626 1999-2001

Transaxle Removal & Installation

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2.0L (Fs) Engine



Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration for component location and torque specifications.
  4.  
  5. Drain the transaxle oil.
  6.  
  7. Remove or disconnect the following:

    Battery and battery box
     
    Air cleaner assembly and fresh air duct
     
    Wheels
     
    Splash shields
     
    Starter
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Vehicle Speed Sensor (VSS) connector
     
    Clutch release cylinder
     
    Transverse member
     
    Extension bar
     
    Change control rod
     
    Tie rod ends from the knuckle
     
    Stabilizer bar link
     
    Lower control arm ball joint
     
    Halfshafts
     
    Joint shaft, install tool 49 G030 455 to hold the side gears after removal

    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle assembly mounting-626 with 2.0L (FS) engine



    Click image to see an enlarged view

    Fig. Exploded view joint shaft assembly-626

     

  8.  
  9. Support the engine assembly with a engine support assembly such as 49 E017 5A0.

    Number 5 engine mount bolt
     
    Engine mount member
     
    Number 2 engine mount
     
    Number 4 engine mount rubber
     
    Number 1 engine mount bracket
     

  10.  
  11. Loosen the engine support assembly and lean the engine towards the transaxle.
  12.  
  13. Support the transaxle with a jack, remove the transaxle bolts and the transaxle.
  14.  

To install:

  1. Place the transaxle onto a jack and raise into position.
  2.  
  3. Install the transaxle bolts and tighten the upper bolts to 66-86 ft. lbs. (90-116 Nm), the lower bolts (except very bottom bolt) to 28-38 ft. lbs. (38-51 Nm) and the very bottom bolt to 14-18 ft. lbs. (19-25 Nm). Refer to the exploded view illustration for bolt locations.
  4.  
  5. Lean the engine towards its normal position and tighten the support assembly.
  6.  
  7. Install or connect the following:

    Number 1 engine mount bracket. Refer to the illustration for component location and torque specifications.
     
    Number 4 engine mount rubber. Refer to the illustration for component location and torque specifications.
     
    Number 2 engine mount. Refer to the illustration for component location and torque specifications.
     

  8.  
  9. Install the engine mount member as follows while referring to the illustration for bolt locations:
    1. Position the direction indicator on the mount member bushings facing towards the front side and install the bushings onto the mount.
    2.  
    3. Put the number 2 engine mount stud bolts through the mount member installation holes. Install mount member bolts A and nuts A and tighten to 50-68 ft. lbs. (67-93 Nm).
    4.  
    5. Loosely tighten the number 2 engine mount nuts and remove the engine support assembly.
    6.  
    7. Tighten the number 2 engine mount nuts B to 55-77 ft. lbs. (75-104 Nm).
    8.  

  10.  
  11. Install or connect the following:

    Number 5 engine mount bolt. Refer to the illustration for component location and torque specifications.
     
    Joint shaft. Install a new circlip with the opening facing up. Hand tighten the bolts A , then tighten the bolts to 32-45 ft. lbs. (43-61 Nm). Refer to the illustration for bolt location.

    Click image to see an enlarged view

    Fig. Position the direction indicator on the mount member bushings facing towards the front side and install the bushings onto the mount-626



    Click image to see an enlarged view

    Fig. Location of the front mount member bolt locations-626



    Click image to see an enlarged view

    Fig. When installing the joint shaft make sure to install a new clip with the opening facing up-626



    Click image to see an enlarged view

    Fig. Tighten the joint shaft bolts as shown-626

     
    Halfshafts
     
    Lower control arm ball joint
     
    Stabilizer bar link
     
    Tie rod ends to the knuckle and tighten the nut to 24-32 ft. lbs. (32-44 Nm) and install a new cotter pinch
     
    Change control rod
     
    Extension bar
     
    Transverse member
     
    Clutch release cylinder
     
    VSS connector
     
    Back up light switch connector
     
    Neutral safety switch connector
     
    Starter
     
    Splash shields
     
    Wheels
     
    Air cleaner assembly and fresh air duct
     
    Battery and battery box
     

  12.  
  13. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  14.  

2.5L (Kl) Engine



Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration for component location and torque specifications.
  4.  
  5. Drain the transaxle oil.
  6.  
  7. Remove or disconnect the following:

    Battery and battery box
     
    Air cleaner assembly and fresh air duct
     
    Wheels
     
    Splash shields
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Vehicle Speed Sensor (VSS) connector
     
    Starter
     
    Clutch release cylinder
     
    Transverse member
     
    Extension bar
     
    Change control rod
     
    Tie rod ends from the knuckle
     
    Stabilizer bar link
     
    Lower control arm ball joint
     
    Halfshafts
     
    Joint shaft, install tool 49 G030 455 to hold the side gears after removal

    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle assembly mounting-626 with 2.5L (KL) engine

     

  8.  
  9. Support the engine assembly with a engine support assembly such as 49 E017 5A0.

    Engine mount member
     
    Number 2 engine mount
     
    Number 4 engine mount rubber
     
    Under cover
     
    Number 1 engine mount bracket
     

  10.  
  11. Loosen the engine support assembly and lean the engine towards the transaxle.
  12.  
  13. Support the transaxle with a jack, remove the transaxle bolts and the transaxle.
  14.  
  15. Remove the number 5 mount
  16.  

To install:

  1. Install the number 5 mount. Refer to the illustration for component location and torque specifications.
  2.  
  3. Place the transaxle onto a jack and raise into position.
  4.  
  5. Install the transaxle bolts and tighten the upper 4 bolts and the 3 side bolts to 50-73 ft. lbs. (68-99 Nm) and the lower 4 bolts to 28-38 ft. lbs. (38-51 Nm). Refer to the exploded view illustration for bolt locations.
  6.  
  7. Lean the engine towards its normal position and tighten the support assembly.
  8.  
  9. Install or connect the following:

    Number 1 engine mount bracket. Refer to the illustration for component location and torque specifications.
     
    Under cover
     
    Number 4 engine mount rubber. Refer to the illustration for component location and torque specifications.
     
    Number 2 engine mount. Refer to the illustration for component location and torque specifications.
     

  10.  
  11. Install the engine mount member as follows while referring to the illustration for bolt locations:
    1. Position the direction indicator on the mount member bushings facing towards the front side and install the bushings onto the mount.
    2.  
    3. Put the number 2 engine mount stud bolts through the mount member installation holes. Install mount member bolts A and nuts A and tighten to 50-68 ft. lbs. (67-93 Nm).
    4.  
    5. Loosely tighten the number 2 engine mount nuts and remove the engine support assembly.
    6.  
    7. Tighten the number 2 engine mount nuts B to 55-77 ft. lbs. (75-104 Nm).
    8.  

  12.  
  13. Install or connect the following:

    Number 5 engine mount bolt. Refer to the illustration for component location and torque specifications.
     
    Joint shaft. Install a new circlip with the opening facing up. Hand tighten the bolts A , then tighten the bolts to 32-45 ft. lbs. (43-61 Nm). Refer to the illustration for bolt location.

    Click image to see an enlarged view

    Fig. When installing the joint shaft make sure to install a new clip with the opening facing up-626

     
    Halfshafts
     
    Lower control arm ball joint
     
    Stabilizer bar link
     
    Tie rod ends to the knuckle and tighten the nut to 24-32 ft. lbs. (32-44 Nm) and install a new cotter pinch
     
    Change control rod
     
    Extension bar
     
    Transverse member
     
    Clutch release cylinder
     
    Starter
     
    VSS connector
     
    Back up light switch connector
     
    Neutral safety switch connector
     
    Starter
     
    Splash shields
     
    Wheels
     
    Air cleaner assembly and fresh air duct
     
    Battery and battery box
     

  14.  
  15. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  16.  

 
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