Automatic Transaxle - Overhaul [CD4E]: Removal & Installation Mazda Tribute I facelift

INSTALLATION

Note. Inspect the solenoid valve body harness connector O-ring seal for damage. Install a new O-ring seal, if damaged, before installing the connector into the case.

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1. Push the solenoid valve body harness connector into the case.
2. Connect the manual valve link to the main control valve body.
3. Install the main control valve body and tighten the bolts in sequence as indicated.
4. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.
5. Remove the manual control lever outer assembly bolt.
6. Using the special tool and pin, align the shifter shaft.
7. Move the manual valve detent lever assembly to the "D" position.
8. Tighten the nut on the ball and remove the special tool.
9. Tighten the detent nut. Rotate back to the "D" position and check the adjustment.
10. Using the special tool and pin, align the shifter shaft.
11. Install the manual control lever.
12. Install and rotate the manual valve detent lever assembly to the neutral position. Low 1 Low 2 Drive Neutral Reverse Park
13. Install the gasket on the case.
14. Install the main control cover, and tighten the bolts in sequence as shown.
15. Install the splash shield.
16. Install the LH front wheel.
17. Lower the vehicle.
18. Install the shift cable and bracket.
19. Connect the shift cable. NOTE: Before installing the vent tube hose, clean out any obstructions in the hose using low air pressure.
20. Install the vent tube hose, and clamp.
21. Connect the transaxle harness connector, and the TR sensor connector.
22. Install the intake tube and air cleaner cover.
23. Connect the breather tube and mass air flow (MAF)/intake air temperature (IAT) sensor. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position.
24. Install the battery tray and battery. .
25. Connect the battery cables.
26. Check the transaxle fluid, add fluid as necessary using MERCON(R) Automatic Transaxle Fluid (ATF).
27. Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary.
28. Make sure the vehicle will only start in PARK and then in NEUTRAL. Verify that the backup lamps illuminate in the REVERSE position.

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1. Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) .
2. Remove the LH front wheel.
3. Remove the splash shield.
4. Remove the output shaft speed (OSS) sensor. Disconnect the OSS sensor electrical connector. Remove the bolt. Inspect the OSS bore.
5. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary.

Note. Apply a light coat of petroleum jelly to the O-ring before installation.

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1. Install the OSS sensor. Connect the OSS sensor electrical connector.
2. Install the splash shield.
3. Install the LH front wheel.
4. Lower vehicle.
5. Check the transaxle fluid level, add fluid as necessary using MERCON (R) Multi-Purpose (ATF) Transaxle Fluid.
6. Start the engine and move the transaxle range selector lever through all gear positions.

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1. Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) .
2. Remove the LH front wheel.
3. Remove the splash shield.
4. Place a drain pan beneath the turbine shaft speed (TSS) sensor.
5. Remove the TSS sensor. Disconnect the TSS sensor electrical connector. Remove the bolt. Inspect the TSS sensor bore.
6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary.

Note. Apply a light coat of petroleum jelly to the O-ring seal before installation.

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1. Install the TSS sensor. Connect the TSS electrical connector.
2. Remove the drain pan.
3. Install the splash shield.
4. Install the LH front wheel.
5. Lower the vehicle.
6. Check the transaxle fluid level, add fluid as necessary using MERCON(R) Automatic Transaxle Fluid (ATF).
7. Start the engine and move the transaxle range selector lever through all gear positions.

REMOVAL

Note. Servicing the intermediate/overdreive servo in the vehicle is only recommended in the event of a leak. If servicing is required due to a servo condition, it is necessary to remove and disassemble the transaxle to inspect the intermediate/overdrive band assembly and direct clutch for damage.

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1. Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) . WARNING: The servo is under pressure. Servo and servo cover are under high spring force. Use caution when removing the servo cover. Failure to follow these instructions may result in personal injury.
2. Assemble the special tool.
3. Remove the splash shield.
4. Remove the transaxle cooler line bracket bolt and position the bracket out of the way. CAUTION: Do not use a screwdriver to remove the retaining ring or damage to the case may occur. Use only snap ring pliers to remove the retaining ring.
5. Using the special tool, remove the servo retaining ring. Install the special tool. Compress the servo assembly by tightening the bolt. Remove the retaining ring.
6. Remove the special tool.
7. Remove the servo cover assembly.
8. Remove the intermediate and overdrive servo piston and return spring.
9. Wipe the servo piston and the servo cover cap with a lint free cloth. CAUTION: Do not clean the rubber sealing surfaces of the servo piston and the servo cover cap with cleaning solvent or damage to the sealing surface may result.
10. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston is attached to the servo rod.
11. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston
12. Inspect the servo retainer spring for cracks, breaks or deformation.

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1. Assemble the special tool.
2. Install the special tool. CAUTION: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring. NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
3. Tighten the special tool bolt. Install the servo cover retaining ring.
4. If the case is stamped "WG", install a wide-grooved snap ring, or the servo will be damaged.
5. Loosen the special tool bolt. When the spring tension is released, remove the special tool.
6. Install the transaxle fluid cooler line.
7. Install the splash shield.
8. Lower the vehicle.
9. Start the vehicle. Place the transaxle range selector lever in each gear and allow to engage. Check for leaks.
10. Check transaxle fluid.

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1. Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) .
2. Remove the splash shield.
3. Remove the cross brace.
4. Remove the lower vibration dampener.
5. Remove the cross brace.
6. Remove the top and bottom mount cups.
7. Remove the rubber mount.

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1. Install a new rubber mount.
2. Install the top and bottom mount cups.
3. Install the cross brace.
4. Install the lower vibration dampener.
5. Install the cross brace.
6. Install the splash shield.
7. Lower the vehicle.

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1. Disconnect the breather tube and mass air flow (MAF) sensor.
2. Remove the intake tube and air cleaner cover.
3. Remove the air cleaner assembly.
4. Install the special tools.
5. Install the special tools.
6. Remove the upper transaxle mount bolt.
7. Remove the upper transaxle insulator.
8. Remove the top and bottom mount cups.

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1. Install the top and bottom mount cups.
2. Install the upper transaxle insulator.
3. Install the upper transaxle bolt.
4. Remove the special tool.
5. Remove the special tool.
6. Install the air cleaner assembly.
7. Install the intake tube and air cleaner cover.
8. Connect the breather tube and mass air flow (MAF) sensor.

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1. Remove the battery tray.
2. Disconnect the breather tube and mass air flow (MAF) / intake air temperature (IAT) sensor.
3. Remove the intake tube and air cleaner cover.
4. Remove the air cleaner assembly.
5. Remove the bolts from the rack.
6. Remove the bolts and nuts from the mount, and remove the mount.

Note. Prior to tightening the mount nuts install the mount bolt for correct alignment.

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1. Install a new mount and bolts. Install the mount. Loosely install the bolt for correct alignment. Install the nuts and bolt.
2. Install the bolts to the rack.
3. Install the air cleaner assembly.
4. Install the intake tube and air cleaner cover.
5. Connect the breather tube and mass air flow (MAF) / intake air temperature (IAT) sensor. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position.
6. Install the battery tray.

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1. Disconnect the breather tube and mass air flow (MAF) sensor.
2. Remove the intake tube and air cleaner cover.
3. Remove the air cleaner assembly.
4. Remove the bolts and nuts from the mount, and remove the mount.

Note. Prior to installing the mount nuts, install the mount bolt for correct alignment

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1. Install a new mount and bolts. Install the mount. Loosely install the bolt Tighten the nuts first, then the bolts.
2. Install the air cleaner assembly.
3. Install the intake tube and air cleaner cover.
4. Connect the breather tube and MAF sensor.

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1. Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) . NOTE: Place a suitable drain pan under the vehicle.
2. Remove the transaxle drain plug and drain the fluid.
3. Remove the LH halfshaft. Refer to «HALFSHAFT -- FRONT»(ref-194642-S12173569032005092900000) .
4. Using the special tools, remove and discard the LH differential seal.

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1. Using the special tool, install the LH differential seal.
2. Install the LH halfshaft. «HALFSHAFT -- FRONT»(ref-194642-S12173569032005092900000) .
3. Remove the drain pan and lower the vehicle.
4. Install the transaxle drain plug. After the fluid has been drained, clean the drain plug threads and apply a small amount of Pipe Sealant with Teflon (R).
5. Add MERCON (R) Automatic Transaxle Fluid (ATF).
6. Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary.
7. Allow the transaxle fluid to reach operating temperature and fill as necessary.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «LIFTING»(ref-178489-S02006613742005061600000) .
2. Remove the battery and tray.
3. Remove the transaxle range (TR) sensor. Disconnect the TR sensor electrical connector. Remove the bolts. Remove the TR sensor.

Note. Make sure the transaxle is in the NEUTRAL position.

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1. Install the transaxle range (TR) sensor and loosely install the bolts.
2. Using the special tool, align the TR sensor and tighten the bolts. Connect the electrical connector. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position.
3. Install the battery and tray.
4. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position.

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1. Disconnect the battery cables. Refer to «BATTERY DISCONNECT»(ref-154598-S40263343402005062800000) .
2. Remove the battery and the battery tray.
3. Disconnect the breather tube and mass air flow (MAF)/intake air temperature (IAT) sensor.
4. Remove the intake tube and air cleaner cover.
5. Remove the air cleaner assembly.
6. Disconnect the transaxle range (TR) sensor.
7. Disconnect the HO2S sensor.
8. Disconnect the transaxle harness connector and remove the wire harness bracket nut.
9. Position the wire harness bracket out of the way.
10. Disconnect the vent hose from the transaxle filler tube bracket.
11. Unclip the wire harness.
12. Disconnect the shift cable.
13. Disconnect the wire harness from the shift cable bracket to gain access to the bracket bolts.
14. Remove the shift cable and bracket, and position out of the way.
15. Disconnect the starter motor harness connector.
16. Disconnect the ground wire.
17. Remove two starter bolts, and remove the starter motor.
18. Installing Special Tools.
19. Remove both electrical connectors from the valve cover to gain access to the engine lifting bracket.
20. Install the special tools.
21. Install the special tools.
22. Remove the upper transaxle retaining bolts.
23. Remove the LH upper transaxle mount plate.
24. Remove the bolts, and remove the rear transaxle mount.
25. Remove the RH engine mount bolt. NOTE: It is necessary to raise the engine a couple of inches in order to remove the transaxle.
26. Using the special tool raise the engine.
27. Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) .
28. Remove both front wheels.
29. Remove the two splash shields.
30. Disconnect the two HO2S sensors.
31. If transaxle disassembly is necessary, remove the drain plug and drain the fluid into a suitable container. Install the drain plug when the fluid has drained. CAUTION: Index-mark the mounting bracket studs and the intermediate shaft bearing bracket holes for correct assembly.
32. Remove the RH halfshaft, intermediate shaft bearing, and intermediate shaft assembly. Refer to «INTERMEDIATE SHAFT»(ref-194642-S12957259132005092900000) .
33. Remove the LH halfshaft assembly. Refer to «HALFSHAFT -- FRONT»(ref-194642-S12173569032005092900000) .
34. Remove the cross brace.
35. Disconnect the HO2S sensor connector and unclip the two clips from the oil pan bolt studs.
36. Remove the exhaust pipe. Install the special tool. Remove the rubber hanger. Remove the bolts, and remove the pipe.
37. Disconnect the front exhaust pipe flange.
38. Disconnect the rear exhaust pipe flange and remove the exhaust pipe.
39. If equipped, remove the driveshaft. Refer to DRIVESHAFT .
40. For four-wheel-drive vehicles, remove the RH exhaust manifold to gain access to the PTO bracket. Refer to EXHAUST MANIFOLD - RH .
41. Remove the bolts and the bracket.
42. Remove the cross brace dampener.
43. Remove the cross brace.
44. Remove the bolts from the PTO unit.
45. Remove the PTO bolt and the PTO unit.
46. Lower the vehicle. NOTE: It is necessary to lower the transaxle in order to clear the subframe to remove the transaxle.
47. Lower the transaxle enough to clear the subframe.
48. Raise the vehicle.
49. Remove the access cover.
50. Remove the four flexplate nuts.
51. Remove the fluid cooler tube. Disconnect the output shaft speed (OSS) sensor. Disconnect the turbine shaft speed (TSS) sensor. Remove the bolt. Remove the fluid cooler tube and position it aside.
52. Remove the OSS sensor.
53. Remove the fluid cooler line.
54. Install the transaxle jack and secure the transaxle to the jack.
55. Remove the bolts.
56. Remove the vent tube.
57. Remove the bolt.
58. Remove the bolt. CAUTION: The torque converter is heavy. Install the special tool before lowering the transaxle.
59. Move the transaxle back far enough to install the special tool.
60. Lower the transaxle from the engine compartment.
61. Make sure the vehicle will only start in PARK, and then in NEUTRAL. Verify that the backup lamps illuminate in the REVERSE position.