Removal & Installation - A/t: Removal & Installation Mazda MX-5 NB

Removal (2.3L - LJ4A-EL)

1. Disconnect negative battery cable. Raise and support vehicle. Drain transmission fluid into proper container. 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 vehicle speed sensor harness connector. Remove front intercooler. Remove cooling fan. 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 axle shaft. See appropriate article in DRIVE AXLES. Lower vehicle.
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 23) Remove No. 4 engine mount. Remove nut and damper from No. 1 engine mount. Remove No. 2 engine mount nut.
6. Remove under cover to 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.

Scheme 23

Removal (2.5L - GF4A-EL)

1. Disconnect negative battery cable. Raise and support vehicle. Drain transmission fluid into proper container. 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, input/turbine speed sensor and shift solenoid harness connectors. Unbolt electrical harness and selector cable brackets. 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. Drain transmission fluid into proper container. 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 right side axle inner joint off joint shaft. Remove joint shaft. Insert differential side gear plug once joint axle is removed.
3. Install appropriate engine support, and remove No. 4 engine mount from top of transaxle. (Scheme 23) Remove No. 1 engine mount at bellhousing of transaxle. Remove No. 2 engine mount nut. Remove engine mount crossmember bolts 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 . 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. Drain transmission fluid into proper container. Remove front wheels. Remove splash shield and starter. Disconnect solenoid valve connector, transaxle range switch, input/turbine speed sensor connectors, and remove harness bracket.
2. Remove shift selector cable retaining clip. Disconnect shifter cable end at transaxle range switch lever. Disconnect transmission oil cooler lines. Lower vehicle and install appropriate engine support. Remove 4 upper transaxle-to-engine bolts. Remove No. 1 engine mount. Raise and support vehicle. Remove No. 2 engine mount-to-transverse crossmember nuts. Remove transverse crossmember. (Scheme 24)
3. Disconnect vehicle speed sensor connector. Remove lower control arm ball joint bolt and nut from left side steering knuckle. Remove outer tie rod end from left side steering knuckle. Remove left and right side axle shafts from transaxle. Remove under cover to gain access to torque converter nuts. Remove torque converter nuts. Remove No. 4 engine mount bracket. Remove engine mount crossmember. Remove No. 2 engine mount. (Scheme 24)
4. Support transmission using appropriate jack. Remove remaining transaxle-to-engine bolts, and slowly remove transaxle. To install transaxle, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8550-S28730763102000091100000). Fill transaxle with required amount of fluid, and check for external leaks.

Scheme 24

1. Disconnect negative battery cable. Disconnect fresh air duct, and remove air cleaner and resonance chamber. Remove battery and battery tray. Support engine from above using engine support assembly. Remove No. 4 engine mount. (Scheme 25) Raise and support vehicle. Remove wheels and splash shields. Drain transmission fluid into proper container. Remove EGR pipe and front exhaust pipe.
2. Disconnect transaxle range switch, vehicle speed sensor, input/turbine speed sensor and solenoid valve connectors. Remove dipstick and filler tube. Disconnect and plug oil cooler lines. Remove tie rod end retaining nuts and disconnect tie rod ends from steering knuckles. Remove lower ball joint retaining bolts and nuts and pry lower control arms from knuckle.
3. Separate left axle shaft from transaxle using pry bar inserted between axle shaft and case. DO NOT damage oil seal. Remove retaining bolts from right side axle shaft bracket and remove axle shaft from transaxle. Disconnect and remove selector cable. Remove intake manifold stay. Remove starter. Through starter hole, mark converter to drive plate for reassembly reference.
4. Remove torque converter nuts. Slightly lower engine using engine support from above. Support transaxle from below using transmission jack. Remove No. 1 and No. 2 engine mounts. (Scheme 25) Remove engine mount crossmember. 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 26) Install NEW clips on axle ends before installing axle shafts. Fill transaxle with required amount of fluid, and check for external leaks.

Scheme 25

Scheme 26

Scheme 27

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 transaxle fluid into proper container. Remove harness brackets. Disconnect transaxle solenoid connector, transaxle range switch and turbine shaft speed sensor.
2. Disconnect dipstick tube and fuel filter mounting nut. Disconnect shift control cable. Remove No. 1 engine mount nut, isolator and stay bracket. (Scheme 27) Support engine, and remove No. 4 engine mount. Remove transverse crossmember. Disconnect vehicle speed sensor connector. Disconnect No. 2 engine mount. Remove No. 5 engine mount bracket.
3. Mark position of front bushings for reassembly reference and remove engine mount crossmember. Disconnect tie rod end and stabilizer control link. Remove lower control arm. Remove left axle shaft. See appropriate article in DRIVE AXLES. Remove right axle shaft. Remove intake manifold bracket and starter. Remove torque converter nuts.
4. Remove No. 2 engine mount. Disconnect oil cooler hoses. Support transaxle by using appropriate jack. Lower engine and lean engine toward transaxle. Remove transaxle-to-engine bolts and lower transaxle.

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 27) 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 28) 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 28