Mazda Car 2002-04

Transaxle Removal & Installation 1

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the transaxle oil.
  6.  
  7. Remove or disconnect the following:

    Front wheels
     
    Battery and battery box
     
    Air cleaner and ducting
     
    Splash shield
     
    Speedometer, throttle and shift cables
     
    Wiring connectors from the transaxle
     
    Fuel lines, if necessary
     

  8.  
  9. If the fuel filter is mounted to the transaxle, unbolt its mounting bracket and position it aside.
  10.  
  11. Remove or disconnect the following:

    Exhaust crossover, coolant, vacuum or EGR pipe mounting brackets from the transaxle

    Click image to see an enlarged view

    Fig. Exploded view of a typical automatic transaxle assembly mounting and related components

     
    Intake manifold support bracket, on the 2.0L engines
     
    Wiring and remove the starter
     
    Exhaust pipe
     
    Tie rod ends
     
    Lower ball joints
     
    Halfshafts and install tool 49 G030 455 to hold the differential side gears in place when the halfshafts are removed
     

  12.  
  13. Remove or disconnect the following:

    Torque converter-to-flywheel nuts and/or bolts
     
    Oil cooler hoses and plug them to prevent leakage
     

  14.  
  15. Attach lifting equipment and support the engine from above.
  16.  
  17. Remove the lower mounting frame
  18.  
  19. Support the transaxle with a jack.
  20.  
  21. Remove the front and left rear mounts.
  22.  
  23. Allow the engine/transaxle to tilt towards the left.
  24.  
  25. Install the remaining bolts and slide the transaxle away from the engine to lower it out of the vehicle. Do not let the torque converter fall out.
  26.  

To install:

  1. Be sure the torque converter is properly placed and carefully guide the transaxle into place. Start all the transaxle-to-engine bolts, then tighten them to specifications.
  2.  
  3. The remainder of the installation is the reverse of the removal procedure.
  4.  

  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:

    Wheels
     
    Splash shields
     
    Battery and battery box
     
    Air cleaner assembly and fresh air duct
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Front exhaust pipe and three way catalytic converter
     
    Speedometer sensor connector
     
    Transmission range switch connector
     
    Input/turbine speed sensor connector
     
    Transaxle connector
     
    Harness bracket
     
    Battery tray bracket
     
    Oil dipstick tube
     
    Oil hose
     
    Brake hose clip and ABS sensor bracket
     
    Tie rod ends from the knuckle
     
    Lower arm bolt
     
    Stabilizer link nut
     
    Lower arm
     
    Transverse member
     
    Halfshafts
     
    Joint shaft, install tool 49 G030 455 to hold the side gears after removal
     
    Selector cable
     
    Intake manifold stay
     
    Starter
     
    Torque converter nuts

    Click image to see an enlarged view

    Fig. Exploded view of the automatic transaxle assembly mounting-Protégé

     

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

    Number 4 engine mount
     
    Number 1 engine mount bracket
     
    Roll damper on models with the 2.0L (FS) engine
     
    Engine mount member
     
    Number 2 engine mount
     

  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 bolts as follows:
    1. Bolts A to 65 ft. lbs. (89 Nm).
    2.  
    3. Bolts B to 86 ft. lbs. (116 Nm).
    4.  
    5. Bolts C to 38 ft. lbs. (51 Nm).
    6.  
    7. Bolts D to 18 ft. lbs. (25 Nm).
    8.  

  4.  
  5. Install or connect the following:

    Number 2 engine mount. Refer to the illustration for component location and torque specifications.
     

  6.  
  7. 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 as illustrated.
    2.  
    3. Put the number 2 engine mount stud bolts through the mount member installation holes. Install mount member bolts A and tighten to 50-68 ft. lbs. (67-93 Nm).
    4.  
    5. Tighten the nuts B to 50-68 ft. lbs. (67-93 Nm) on 1.6L (ZM) and 1.8L (FP) engines or 63-86 ft. lbs. (86-116 Nm) on 2.0L (FS) engines.
    6.  
    7. By aligning the holes on the stud bolts, install the number 4 mount bracket. Align hole of the bracket with the rubber and hand tighten bolt A . Tighten nut B and tighten bolt A to 50-68 ft. lbs. (67-93 Nm).

      Click image to see an enlarged view

      Fig. Automatic transaxle assembly bolt torque sequence-1.6L (ZM) engine



      Click image to see an enlarged view

      Fig. Automatic transaxle assembly bolt torque sequence-1.8L (FP) and 2.0L (FS) engines

    8.  

  8.  
  9. Install or connect the following:

    Roll damper, on 2.0L (FS) engines
     
    Number 1 engine mount
     
    Torque converter nuts
     
    Starter
     
    Intake manifold stay
     
    Selector cable
     
    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.
     
    Halfshafts
     
    Transverse member
     
    Lower arm
     
    Stabilizer link nut
     
    Lower arm bolt
     
    Tie rod ends to the knuckle
     
    ABS sensor bracket and brake hose clip
     
    Oil hose
     
    Oil dipstick tube
     
    Battery tray bracket
     
    Harness bracket
     
    Transaxle connector
     
    Input/turbine speed sensor connector
     
    Transmission range switch connector
     
    Speedometer sensor connector
     
    Front exhaust pipe and three way catalytic converter
     
    EGR pipe
     
    Air cleaner assembly and fresh air duct
     
    Battery and battery box
     
    Splash shields
     
    Wheels
     

  10.  
  11. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.

    Click image to see an enlarged view

    Fig. Number 4 mount fastener locations-Protégé with automatic transaxle

  12.  

  1. Refer to the illustration for component location and torque specifications.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Refer to the illustration for component location and torque specifications.
  6.  
  7. Drain the transaxle oil, coolant and engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Crossmember and bracket, on models equipped with 16 inch wheels
     
    Rear crossbar, on models equipped with 16 inch wheels
     
    Exhaust system
     
    Drive shaft
     
    Throttle cable
     
    Dipstick tube
     
    Performance rod
     
    Exhaust bracket
     
    Shift rod
     
    Transmission range selector switch connector
     
    Output speed sensor connector
     
    Solenoid connector
     
    Input/turbine speed sensor
     
    Harness bracket
     
    Intake manifold bracket
     
    Oil filter
     
    Water hose and oil cooler
     
    Under cover
     
    Torque converter bolts
     
    Harness
     
    Wiring harness from the Power Plant Frame (PPF)
     

  10.  
  11. Support the transmission with a jack.
    CAUTION
    Removing the PPF spacers will reduce the performance of the PPF. If the spacers are removed, replace the PPF as an assembly.



    PPF front bolts
     
    Differential side bolts and pry out the spacer
     



    Differential mounting spacer
     
    Transmission side bolts and the PPF
     
    Transmission bolts and the transmission; keep the torque converter end slightly elevated during removal
     

  12.  

To install:

  1. Support the transmission with a jack.
  2.  
  3. Install or connect the following:

    Transmission into position, make sure the torque converter side is slightly elevated, once aligned, install and tighten the bolts to 48-65 ft. lbs.
     
    Differential mounting spacer and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
     

  4.  
  5. Support the transmission with a jack until it is level.

    PPF in position and if removed install the sleeve
     
    Spacer and bolts and tighten the reamer bolt making sure the threading is aligned correctly. The reamer bolt should be installed in the forward hole. Tighten the outer bolts making sure the threads are properly aligned. Tighten all bolts in the sequence illustrated to 91 ft .lbs. (123 (Nm).
     
    PPF front bolts and tighten to 91 ft. lbs. (123 Nm)
     

  6.  
  7. Remove the jack and connect the wiring harness.
  8.  
  9. Using a straightedge and Vernier caliper measure the distance A which should be 1.99-2.46 inch (50.5-62.5mm). If the distance is not as specified, reposition the PPF to the transmission.
  10.  
  11. Install or connect the following:

    Torque converter bolts. Align the holes while turning the converter, use a suitable tool to lock the flywheel and hand tighten the bolts in a criss-cross pattern. Once all the bolts are hand tight, tighten the bolts to 36 ft. lbs. (49 Nm).
     
    Under cover
     
    Oil cooler, tighten the oil cooler bolts to 28 ft. lbs. (39 Nm)
     
    Water hose and
     
    Oil filter
     
    Intake manifold bracket
     
    Harness bracket
     
    Input/turbine speed sensor
     
    Solenoid connector
     
    Output speed sensor connector
     
    Transmission range selector switch connector
     
    Shift rod
     
    Exhaust bracket
     
    Performance rod
     
    Dipstick tube
     
    Throttle cable. Measure the free-play on the cable, if the free-play is not 0.04-0.11 inch (1-3mm), then adjust by turning the lock nuts until the desired specification is reached and tighten the lock nuts to 10 ft. lbs. (14 Nm).
     
    Drive shaft
     
    Exhaust system
     
    Rear crossbar, on models equipped with 16 inch wheels
     
    Crossmember and bracket, on models equipped with 16 inch wheels
     
    Negative battery cable
     

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

    Click image to see an enlarged view

    Fig. Exploded view of the automatic transmission assembly-Miata



    Click image to see an enlarged view

    Fig. Tighten the differential bolts in the sequence illustrated-Miata with an automatic transmission



    Click image to see an enlarged view

    Fig. Measure the distanceAwhich should be 1.99-2.46 inch (50.5-62.5mm)-Miata with an automatic transmission



    Click image to see an enlarged view

    Fig. Adjust the free-play on the throttle and adjust using the lock nutsA-Miata with an automatic transmission

  14.  



Click image to see an enlarged view

Fig. Exploded view of the automatic transaxle assembly mounting-Mazda 3 models

  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 duct and cover
     
    Negative battery cable
     
    Battery, tray and box
     
    Air cleaner assembly
     
    Exhaust manifold insulator
     
    Wheels
     
    Splash shields
     
    Under cover
     
    Input/turbine speed sensor connector
     
    Vehicle speed sensor connector
     
    Transaxle connector
     
    Transaxle range switch connector
     
    Ground wiring harness
     
    Oil pressure switch connector
     
    Harness bracket
     
    Upper transaxle bolts
     
    Stabilizer bar link
     
    Tie rod ends from the knuckle
     
    Lower control arm ball joint
     
    Halfshafts
     

  8.  
  9. Remove the joint shaft as follows:
    1. Disconnect the right halfshaft from the joint shaft by tapping the transaxle side outer ring with a brass bar and a hammer. Disconnect the joint shaft bracket from the block and remove the joint shaft.
    2.  
    3. Install tool 49 G030 455 to hold the side gears after removal
    4.  

  10.  
  11. Support the engine assembly with a engine support assembly such as 49 E017 5A0.
  12.  
  13. Remove or disconnect the following:

    Selector cable
     

  14.  
  15. Remove the oil cooler as follows:
    1. Remove the water hose.
    2.  
    3. Remove the oil hose.
    4.  
    5. Remove the hose clamp.
    6.  
    7. Remove the connector bolt, packing, oil pipe, packing and oil cooler.
    8.  

  16.  
  17. Remove or disconnect the following:

    Starter
     
    End plate cover
     
    Torque converter bolts, through the starter opening
     

  18.  
  19. Install an engine support device such as 49 E017 5A0.

    Number 1 engine mount rubber
     
    Battery tray bracket
     

  20.  
  21. Remove the number 4 engine mount and joint bracket as follows:
    1. Install two suitable pieces of wood between the front fender panel and upper apron reinforcement as illustrated. The wood size should be approximately 1.38 inch (35mm) on 4 door models or 2.36 inch (60mm) on 5 door models.

      Click image to see an enlarged view

      Fig. Install two suitable pieces of wood between the front fender panel and upper apron reinforcement-Mazda 3 with an automatic transaxle

    2.  

  22.  
  23. Loosen the engine support assembly and lean the engine towards the transaxle.
  24.  
  25. Support the transaxle with a jack, remove the transaxle bolts and the transaxle.
  26.  

To install:

  1. Place the transaxle onto a jack and raise into position.
  2.  
  3. Install the transaxle bolts and tighten the bolts to 28-38 ft. lbs. (37-52 Nm). Refer to the exploded view illustration for bolt locations.
  4.  
  5. Install or connect the following:

    Number 4 engine mount bracket to the transaxle case and tighten the bolts to 49-68 ft. lbs. (66-93 Nm)
     
    Number 1 engine mount rubber to the crossmember and hand tighten the bolts
     
    Number 4 engine mount rubber with the body stud passing through the holes and tighten the bolts to 61-87 ft. lbs. (83-113 Nm)
     
    Battery tray bracket on the number 4 engine mount rubber with the body stud bolts passing through the holes. Tighten retainers identified in the illustration as 2 to 32-45 ft. lbs. (44-61 Nm) and the retainers identified as 1 in the same illustration to 61-86 inch lbs. (7-10 Nm).

    Click image to see an enlarged view

    Fig. Number 1 engine mount rubber bolt locations-Mazda 3 models with an automatic transaxle



    Click image to see an enlarged view

    Fig. Install the number 4 engine mount rubber with the body stud passing through the holes-Mazda 3 models with an automatic transaxle



    Click image to see an enlarged view

    Fig. Install the battery tray bracket on the number 4 engine mount rubber with the body stud bolts passing through the holes-Mazda 3 models with an automatic transaxle

     

  6.  
  7. Remove the engine support device and tighten the number 1 mount rubber bolts to 68-85 ft. lbs. (116 Nm).

    Torque converter bolts and tighten to 25-44 ft. lbs. (34-60 Nm)
     
    End plate cover
     
    Starter
     

  8.  
  9. Install the oil cooler in the reverse order of removal keeping in mind the following steps and referring to the oil cooler exploded illustration for torque specifications:
    1. Apply compressed air to the cooler side opening to clear any debris. Apply the air for less than a minute only.
    2.  
    3. If reusing the same oil hose, install a new clamp right on the mark left by the old clamp and apply force in the direction of the arrow to secure the clamp. Align the marks and slide the oil hose onto the pipe until seated as illustrated. Make sure the hose clamp does not interfere with any other component.

      Click image to see an enlarged view

      Fig. Exploded view of the oil cooler assembly and related components-Mazda 3 models with an automatic transaxle



      Click image to see an enlarged view

      Fig. Align the marks and slide the oil hose onto the pipe until seated-Mazda 3 models with an automatic transaxle



      Selector cable
       
      Joint shaft. Install a new circlip with the opening facing up. Hand tighten the bolts, then tighten the bolts to 31-45 ft. lbs. (42-62 Nm). Refer to the illustration for bolt location.
       
      Halfshafts
       
      Lower control arm ball joint. Tighten the retainers to 31-43 ft. lbs. (43-59 Nm).
       
      Tie rod ends to the knuckle. Tighten the retainers to 27-37 ft. lbs. (37-50 Nm).
       
      Stabilizer bar link. Tighten the retainers to 30-40 ft. lbs. (40-54 Nm).
       
      Harness bracket
       
      Oil pressure switch connector
       
      Ground wiring harness
       
      Transaxle range switch connector
       
      Transaxle connector
       
      Vehicle speed sensor
       
      Input/Turbine speed sensor connector
       
      Under cover
       
      Splash shields
       
      Wheels
       
      Exhaust manifold insulator
       
      Air cleaner assembly
       
      Battery tray and battery
       

    4.  

  10.  
  11. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  12.  

Fn4a-EL Transaxle





Click image to see an enlarged view

Fig. Exploded view of the FN4A-EL automatic transaxle assembly mounting-Mazda 6 models

  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:

    Negative battery cable
     
    Battery and battery tray
     
    Air cleaner assembly
     
    Wheels
     
    Splash shields
     
    Under cover
     
    Steering gear, linkage and pipe assembly bolts from the crossmember and using mechanics wire, position the steering gear and linkage assembly aside.
     
    Heated Oxygen (HO 2 S) connector
     
    Oil pressure switch connectors for the oil filter and transaxle
     
    Input/turbine speed connector
     
    Transmission range switch connector
     
    Transaxle connector
     
    Vehicle speed sensor connector
     
    Oil dipstick tube
     
    Harness bracket
     
    Oil hose
     
    Selector cable
     
    Transaxle upper mount bolts
     
    Starter
     
    Endplate cover
     
    Lower control arm ball joints
     
    Damper fork
     
    Tie rod ends from the knuckle
     
    Stabilizer bar link
     
    Halfshafts
     

  8.  
  9. Disconnect the right halfshaft from the joint shaft by tapping the transaxle side outer ring with a brass bar and a hammer. Disconnect the joint shaft bracket from the block and remove the joint shaft.
  10.  
  11. Install tool 49 G030 455 to hold the side gears after removal.
  12.  
  13. Support the engine assembly with a engine support assembly such as 49 E017 5A0.
  14.  
  15. Remove or disconnect the following:

    Number 1 engine mount
     
    Lower front shock absorber bolt
     
    No. 1 engine mount center bolt
     

  16.  
  17. Support the crossmember with a jack and remove the nuts and the crossmember bracket.

    Crossmember
     
    Torque converter nuts, hold the crankshaft pulley to prevent the flywheel from turning while loosening the nuts and remove the nuts through the starter motor opening
     
    Number 4 engine mount
     
    Lower transaxle bolts
     

  18.  
  19. Loosen the engine support assembly and lean the engine towards the transaxle.
  20.  
  21. Support the transaxle with a jack, remove the transaxle bolts and the transaxle.
  22.  

To install:

  1. Place the transaxle onto a jack and raise into position.
  2.  
  3. Install the transaxle bolts and tighten the bolts to 28-38 ft. lbs. (37-52 Nm). Refer to the exploded view illustration for bolt locations.
  4.  
  5. Install the torque converter nuts and tighten to 25-32 ft. lbs. (34-44 Nm).
  6.  
  7. Install the No. 1 engine mount and No. 4 engine mount bracket as follows:
  8.  
  9. Install the No. 1 engine mount and No. 4 engine mount bracket as follows:
    1. Make sure the mount is installed as illustrated.
    2.  
    3. Align the bolt holes with the stud bolts, install the No. 4 mount bracket to the transaxle.
    4.  
    5. Align the holes with the stud bolts and install the No. 1 engine mount to the transaxle.
    6.  
    7. Align the hole on the No. 4 engine mount bracket with the No. 4 mount rubber on the car and hand tighten bolt D. Refer to the illustration for bolt locations.
    8.  

  10.  
  11. Hand tighten bolts B, C and A.
    1. Tighten bolts B and C then bolt A to 49-68 ft. lbs. (66-93 Nm).
    2.  
    3. Tighten bolt D to 63-86 ft. lbs. (85-116 Nm).
    4.  
    5. Tighten bolt E on the No. 1 mount to 63-86 ft. lbs. (85-116 Nm).
    6.  

  12.  
  13. Remove the engine support device.

    Click image to see an enlarged view

    Fig. Install the No. 1 mount and No. 4 mount bracket and tighten the bolts in the sequence and specifications outlined in the text-Mazda 6 models with a FN4A-EL automatic transaxle



    Click image to see an enlarged view

    Fig. Tighten bolt E on the No. 1 mount to the specification outlined in the text-Mazda 6 models with a FN4A-EL automatic transaxle

  14.  
  15. Install the remaining components in the reverse order of removal.
  16.  
  17. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  18.  

Gf4a-EL Transaxle



  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 cover, battery and tray
     
    Air cleaner assembly
     
    Selector cable clip and nut and the cable
     
    Transaxle range switch connector
     
    Input/Turbine speed sensor connector
     
    Solenoid valve connector
     
    Harness bracket
     
    Selector cable bracket
     
    Number 1 engine mount stay bracket
     
    Starter
     
    Heated Oxygen (HO 2 S) connector
     
    Wheels
     
    Splash shields
     
    Exhaust pipe
     
    Lower ball joint
     
    Right side halfshaft
     
    Joint shaft
     

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

    Number 4 mount
     
    Number 1 engine mount nut
     
    Engine mount member
     
    Oil hose
     
    Under covers
     
    Torque converter bolts
     
    Left side halfshaft
     
    Number 1 engine mount bolt
     

  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.

    Click image to see an enlarged view

    Fig. Exploded view of the GF4A-EL automatic transaxle assembly (1 OF 2)-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the GF4A-EL automatic transaxle assembly (2 OF 2)-Millenia

  14.  

To install:

  1. Place the transaxle onto a jack and raise into position.
  2.  
  3. Install the transaxle bolts and tighten the bolts to 50-73 ft. lbs. (68-99 Nm).
  4.  
  5. Install or connect the following:

    Number 1 engine mount bolt. Make sure the holes align before tightening. Tighten the bolt to 77 ft. lbs. (104 Nm).
     
    Left side halfshaft
     
    Torque converter bolts and tighten to 32-44 ft. lbs. (44-60 Nm)
     
    Under covers
     
    Oil hose
     
    Engine mount member and number 2 engine mount, make sure the number 2 mount stud bolt passes through the number 2 mount bracket installation hole and tighten the bolt A to 68 ft. lbs. (93 Nm). Tighten bolt B to 77 ft. lbs. (104 Nm). Refer to the illustration for component location.
     
    Number 1 engine mount nut
     
    Number 4 mount retainers. Refer to the illustration for component location and torque specifications.
     
    Joint shaft

    Click image to see an enlarged view

    Fig. Install the engine mount member bolts and tighten to specification-LJ4A-EL automatic transaxle assembly-Millenia with GF4A-EL automatic transaxle

     
    Right side halfshaft
     
    Lower ball joint
     
    Exhaust pipe
     
    Splash shields
     
    Wheels
     
    HO 2 S connector
     
    Starter
     
    Number 1 engine mount stay bracket
     
    Harness bracket
     
    Solenoid valve connector
     
    Input/Turbine speed sensor connector
     
    Transaxle range switch connector
     
    Selector cable nut and clip
     
    Air cleaner assembly
     
    Battery tray, battery and cover
     

  6.  
  7. Fill the transmission with fluid.
  8.  
  9. Start the engine and check for leaks and proper operation.
  10.  

 
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