. Support transaxle from below using transmission jack.
5. Remove front torque converter housing access plates and cover. Mark converter to drive plate for reassembly reference, and remove torque converter bolts. Slightly lower engine using engine support from above. Remove transaxle-to-engine bolts, and lower transaxle assembly from vehicle.

To install transaxle, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Refer to illustration for transaxle-to-engine mounting bolt identification. (Scheme 265) Install NEW clips on axle ends before installing axle shafts. Fill transaxle with required amount of fluid, and check for external leaks.

Scheme 265

1. Disconnect negative and positive battery cables. Remove battery and tray. Disconnect breather tube and mass air flow (MAF)/intake air temperature (IAT) sensor. Remove intake tube and air cleaner cover. Remove air cleaner assembly.
2. Disconnect transaxle range sensor. Disconnect HO2S sensors. Disconnect transaxle harness connector and remove wire harness bracket nut. Position wire harness bracket aside and remove spacer.
3. Unclip wire harness and disconnect shift cable. Remove hift cable and bracket, and position aside. Disconnect starter motor harness connector. Disconnect ground wire.
4. Remove starter bolts and starter motor. Remove electrical connectors from valve cover to gain access to engine lifting bracket. Support engine from above using engine support assembly. Remove upper transaxle retaining bolts.
5. Remove left upper transaxle mount plate. Remove bolts, and rear transaxle mount. Remove right engine mount bolt. It is necessary to raise engine a couple of inches in order to remove transaxle. Raise and support vehicle. Remove front wheels and splash shields.
6. If transaxle disassembly is necessary, drain fluid into a suitable container. Mark mounting bracket studs and intermediate shaft bearing bracket holes for reassembly reference. Remove right halfshaft, intermediate shaft bearing, and intermediate shaft assembly. Remove left halfshaft assembly. Remove cross brace. Remove exhaust pipe.
7. Disconnect front exhaust pipe flange. Disconnect rear exhaust pipe flange and remove exhaust pipe. Remove bolts and driveshafts. Squeeze tabs and remove power take off (PTO) unit vent tube. On 4WD vehicles, remove alternator, bracket, and rear exhaust manifold assembly.
8. Remove bolts from bracket. Remove bolts and bracket. Remove cross brace. Lower vehicle. Lower transaxle enough to clear subframe. Raise and support vehicle. Remove access cover. Remove flexplate nuts. Remove fluid cooler tube and line. CAUTION: Torque converter is heavy. Install special tool before lowering transaxle.
9. Install transaxle jack and support transaxle to jack. Remove bolts. Remove rear transaxle mount and place a suitable jack under engine. Then remove driver's side transaxle mount. This will reduce risk of engine movement during separation of transaxle assembly from engine. Remove bolts. Move transaxle back far enough to install special tool. Lower transaxle from engine compartment with PTO unit attached.

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