Automatic Transaxle - Overhaul [CD4E]: Specifications — Mazda Tribute I facelift (2004-2007)

TORQUE CONVERTER CLUTCH (TCC) SOLENOID

The TCC solenoid is a pulse width modulating (PWM) style solenoid. The PWM solenoid is used to control the apply and release of the bypass clutch in the torque converter. By modulating the pulse width of the TCC solenoid the pressure in the S4 circuit varies modulating the apply and release of the bypass clutch in the torque converter.

TORQUE DEMAND

The torque demand downshift occurs automatically during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio. The transaxle will disengage the torque converter clutch (TCC) to provide added acceleration, if applied.

TORQUE CONVERTER

The torque converter is a four element assembly. The torque converter contains an impeller, a turbine, a reactor, and a torque converter clutch (TCC) for increased fuel economy. It couples the engine to the turbine shaft assembly, provides torque multiplication and absorbs engine shock of gear shifting.

TORQUE CONVERTER CLUTCH (TCC)

The torque converter clutch (TCC) provides a mechanical link or direct drive between the engine crankshaft and turbine shaft when applied. The application of the torque converter clutch is controlled by the powertrain control module (PCM). Under certain conditions, the PCM sends the appropriate signal to the TCC solenoid which allows fluid pressure within the torque converter to force the TCC piston plate and damper assembly against the cover creating a mechanical link between the engine and transaxle.

A new or re-manufactured torque converter must be installed if one or more of the following statements are true: A torque converter malfunction has been detected based on completed diagnostic procedures. NOTE: Stud threads can be repaired using a "thread chase". Converter stud(s), impeller hub or bushing is damaged. If there is a discoloration of the torque converter (due to overheating). The torque converter is found to be out of specification, when carrying out the following checks: Torque Converter Pump Insert Check Torque Converter End Play Check Torque Converter Turbine Torque Check Torque Converter Leakage Check If there is evidence of transaxle assembly damage or fluid contamination due to the following transaxle or converter failure modes: Major Metallic Failure Multiple Clutches Or Clutch Plate Failures Component Wear Which Results In Metallic Contamination

Scheme 259

Scheme 259: TORQUE CONVERTER CLEANING & INSPECTION

When a new or re-manufactured torque converter is installed the following actions must take place: All cooler lines must be thoroughly cleaned by back and forward flushing. All coolers (in-tank and auxiliary) must be thoroughly cleaned by back and forward flushing. Carry out transaxle cooler flow test, see «TRANSAXLE FLUID COOLER FLOW TEST»(ref-178641-S00596271582005061800000) . If the transaxle cooling system fails the flow test, new coolers or lines must be installed. If new cooler lines are to be installed, refer to «TRANSAXLE FLUID COOLER TUBES»(ref-178654-S08463599952005061900000) . If new coolers are to be installed, use only factory approved service parts and refer to «AUXILIARY TRANSAXLE FLUID COOLER»(ref-178654-S01061802242005061900000) .
If a new or re-manufactured torque converter is not being installed, do the following: Thoroughly clean the torque converter. All cooler lines must be thoroughly cleaned by back and forward flushing using service manual procedures. All coolers (in-tank and auxiliary) must be thoroughly cleaned by back and forward flushing using service manual procedures. Carry out transaxle cooler flow test as outlined in this section. If the transaxle cooling system fails the flow test, new coolers or lines must be installed. If new cooler lines are to be installed, refer to «TRANSAXLE FLUID COOLER TUBES»(ref-178654-S08463599952005061900000) . If new coolers are to be installed, use only factory approved service parts and refer to «AUXILIARY TRANSAXLE FLUID COOLER»(ref-178654-S01061802242005061900000) .
Carry out all torque converter checks listed in this article. NOTE: If leaks or damage are detected during inspection, a new torque converter should be installed.
Check seal contact surface on impeller hub of torque converter for excessive wear or scoring.
Inspect the torque converter studs for damage.

TORQUE CONVERTER FLUSHING

CAUTION

Mineral spirits used to clean the torque converter must be fresh, non- chlorinated and non-halogenated. Do not use water-based solvents or damage to the transaxle or torque converter can occur. If local ordinances state that water-based solvent must be used, use clean automatic transaxle fluid as recommended for this transaxle.

Partially fill the torque converter using MERCON (R) Automatic Transaxle Fluid (ATF).
Hand agitate the converter, then thoroughly drain the fluid.
Repeat this procedure until the converter is clean.
After flushing, drain the remainder of the solvent.
Add 1.9 liters (2 quarts) of clean MERCON (R) Automatic Transaxle Fluid (ATF) and agitate by hand.
Thoroughly drain the converter.
Refill the torque converter with MERCON (R) Automatic Transaxle Fluid (ATF) and install into transaxle.

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Scheme 260: INSPECTION

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Clean the outside surface of the torque converter.
Install the special tool into converter hub. WARNING: Always follow correct safety procedures while using press. Failure to follow these instructions can result in personal injury.
Position the torque converter with the installed special tool into an arbor press. Secure press. Apply enough force from press to seal tool into torque converter. NOTE: Use clean dry shop air.
Using the special tool, apply air pressure to the valve.
With the special tool installed and air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, install a new converter.
Remove air hose. Release the pressure and then slowly release the press, and the tool. Remove the converter from the press.

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Scheme 265: INSPECTION

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Insert the special tools in the turbine.
Tighten the center collect of the tool.
Using the special tool, position the indicator button on the converter housing and set the dial at zero.
Pull up on the special tool and observe the dial indicator reading.
If the end play exceeds specification, install a new or re-manufactured torque converter.

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Scheme 268: INSPECTION

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Install the oil pump drive shaft into the torque converter.
Install a torque wrench with a 5/16 Allen head socket attached on the oil pump drive shaft.
Verify that the insert can hold torque.
If the insert cannot hold the specified torque, install a new torque converter.

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Scheme 271: INSPECTION

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Install special tools into the turbine splines in the torque converter.
Attach a torque wrench and determine the torque required to turn the turbine.
If the torque exceeds specification, install a new torque converter.

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Scheme 274: ASSEMBLY NOTE

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Prepare the transaxle for assembly by proceeding with the following steps: Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent. Dry all parts with moisture-free regulated compressed air (do not use shop towels). Lubricate all internal parts (including friction plates) with MERCON (R) Automatic Transaxle Fluid (ATF). Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly: Drive sprocket thrust washers. Driven sprocket thrust bearing shims. Differential case thrust bearing shims. Low/reverse clutch pressure plates. During assembly, use petroleum jelly to hold the parts in place (do not use grease). Lightly coat bolt and nut threads with automatic transaxle fluid for correct installation torque specifications.
Install intermediate and overdrive band assembly into the transaxle case.
Install the No. 1 pump support thrust bearing. Lubricate the seal rings with MERCON (R) Automatic Transaxle Fluid (ATF). NOTE: Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle.
Install pump assembly into the case. NOTE: Tighten the bolts in the indicated sequence.
Install the pump assembly bolts.
Using the special tools, install the low/reverse clutch piston. Lubricate seals and piston bore with clean MERCON (R) Automatic Transaxle Fluid (ATF).
Install the low/reverse clutch return spring assembly.
Install the low/reverse clutch return spring retaining ring. CAUTION: The low/reverse clutch wave spring is fitted in this position for measurement purposes only.
Install the low/reverse clutch wave spring.
Install the low/reverse clutch plates. Install the low/reverse clutch external spline (steel) clutch plates. Install the low/reverse clutch internal spline (friction) clutch plates. Install the low/reverse clutch pressure plate. CAUTION: The low one-way clutch thrust plate is fitted in the position for measurement purposes only.
Install the low one-way clutch thrust plate.
Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate. Take a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance. Pressure plate sizes: 2.57-2.46 mm (0.101-0.097 in) 2.36-2.26 mm (0.092-0.089 in) 2.16-2.06 mm (0.085-0.081 in) NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.
Remove the low one-way clutch thrust plate, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring, and the low/reverse clutch internal spline clutch plates (friction). Low one-way clutch thrust plate. Low/reverse clutch pressure plate. Low/reverse clutch external spline clutch plates (steel). Low/reverse clutch wave spring. Low/reverse clutch internal spline clutch plates (friction).
Install the No. 1 pump support thrust bearing assembly. NOTE: Remove the seal sizer from forward/coast/direct clutch cylinder.
Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
Install the turbine shaft.
Install the No. 4 turbine shaft thrust bearing.
Install the forward one-way clutch and low/intermediate sun gear assembly.
Install the No. 5 low/intermediate sun gear thrust bearing.
Install the low/intermediate carrier assembly.
Install the No. 6 low/intermediate carrier thrust bearing.
Install the low/intermediate ring gear assembly.
Install the No. 7 reverse/overdrive sun gear thrust bearing.
Install the reverse/overdrive sun gear and shell assembly.
Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
Install the low/reverse clutch plates (model dependent). Install the low/reverse clutch external spline (steel) clutch plates. Install the low/reverse clutch internal spline (friction) clutch plates. Install the low/reverse clutch pressure plate previously selected.
Install the low/reverse clutch wave spring.
Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.
Install the low one-way clutch thrust plate. NOTE: Make sure to position the low one-way clutch retaining ring as shown.
Install the low one-way clutch retaining ring.
Install the manual valve detent lever actuating rod assembly. Install the parking cam actuator lever.
Install the manual valve detent lever.
Install the special tools.
Install the special tool with short spacers.
Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area. Record this dimension. This dimension is designated with A.
Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft. Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement. The average of these two dimensions is dimension B. Remove the special tools.
Subtract dimension B from dimension A to get dimension C.
Use the third dimension to select the correct No. 11 driven sprocket shim. Select a shim from the driven sprocket shim chart. Driven Sprocket Alignment Shim No.11
Install and lubricate the following: Lubricate the needles and seals in the No. 18 driven sprocket bearing. Install the selected No. 11 driven sprocket shim. Install the No. 12 driven sprocket bearing.
Install the No. 9 reverse/overdrive ring gear thrust bearing. NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
Install the reverse/overdrive ring gear assembly.
Install the special tools.
Install the special tool with short spacers.
Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area. Repeat this measurement 180 degrees from the first measurement. The average of these two dimensions is dimension A. Remove the special tools.
Add 25.4 mm (1.00 in) (thickness of special tool) and thickness of short spacers. This is the dimension B.
Subtract dimension A from dimension B. This is dimension C.
Select No. 10 thrust washer from the drive sprocket thrust washer chart. Use the third dimension to select the No. 10 drive sprocket thrust washer. Drive Sprocket Alignment No. 10 Thrust Washer
Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
Remove the reverse/overdrive ring gear assembly.
Install the filter and seal assembly.
Install the special tool in the filter eyelet and transaxle hole. NOTE: Lubricate the filter recirculating regulator exhaust seal before installation.
Using the special tool, install the filter recirculating regulator exhaust seal.
Install the chain pan in the transaxle case.
Assemble and install the drive chain assembly. Drive chain (copper colored link facing upward). Driven sprocket assembly. Reverse/overdrive ring gear assembly. Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
Install the chain pan cover by snapping it into place.
Install the No. 13 driven sprocket thrust bearing.
Install the final drive carrier and differential assembly. NOTE: Plastic washers should be placed between bolt heads and special tool.
Install the special tools. Install the special tool. Install the special tool and bolts.
Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub. Repeat this measurement 180 degrees from the first measurement. The average of these two dimensions is dimension B.
Use combined thickness of the special tool with long spacers 177.8 mm (7.11 in) as dimension A.
Subtract dimension B from dimension A. This is dimension C.
Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart. Differential End Play No. 14 Shim
Install the differential bearing assembly Install the No. 14 differential bearing shim (selective fit). Install the No. 15 differential bearing. NOTE: Check for correct alignment of the lube tube on the converter housing.
Install the torque converter housing onto the transaxle case. Position and install the split flange gasket. NOTE: Tighten the bolts in the indicated sequence.
Install the torque converter housing-to-transaxle case bolts. NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod.
Lubricate the assembly with clean MERCON(R) Automatic Transaxle Fluid (ATF). Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly. Install the intermediate and overdrive servo apply rod and piston assembly. Install the overdrive servo apply rod spring.
Install the special tool. NOTE: Struts on the special tool fit into the servo cover retaining ring groove.
Assemble the special tool. Install struts. Install bar. Install bolts. Install the center bolt.
Using the special tool, measure the distance to the bar of special tool. Record this as dimension A.
Back off the center bolt of special tool until the piston movement stops.
Using the special tool, measure the dimension to the bar of special tool record as dimension B. Subtract dimension A from B to find the travel. If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly. Intermediate/Overdrive Servo Apply Rod WARNING: Servo return spring force is very high. Failure to follow these instructions can result in personal injury.
Assemble the special tool.
Install the special tool. 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.
Tighten the special tool bolt. Install the servo cover retaining ring, using retaining ring pliers.
Loosen the special tool bolt. When spring tension is released, remove the special tool. CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston. NOTE: If any leaks occur, make sure the special tool is correctly seated.
Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 19 kPa (2.76 psi) of moisture-free regulated compressed air. Reverse clutch test port. Forward clutch test port. Direct clutch test port. Low/reverse clutch test port. Servo release test port. Servo apply test port. Transaxle air test plate. If air leakage is detected, disassemble the transaxle and locate source of leakage.
Install the thermostatic fluid level control valve. Position the thermostatic fluid level control valve. Install the bracket. Install the thermostatic fluid level control valve bracket bolt.
Install forward clutch circuit filter (if equipped). CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.
Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case. CAUTION: Handle main control valve body with care to prevent manual valve damage.
Connect the manual valve. Lift the main control away from the case. Connect the Z-link to the manual valve. NOTE: Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others.
Install the main control valve body mounting bolts.
Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.
Move the manual control lever shaft to the "D" position. Install pin to hold special tool in place.
Move the manual valve detent lever assembly to the "D" position.
Tighten the nut on the ball. Remove the shifter pin from the special tool.
Tighten the detent nut. Rotate back to "D" position to recheck the adjustment.
Using the special tool, recheck the manual control lever assembly setting.
Install the manual control lever.
Rotate the manual valve detent lever assembly to the NEUTRAL position. Low 1 Low 2 Drive Neutral Reverse Park
Position the transaxle range (TR) sensor.
Using the special tool, align the TR sensor and tighten the bolts.
Install the main control cover gasket. NOTE: Tighten the bolts in the indicated sequence.
Install the main control cover.
Install the vent tube.
Install a new transaxle filler tube grommet.
Install the transaxle filler tube assembly. Install the tube. Install the transaxle filler tube bolt. Install the fluid level indicator.
Install the turbine shaft speed (TSS) sensor. Use petroleum jelly on the O-ring seal and position the TSS sensor. Install a new O-ring seal. Install the TSS sensor bolt.
Using the special tool, install the LH differential seal.
Using the special tool, install the RH differential seal. NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.
Using the special tool, install the torque converter fluid seal. Coat the torque converter seal garter spring with petroleum jelly.
Install the drain plug.
Install the output shaft speed (OSS) sensor. NOTE: Check for correct rotation of the pump drive shaft.
Install the pump drive shaft.
Using the special tool, install the torque converter.
Remove the transaxle from the special tool.

Scheme 376

Scheme 376: TRANSAXLE - INSTALLATION

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If installing a new or re-manufactured transaxle, install the roll restrictor bracket. NOTE: If the torque converter was not installed during assembly it must be installed now.
Using the special tool, install the torque converter. NOTE: The torque converter hub must be fully seated into the transaxle pump drive gear.
Check the installation depth of the torque converter. Lay a straightedge on the transaxle converter housing. Check the clearance between the straight edge and the pilot hub.
Lubricate the torque converter pilot hub with Multi-Purpose Grease.
Install the special tool.
Position the transaxle in place.
Remove the special tool.
Move the transaxle assembly toward the engine assembly and install the bolt.
Install the bolts.
Remove the transaxle jack.
Install the fluid cooler line.
Install the OSS sensor.
Install the fluid cooler tube. Install the fluid cooler tube. Install the bolt. Connect the output shaft speed (OSS) sensor. Connect the turbine shaft speed (TSS) sensor (white connector).
Install four flexplate nuts.
Install the access cover.
Connect the main control cover vent tube.
Lower the vehicle.
Using the special tool, raise the transaxle enough to install the cross brace.
Raise the vehicle.
Install the PTO unit and bolt.
Install the PTO bolts.
Install the cross brace.
Install the crossmember dampener.
Install the PTO bracket.
For four-wheel-drive vehicles, install the RH exhaust manifold. Refer to EXHAUST MANIFOLD - RH .
If equipped, install the driveshaft. Refer to DRIVESHAFT .
Install the exhaust pipe, and connect the exhaust pipe flange.
Connect the front flange.
Install the exhaust pipe. Install the pipe, and install the bolts. Install the rubber hanger. Remove the special tool.
Connect the HO2S sensor wire to the oil pan bolt studs and connect the connector.
Install the cross brace.
Install the LH halfshaft assembly. Refer «HALFSHAFT -- FRONT»(ref-194642-S12173569032005092900000) . CAUTION: Align the mounting bracket studs and the intermediate shaft bearing bracket holes with the marks made during removal.
Install the RH halfshaft, intermediate shaft bearing, and intermediate shaft assembly. Refer «HALFSHAFT -- FRONT»(ref-194642-S12173569032005092900000) .
Install the two splash shields.
Install both front wheels.
Lower the vehicle.
Lower the engine onto the RH engine mount.
Install the bolt for the RH engine mount.
Install the rear transaxle mount.
Install the transaxle mount assembly.
Install the bolts.
Remove the special tool.
Remove the special tool.
Remove the special tool.
Connect the electrical connectors to the valve cover.
Install the starter motor, and install two bolts.
Install the ground cable.
Install the starter motor harness connector.
Install the shift cable and bracket.
Install the wire harness clip to the shift cable bracket.
Connect the shift cable.
Connect the wire harness.
Install the wire harness bracket, and connect the transaxle harness connector.
Connect the HO2S sensor.
Connect the two HO2S sensors.
Connect the transaxle range (TR) sensor. NOTE: If not done during assembly, the digital TR sensor must be aligned.
Using the special tool, align the digital TR sensor.
Install the air cleaner assembly.
Install the intake tube and air cleaner cover.
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.
Install the battery and tray.
Connect the battery cables.
Check the power take off (PTO) unit. Refer to POWER TAKE OFF UNIT DRAINING AND FILLING .
Fill the transaxle. Refer to «TRANSAXLE FLUID DRAIN AND REFILL»(ref-178654-S13991328922005061900000) .

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Scheme 427: REMOVAL

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Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) . NOTE: Determine the source of the fluid leak. If the leak is from the transaxle, continue with this procedure.
If it is determined that the fluid leak is coming from the power take off (PTO) unit, remove the PTO. Refer to POWER TAKE OFF UNIT - 3.0L DURATEC (4V) . NOTE: Place a suitable drain pan under the vehicle.
Remove the transaxle drain plug and drain the fluid.
Remove the RH halfshaft. Refer to «HALFSHAFT -- FRONT»(ref-194642-S12173569032005092900000) .
If equipped remove the PTO. Refer to POWER TAKE OFF UNIT - 3.0L DURATEC (4V) .
If the vehicle is equipped with a PTO, use the special tools to remove the RH differential seal.
If the vehicle is not equipped with a PTO, use the special tools to remove the RH differential seal.

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Scheme 430: INSTALLATION

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If the vehicle is equipped with a PTO, use the special tools to install the RH differential seal.
If the vehicle is not equipped with a PTO, use the special tools to install the RH differential seal.
If equipped install the PTO. Refer to POWER TAKE OFF UNIT - 3.0L DURATEC (4V) .
Install the RH halfshaft. Refer to «HALFSHAFT -- FRONT»(ref-194642-S12173569032005092900000) .
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).
Remove the drain pan and lower the vehicle.
Add MERCON(R) Automatic Transaxle Fluid (ATF).
Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary.
Allow the transaxle fluid to reach operating temperature and fill as necessary.

Scheme 433

Scheme 433: REMOVAL

Raise and support the vehicle. Refer to «LIFTING»(ref-178489-S02006613742005061600000) .
Place a suitable container under the transaxle drain plug. NOTE: If an integral problem is suspected, drain the fluid through a paper filter. A small amount of metal or friction particles may be found from normal wear. However, if excessive metal and friction particles are present, internal service will be required.
Remove the transaxle drain plug and drain transaxle fluid.

Scheme 434

Scheme 434: INSTALLATION

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).
Lower the vehicle
Add 3.7 liters (3.9 quarts) of MERCON (R) Automatic Transaxle Fluid (ATF).
Start the engine and run through all gears for a total of five minutes at idle. Turn off the engine.
Repeat the previous steps to help flush fluid from the torque converter.

Automatic Transaxle - Overhaul [CD4E]: Specifications Mazda Tribute I facelift