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. Drain the transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Speedometer cable and/or sensor wires from the transaxle

    Click image to see an enlarged view

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

     
    Clutch release (slave) cylinder from the transaxle
     
    Water, secondary air and Exhaust Gas Recirculation (EGR) pipe brackets
     
    Wiring harness clip
     
    Coupler for the neutral switch and backup lamp switch
     
    Body ground connector
     
    2 upper transaxle mounting bolts and mount an Engine Support tool 49-eR301-025A to the engine hanger
     
    Front wheels
     
    Engine under and side covers
     
    Intake manifold support bracket, if necessary
     
    Halfshafts
     

  6.  
  7. Insert a Differential Side Gear Holder 49-B027-001 to hold the side gears in place and prevent misalignment.
  8.  
  9. Remove or disconnect the following:

    Transaxle crossmember
     
    Gearshift control rod from the transaxle
     
    Extension bar from the transaxle
     
    Wiring connectors
     
    Starter motor
     
    End plates
     

  10.  
  11. Lean the engine toward the transaxle side to lower the transaxle by loosening the engine support hook bolt. Support the transaxle with a transaxle jack.
  12.  
  13. Remove or disconnect the following:

    Engine brackets, as necessary
     
    Remaining transaxle bolt
     
    Transaxle
     

  14.  

To install:

  1. Before installing the transaxle, lightly coat the splines of the primary shaft gear with molybdenum disulfide grease.
  2.  
  3. Attach a thick rope to 2 places on the transaxle. Place a board on the jack and lower the transaxle onto the board. Using the jack, lift the transaxle into position and throw the end of the rope over the support fixture bar. Tension the rope to guide the transaxle onto its mounts while lifting the transaxle with the jack.
  4.  
  5. Once the transaxle is in place, have an assistant install and tighten all the transaxle-to-engine mounting bolts.
  6.  
  7. The remainder of the installation is the reverse of the removal procedure. Tighten all fasteners to specifications.
  8.  
  9. Fill the transaxle with fluid.
  10.  

  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:

    Crossmember and bracket, on models equipped with 16 inch wheels
     
    Rear crossbar, on models equipped with 16 inch wheels
     
    Under cover
     
    Starter
     
    Front and middle exhaust pipes
     
    Shifter knob
     
    Rear console and insulator
     
    Shift lever assembly
     
    Dust boot
     
    Front crossbar
     
    Drive shaft
     
    Clutch release cylinder
     
    Back up light switch connector
     
    Neutral safety switch connector
     
    Speedometer sensor connector
     
    Wiring harness from the Power Plant Frame (PPF)
     

  8.  
  9. 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 bracket
     
    Differential side bolts and pry out the spacer
     



    Differential mounting spacer
     
    Transmission side bolts and the PPF
     
    Transmission bolts and the transmission

    Click image to see an enlarged view

    Fig. Exploded view of the M15M-D manual transmission assembly-Miata



    Click image to see an enlarged view

    Fig. Exploded view of the Y16M-D manual transmission assembly-Miata



    Click image to see an enlarged view

    Fig. Remove the PPF bracket-Miata



    Click image to see an enlarged view

    Fig. Remove the differential side bolts and pry out the spacer-Miata



    Click image to see an enlarged view

    Fig. Remove the differential mounting spacer-Miata

     

  10.  

To install:

  1. Tilt the engine by pushing up on the front oil pan with a wooden block placed on a transmission jack.
  2.  
  3. Support the transmission with a jack.
  4.  
  5. Install or connect the following:

    Transmission into position and tighten the bolts to 48-65 ft. lbs. (64-89 Nm) on models equipped with the M15M-D transmission or 76-91 ft. lbs. (104-123 Nm) on models equipped with the Y16M-D transmission.
     
    Differential mounting spacer and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
     

  6.  
  7. 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 bracket and tighten bolts A to 91 ft. lbs. (123 Nm) and bolts B to 39 ft. lbs. (53 Nm).
     

  8.  
  9. Remove the jack and connect the wiring harness.
  10.  
  11. Using a straightedge and Vernier caliper measure the distance A which should be 2.37-2.83 inch (60-72mm). If the distance is not as specified, reposition the PPF to the transmission.

    Click image to see an enlarged view

    Fig. The reamer bolt should be installed in the forward hole-Miata



    Click image to see an enlarged view

    Fig. Tighten the PPF bolts using this sequence-Miata



    Click image to see an enlarged view

    Fig. Measure the distanceAwhich should be 2.37-2.83 inch (60-72mm)-Miata



    Click image to see an enlarged view

    Fig. Fill the change control case with the specified amount of the proper oil-Miata



    Click image to see an enlarged view

    Fig. Apply grease to the shift lever components-Miata

  12.  
  13. Install or connect the following:
    NOTE
    The change control assembly must be filled with 4.9-5.8 cubic inch (80-95cc) of GL-4 or 5 oil if the extension housing was removed or the transmission overhauled.



    Speedometer sensor connector
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Clutch release cylinder
     
    Drive shaft
     
    Front crossbar
     
    Dust boot
     

  14.  
  15. Fill the change control case with the specified amount of the proper oil.
  16.  
  17. Apply grease to the shift lever components as illustrated.
  18.  
  19. Apply sealant to the contact surfaces of the shift lever and change control case.
  20.  
  21. Install the shift lever.
  22.  
  23. Install or connect the following:

    Rear console and insulator
     
    Shifter knob
     
    Starter
     
    Under cover
     
    Rear crossbar, on models equipped with 16 inch wheels
     
    Crossmember and bracket, on models equipped with 16 inch wheels
     
    Front and middle exhaust pipes
     

  24.  
  25. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  26.  



Click image to see an enlarged view

Fig. Exploded view of the manual 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 and battery box
     
    Air cleaner assembly
     
    Exhaust manifold insulator
     
    Wheels
     
    Splash shields
     
    Under cover
     
    Starter
     
    Back up light switch connector
     
    Neutral safety switch connector, if equipped
     
    Vehicle speed sensor
     
    Shift cable and select cable using a fastener remover as illustrated.

    Click image to see an enlarged view

    Fig. Remove the shift cable and select cable using a fastener remover-Mazda 3 models

     
    Harness bracket
     
    Clutch release cylinder
     
    Transaxle upper mount bolts
     
    Tie rod ends from the knuckle
     
    Stabilizer bar link
     
    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:

    Number 1 engine mount rubber
     
    Battery tray bracket
     

  14.  
  15. 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 a manual transaxle

    2.  

  16.  
  17. Install an engine support device such as 49 E017 5A0.
  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 upper bolts to 28-38 ft. lbs. (37-52 Nm), the lower bolts 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 49-62 ft. lbs. (66-93 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 1 to 32-45 ft. lbs. (44-61 Nm) and the retainers identified as 2 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 a manual 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 a manual 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 a manual transaxle

     

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

    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.

    Click image to see an enlarged view

    Fig. Exploded view of the joint shaft assembly-Mazda 3

     
    Halfshafts
     
    Lower control arm ball joint. Tighten the retainers to 32-43 ft. lbs. (43-59 Nm).
     
    Stabilizer bar link. Tighten the retainers to 30-40 ft. lbs. (40-54 Nm).
     
    Tie rod ends to the knuckle. Tighten the retainers to 27-37 ft. lbs. (37-50 Nm).
     
    Clutch release cylinder. Tighten the retainers to 14-19 ft. lbs. (18-25 Nm).
     
    Harness bracket
     
    Shift and select cables
     
    Vehicle speed sensor
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Starter
     
    Under cover
     
    Splash shields
     
    Wheels
     
    Exhaust manifold insulator
     
    Air cleaner assembly
     
    Battery tray and battery
     

  8.  
  9. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  10.  

2.0L (Fs) Engine



  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



  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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