Automatic Transaxle - Service, Removal & Installation [JA5AEL]: Removal & Installation Mazda MPV II рестайлинг

AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT

Scheme 202

1. Remove the oil dipstick.
2. Remove the oil drain plug and washer.
3. Drain the ATF into a container.
4. Install a new washer and the drain plug. Tightening Torque 39-54 N.m {3.9-5.6 kgf.m, 29-40 ft.lbf}
5. Add the specified type of ATF through the oil filler tube, until ATF level reaches lower notch of dipstick. ATF Type M-III Or Equivalent
6. Verify that the ATF level is in the HOT (65°C {149°F}) range. Add ATF to the specified level as necessary.

O/D OFF SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the steering wheel. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
3. Remove the column cover.
4. Remove the combination switch.
5. Disconnect the connector.
6. Remove the selector lever component.
7. Install the selector lever component. Tightening Torque 7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf}
8. Connect the connector.
9. Install the combination switch.
10. Install the column cover.
11. Install the steering wheel (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
12. Connect the negative battery cable.

TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION

1. Remove the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)
2. Disassemble the automatic transaxle, and then remove the TFT sensor. See «OVERHAUL - JA5A-EL»(ref-178357) .
3. Install a TFT sensor, and then assemble the automatic transaxle. See «OVERHAUL - JA5A-EL»(ref-178357) .
4. Remove the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)
5. Carry out the line pressure test. (See «LINE PRESSURE TEST»(ref-178052-S18792528502005061000000) .)
6. Inspect the operation of the TR switch. (See «TRANSAXLE RANGE (TR) SWITCH INSPECTION»(ref-178052-S39219506732005061000000) .)
7. Inspect the operation of the selector lever. (See SELECTOR LEVER INSPECTION .)
8. Carry out the mechanical system test. (See «MECHANICAL SYSTEM TEST»(ref-178052-S28664009742005061000000) .)
9. Carry out the road test. (See «ROAD TEST»(ref-178052-S24978590142005061000000) .)

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

1. Disconnect the coupler component.
2. Remove the oil dipstick.
3. Insert the thermistor probe into the filler tube.
4. Start the engine.
5. Measure resistance between the terminals G and F. If not as specified, replace the TFT sensor. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)
6. Connect the coupler component.

Scheme 208

Scheme 209

1. Disconnect the terminal component No. 2 connector.
2. Measure resistance between the terminals E and F. If not as specified, inspect the input/turbine speed sensor. (See «INSPECTION OF INDIVIDUAL PART»(ref-178052-S23322834172005061000000) .) Resistance (ATF temperature: 20°C {68°F}) 513-627 Ohms
3. Connect the terminal component No. 2 connector.

Scheme 210

1. Remove the input/turbine speed sensor. (See «INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION»(ref-178052-S31971889702005061000000) .)
2. Measure resistance between the terminals of the input/turbine speed sensor. If not as specified, replace the input/turbine speed sensor. If it is normal, replace the harness. Resistance (ATF Temperature: 20°C {68°F}) 513-627 Ohms
3. Install the input/turbine sensor. (See «INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION»(ref-178052-S31971889702005061000000) .)

INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION

1. Remove the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)
2. Remove the input/turbine speed sensor. See steps 41-42 under «DISASSEMBLY COMPONENTS»(ref-178357-S22046301582005061400000) .
3. Install the input/turbine speed sensor. See step 24-25 under «COMPONENTS»(ref-178357-S10078696822005061400000) .
4. Install the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)

Scheme 211

Scheme 212

1. Disconnect the terminal component No. 2 connector.
2. Measure resistance between the terminals C and D. If not as specified, inspect the intermediate sensor. (See «Inspection Of Individual Part»(ref-178052-S40328906252005061000000) .) Resistance (ATF Temperature: 20°C {68°F}) 513-627 Ohms
3. Connect the terminal component No. 2 connector.

Scheme 213

1. Remove the intermediate sensor. (See «INTERMEDIATE SENSOR REMOVAL/INSTALLATION»(ref-178052-S09185046722005061000000) .)
2. Measure resistance between the terminals of the intermediate sped sensor. If not as specified, replace the intermediate sensor. If it is normal, replace the harness. Resistance (ATF Temperature: 20°C {68°F}) 513-627 Ohms
3. Install the intermediate sensor. (See «INTERMEDIATE SENSOR REMOVAL/INSTALLATION»(ref-178052-S09185046722005061000000) .)

INTERMEDIATE SENSOR REMOVAL/INSTALLATION

1. Remove the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)
2. Remove the intermediate sensor. See steps 14-15 under «DISASSEMBLY COMPONENTS»(ref-178357-S22046301582005061400000) .
3. Install the intermediate sensor. See steps 51-52 under «COMPONENTS»(ref-178357-S10078696822005061400000) .
4. Install the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)

Scheme 214

Scheme 215

1. Disconnect the terminal component No. 2 connector.
2. Measure resistance between the terminals A and B. If not as specified, inspect the VSS. (See «INSPECTION OF INDIVIDUAL PART»(ref-178052-S26205843672005061000000) .) Resistance (ATF Temperature: 20°C {68°F}) 513-627 Ohms
3. Connect the terminal component No. 2 connector.

Scheme 216

1. Remove the VSS. (See «VEHICLE SPEEDOMETER SENSOR (VSS) REMOVAL/INSTALLATION»(ref-178052-S19652015892005061000000) .)
2. Measure resistance between the terminals of the VSS speed sensor. If not as specified, replace the VSS. If it is normal, replace the harness. Resistance (ATF Temperature: 20°C {68°F}) 513-627 Ohms
3. Install the VSS. (See «VEHICLE SPEEDOMETER SENSOR (VSS) REMOVAL/INSTALLATION»(ref-178052-S19652015892005061000000) .)

VEHICLE SPEEDOMETER SENSOR (VSS) REMOVAL/INSTALLATION

1. Remove the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)
2. Remove the VSS. See steps 16-17 under «DISASSEMBLY COMPONENTS»(ref-178357-S22046301582005061400000) .
3. Install the VSS. See steps 48-50 under «COMPONENTS»(ref-178357-S10078696822005061400000) .
4. Install the automatic transaxle. (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION»(ref-178052-S14579927792005061000000) .)

Scheme 217

Scheme 218

Scheme 219

1. Disconnect the negative battery cable.
2. Disconnect the terminal component No. 1 connector.
3. Measure the resistance between the following terminals. If not as specified, inspect each solenoid valve. (See «RESISTANCE INSPECTION (OFF-VEHICLE)»(ref-178052-S30713906842005061000000) .) ATF Temperature: 20°C {68°F}
4. Connect the terminal component No. 1 connector.
5. Connect the negative battery cable.

AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION

The oil pan could contain small chips, shavings, and other particles helpful in checking 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.

Scheme 220

Scheme 221

1. Disconnect the negative battery cable.
2. Drain the ATF into a container. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT»(ref-178052-S24716482602005061000000) .)
3. Remove the battery, battery tray, and battery carrier.
4. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
5. Remove the front wheel and tire.
6. Remove the splash shield.
7. Remove the starter.
8. Remove in the order indicated in the figure.
9. After removal, remove the oil pan to inspect the condition of the transaxle.
10. Install in the reverse order of removal.
11. Install the starter.
12. Install the splash shield.
13. Install the wheel and tire.
14. Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
15. Install the battery carrier, and battery.
16. Fill the transaxle with the specified ATF after installation. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT»(ref-178052-S24716482602005061000000) .)
17. Inspect for leakage of ATF from all connecting points.
18. Connect the negative battery cable.
19. Inspect the operation of the TR switch. (See «TRANSAXLE RANGE (TR) SWITCH INSPECTION»(ref-178052-S39219506732005061000000) .)
20. Inspect the operation of the selector lever. (See SELECTOR LEVER INSPECTION .)
21. Carry out the mechanical system test. (See «MECHANICAL SYSTEM TEST»(ref-178052-S28664009742005061000000) .)
22. Carry out the road test. (See «ROAD TEST»(ref-178052-S24978590142005061000000) .)

Scheme 222

1. Remove the windshield wiper link.
2. Remove the windshield wiper motor.
3. Support the engine using the SSTs .
4. Remove the No. 4 engine mount bracket.

Scheme 223

1. Support the engine on the jack.

Scheme 224

Scheme 225

1. Loosen the SSTs (engine support) and lean the engine toward the transaxle. WARNING: Verify that the transaxle is securely supported by the jack. If the transaxle falls, serious injury or death and damage to the vehicle could result. Before removing the transaxle make sure that the jack is securely supporting it.
2. Support the transaxle on a jack.
3. Remove the transaxle mounting bolts.
4. Remove the transaxle.

TRANSAXLE INSTALLATION NOTE

Scheme 226

Scheme 227

1. Set the transaxle on a jack and lift it into place.
2. Install the transaxle mounting bolts. Tightening Torque 37-52 N.m {3.8 kgf.m, 28-38 ft.lbf}

NO. 1 ENGINE MOUNT INSTALLATION NOTE

1. Use the SSTs (engine support) to make sure the transaxle bolt holes and No. 1 engine mount align.
2. Tighten the bolts to the specified torque.

Scheme 228

Scheme 229

1. Position the direction indicator on engine mount member bushings facing toward the front side, and install the bushings onto the engine mount member.
2. To install the engine mount member, put the No. 2 engine mount stud through the engine mount member installation holes.
3. Install the engine mount member bolts A and nuts A. Tightening Torque A: 64-89 N.m {6.5-9.1 kgf.m, 47-65 ft.lbf}
4. Loosely tighten the No. 2 engine mount nuts B and C.
5. Remove the SSTs (engine support).
6. Tighten the No. 2 engine mount nuts B and C. Tightening Torque B: 67-93 N.m {6.8-9.5 kgf.m, 50-68 ft.lbf} C: 85-116 N.m {8.7-11.9 kgf.m, 63-85 ft.lbf}

ON-VEHICLE REMOVAL

Scheme 230

1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents.
2. Disconnect the negative battery cable.
3. Remove the battery, battery tray, and battery carrier.
4. Remove the air cleaner component.
5. Drain the ATF into separate containers.
6. Remove the splash shield.
7. Remove the oil hose and oil pipe. (See «OIL COOLER REMOVAL/INSTALLATION»(ref-178052-S08016497082005061000000) .)
8. Remove the heater pipe bracket. (See HEATER PIPE AND HOSE COMPONENT REMOVAL/INSTALLATION .)
9. Remove the control valve body cover.
10. Disconnect the solenoid valve connectors, then remove harness clips.
11. Remove the control valve body.

Scheme 231

Scheme 232

1. Position the manual valve so that it protrudes from the control valve body end by 3.0 mm.
2. Install the control valve body while holding the manual valve in the position. Tightening Torque B: 6.9 N.m {0.70-0.90 kgf.m, 5.1-6.5 ft.lbf}
3. Connect the solenoid connectors, then install harness clips.
4. Apply a light coat of silicon sealant to the contact surfaces of the control valve body cover and transaxle case.
5. Install the control valve body cover. Tightening Torque B: 6.9 N.m {0.70-0.90 kgf.m, 5.1-6.5 ft.lbf}
6. Install the heater pipe bracket. (See HEATER PIPE AND HOSE COMPONENT REMOVAL/INSTALLATION .)
7. Install the oil hose and oil pipe. (See «OIL COOLER REMOVAL/INSTALLATION»(ref-178052-S08016497082005061000000) .)
8. Install the splash shield.
9. Install the air cleaner component.
10. Install the battery carrier, battery tray, and battery.
11. Connect the negative battery cable.
12. Fill the transaxle with the specified ATF. (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT»(ref-178052-S24716482602005061000000) .)
13. Inspect for leakage of ATF from the oil pan or the oil hose connecting points.
14. Carry out the mechanical system test. (See «MECHANICAL SYSTEM TEST»(ref-178052-S28664009742005061000000) .)
15. Carry out the road test. (See «ROAD TEST»(ref-178052-S24978590142005061000000) .)

RADIATOR (IN TANK OIL COOLER) INSTALLATION NOTE

1. The automatic transaxle oil cooler flushing must be performed whenever a transaxle is removed for service because the existing fluid may be contaminated, and to prevent contamination of new fluid. The fluid flushing must be performed after installation of the overhauled or replaced transaxle.
2. Follow the instructions in the manufacturer's publication for flushing operation.

Scheme 233

Scheme 234

Scheme 235

1. Apply compressed air to cooler-side opening, and blow any remaining grime and foreign material from the cooler pipes. Compressed air should be applied for no less than one minute .
2. Align the marks, and slide the oil hose onto the oil pipe until it is fully seated as shown.
3. Install the hose clamp onto the hose. If reusing the hose, install the new hose clamp exactly on the mark left by the previous hose clamp.
4. Verify that the hose clamp does not interfere with any other components.

Scheme 236

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

Scheme 237

Scheme 238

1. Inspect the height of the heater tabs.
2. Insert the end of a medium tip screwdriver between the end of the header tab and the outer tank.
3. Pivot the screwdriver to pry the tab away from the tank and repeat the procedure for each tab.
4. Remove the radiator outer tank and O-ring (gasket) from the core header when all of the tabs are opened.
5. Inspect the gasket surface of the radiator core header to ensure it is clean and free of foreign material or damage.
6. Inspect the radiator outer tank for warping. If it is warped, replace radiator tank.

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

1. Install a new O-ring and ensure it is not twisted.
2. Position the radiator tank in the original direction to the core using care not to scratch the tank sealing surface with the header tabs.
3. With the jaws of locking-type pliers (vise grips) closed and locked, turn the adjusting screw to position the jaws against the drill bit with the diameter measured (height) in removal procedure. Tighten the lock nut on the adjusting screw against the handle to lock the adjustment in place.
4. Squeeze the header tabs down in order as shown against the lip of radiator outer tank base with locking-type pliers while rotating the pliers toward the tank.
5. Verify the height of the header tabs is same as the height before removal.
6. Inspect for the leakage of radiator according to the following procedure. Cover the radiator inlet and outlet. Cover the ATF cooler inlet and outlet. Connect a radiator tester. Apply pressure of 145 kPa {1.5 kgf/m 2 , 21 psi} and verify that the pressure is held. Put the radiator into water slowly with the radiator tester connected. Inspect for air leakage.

Scheme 244

1. Remove in the order indicated in the figure.
2. Install in the reverse order or removal.

Scheme 245

1. Set the SST or equivalent against the drive plate.
2. Remove the bolts and the drive plate.

Scheme 246

1. Set the SST or equivalent against the drive plate.
2. Tighten the drive plate mounting bolts in two or three steps in the order shown. Tightening Torque 73-87 N.m {7.4-8.9 kgf.m, 54-64 ft.lbf}