Mazda Car 2002-04

Transaxle Removal & Installation 2

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A26mx-R Transaxle



  1. Before servicing the vehicle, refer to the precautions section.
    NOTE
    Refer the exploded view illustration for component locations and if applicable, their retainer torque specifications.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the battery and battery tray.
  6.  
  7. Remove the wheels, tires and splash shields.

    Click image to see an enlarged view

    Fig. Exploded view of the A26MX-R manual transaxle assembly mounting-Mazdaspeed6 models

  8.  
  9. Remove the under cover.
  10.  
  11. Remove the steering gear and linkage, and pipe assembly installation bolts from the front crossmember, then suspend the steering gear and linkage with a cable.
  12.  
  13. Drain the transfer oil into a suitable container.
  14.  
  15. Remove the front pipe.
  16.  
  17. Disconnect the propeller shaft from the transfer side.
  18.  
  19. Remove the transfer oil cooler with the hose still connected.
  20.  
  21. Remove the lower arm (front, rear) ball joint.
  22.  
  23. Remove the damper fork.
  24.  
  25. Remove the tie-rod end ball joint.
  26.  
  27. Remove the stabilizer control link.
  28.  
  29. Remove the ABS sensor.
  30.  
  31. Remove thetie-rod end ball joint.
  32.  
  33. Remove the pinch bolt.
  34.  
  35. Separate the right side drive shaft from the joint shaft by tapping on a brass bar inserted between them.
  36.  
  37. Remove the joint shaft. Remove the bolts and pull the joint shaft straight out.
    CAUTION
    The sharp edges of the joint shaft can slice or puncture the oil seal. Be careful when removing the joint shaft from the transaxle.



    Click image to see an enlarged view

    Fig. Exploded view of the transfer assembly mounting-Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Exploded view of the joint shaft assembly mounting-Mazdaspeed6 models

  38.  
  39. Remove the clip.
  40.  
  41. Remove the No.1 engine mount.
  42.  
  43. Remove the crossmember bracket as follows:
    WARNING
    Removing the crossmember is dangerous. The crossmember component could fall and cause serious injury or death. Verify that the jack securely supports the crossmember component before removing the crossmember bracket.

    1. Support the crossmember component with a jack and remove the nuts.
    2.  
    3. Remove the crossmember bracket.
    4.  

  44.  
  45. Remove the transverse member.
  46.  
  47. Remove the stabilizer control link nut.
  48.  
  49. Remove the front shock absorber lower side bolt.
  50.  
  51. Remove the crossmember component.

    Click image to see an enlarged view

    Fig. Exploded view of the crossmember assembly mounting-Mazdaspeed6 models

  52.  
  53. Remove the catalytic converter bracket.
  54.  
  55. Remove the transfer bracket, insulator and transfer.
  56.  
  57. Remove the air cleaner.
  58.  
  59. Remove the charge air cooler.
  60.  
  61. Disconnect the reverse and neutral switch connectors.
  62.  
  63. Drain the transaxle fluid.
  64.  
  65. Remove the drive shaft.
  66.  
  67. Remove the engine wiring harness bracket.
  68.  
  69. Remove the oxygen sensor bracket.
  70.  
  71. Remove the selector cable and shift cable.
  72.  
  73. Remove the wiring harness bracket.
  74.  
  75. Remove the water pipe installation bolt and nut.
  76.  
  77. Remove the upper side transaxle mounting bolt.
  78.  
  79. Support the engine with an engine support device such as 49 C017 5AO as illustrated.
    CAUTION
    When setting tool 49 C017 5AO on the right side, make sure it doesn't interfere with the DSC HU/CM.



    Click image to see an enlarged view

    Fig. Install the left/right front shaft of the 49 C017 5AOwith front foot No.2 to the bolt as shown-Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Install the right rear shaft of the 49 C017 5AOto the bolt of the right shock absorber as shown-Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Install the left rear shaft of the 49 C017 5AOto the bolt of the left shock absorber. (Identical position to the right side)-Mazdaspeed6 models

  80.  
  81. Remove the No.4 engine mount bracket.
  82.  
  83. Remove the clutch release cylinder.
  84.  
  85. Remove the lower side transaxle mounting bolt.
  86.  
  87. Remove the bolt shown in the figure and set the brake pipe out of the way.

    Click image to see an enlarged view

    Fig. Remove the bolt shown and set the brake pipe out of the way-Mazdaspeed6 models

  88.  
  89. Lean the engine toward the transaxle.
  90.  
  91. Support the transaxle on a jack.
  92.  
  93. Remove the transaxle mounting bolts.
  94.  
  95. Remove the transaxle.
  96.  

To install:

  1. Installation is the reverse of removal, please note the following:
    1. Install the transaxle mounting bolts and tighten to 28-38 ft. lbs. (37-52 Nm).
    2.  
    3. Tighten the brake pipe bolt to 14-18 ft. lbs. (18-25 Nm).
    4.  
    5. Install the No.4 engine mount bracket.
    6.  
    7. Verify that the engine mount rubber is installed as shown.

      Click image to see an enlarged view

      Fig. No.4 engine mount bracket mounting-Mazdaspeed6 models

    8.  
    9. By aligning the holes with the stud bolts, install the No.4 engine mount bracket to the transaxle. Align the hole of the No.4 engine mount bracket with the No.4 engine mount rubber on vehicle, and temporarily tighten nut D.
    10.  
    11. Lightly tighten nuts B, C and bolt A.
    12.  
    13. Tighten nuts B, C in order of B through C, then bolt A.
    14.  
    15. Tighten nut D.
    16.  
    17. Bolts A, B and C torque to 49-67 ft. lbs. (66-93 Nm).
    18.  
    19. Nut D torque to 63-86 ft. lbs. (85-116 Nm).
    20.  
    21. Install the transfer bracket.
    22.  
    23. Hand-tighten the bolt A and B.
    24.  
    25. Tighten the bolts in order of C, A, B and D to 31-45 ft. lbs. (42-62 Nm).

      Click image to see an enlarged view

      Fig. Transfer bracket mounting-Mazdaspeed6 models



      Click image to see an enlarged view

      Fig. No 1 engine mount assembly-Mazdaspeed6 models



      Click image to see an enlarged view

      Fig. Transverse mount assembly-Mazdaspeed6 models

    26.  
    27. Install the No.1 engine mount.
    28.  
    29. Align the hole of the No.1 engine mount rubber with the bolt hole of transaxle.
    30.  
    31. Hand-tighten the bolt A, B, and C. Tighten the bolts to 68-86 ft. lbs. (93-116 Nm).

      Click image to see an enlarged view

      Fig. Install a new clip onto the joint shaft with the opening facing up and that the clip diameter does not exceed 1.34 inches (34mm)-Mazdaspeed6 models

    32.  

  2.  

A65m-R Transaxle





Click image to see an enlarged view

Fig. Exploded view of the A65M-R manual 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:

    Battery and battery tray
     
    Air cleaner assembly
     
    Starter
     
    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.
     
    Shift cable and select cable
     
    Back up light switch connector
     
    Neutral safety switch connector
     
    Clutch release cylinder
     
    Ground harness
     
    Transaxle upper mount bolts
     
    Lower control arm ball joints
     
    Damper fork
     
    Tie rod ends from the knuckle
     
    Stabilizer bar link
     
    Halfshafts

    Click image to see an enlarged view

    Fig. Exploded view of the joint shaft assembly-Mazda 6 models with the 3.0L (AJ) engine

     

  8.  
  9. Disconnect the left halfshaft from the joint shaft by inserting a prybar between the transaxle and the halfshaft outer ring. 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. Remove No. 4 engine mount bracket and rubber.
  14.  
  15. Support the engine assembly with a engine support assembly such as 49 E017 5A0.
  16.  
  17. Remove or disconnect the following:

    Number 1 engine mount bracket
     
    Lower front shock absorber bolt
     
    No. 1 engine mount. Remove the intake manifold and attach tool 49 UN30 3050 to the head as shown and remove the mount.
     

  18.  
  19. Support the crossmember with a jack and remove the nuts and the crossmember bracket.

    Crossmember

    Click image to see an enlarged view

    Fig. When removing the No. 1 engine mount, remove the intake manifold and attach tool 49 UN30 3050 to the head as shown-Mazda 6 models with the A65M-R manual transaxle

     
    Lower transaxle bolts
     

  20.  
  21. Loosen the engine support assembly and lean the engine towards the transaxle.
  22.  
  23. Support the transaxle with a jack, remove the transaxle bolts and the transaxle.
  24.  

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 crossmember in the reverse order of removal and refer to the exploded view illustration for component locations and torque specifications.
  6.  
  7. Align the hole of the No. 1 engine mount rubber with the bolt hole of the transaxle. Hand tighten bolt A and then tighten bolts B and C to 49-68 ft. lbs. (66-93 Nm) and then tighten bolt A to 49-68 ft. lbs. (66-93 Nm).

    Click image to see an enlarged view

    Fig. Tighten the No. 1 mount in the sequence and specifications outlined in the text-Mazda 6 models with a A65M-R manual transaxle

  8.  
  9. Install the No. 4 engine mount as follows:
    1. Make sure the No. 4 mount is installed as illustrated.
    2.  
    3. Hand tighten bolts A and B.
    4.  
    5. Align the holes on the contact area of the front frame with bolt C hole.
    6.  
    7. Tighten bolt A and then B to 55-74 ft. lbs. (74-100 Nm).
    8.  
    9. Tighten bolt C and then D to 55-74 ft. lbs. (74-100 Nm).
    10.  
    11. Make sure the No. 4 mount is installed as illustrated.
    12.  
    13. Hand tighten bolt F.
    14.  
    15. Raise the transaxle with a floor jack and align the hole on the No. 4 engine mount bracket with the stud bolts on the transaxle.
    16.  
    17. Install bolts F, G and H and tighten in that sequence to 49-68 ft. lbs. (66-93 Nm).
    18.  
    19. Tighten bolt E to 63-86 ft. lbs. (85-116 Nm).
    20.  

  10.  
  11. Remove the engine support device.

    Click image to see an enlarged view

    Fig. Install the No. 4 mount and tighten bolts A thru D in the sequence and specifications outlined in the text-Mazda 6 models with a A65M-R manual transaxle



    Click image to see an enlarged view

    Fig. When installing the No. 4 mount, tighten bolts F, G and H, then bolt E in the sequence and specifications outlined in the text-Mazda 6 models with a A65M-R manual transaxle

  12.  
  13. Install the remaining components in the reverse order of removal.
  14.  
  15. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  16.  

F25m-R 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 and battery box
     
    Air cleaner assembly and fresh air duct
     
    Wheels
     
    Splash shields
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Front exhaust pipe and three way catalytic converter
     
    Starter
     
    Speedometer sensor connector
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Clutch release cylinder
     
    Extension bar
     
    Change control rod
     
    Tie rod ends from the knuckle
     
    Lower control arm ball joint
     
    Halfshafts
     
    Joint shaft, install tool 49 B027 006 to hold the side gears after removal
     

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

    Number 4 engine mount
     
    Engine mount member
     
    Number 2 engine mount
     
    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.  


    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle assembly mounting-Protege with F25M-R transaxle


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 48-65 ft. lbs. (64-89 Nm), the lower bolts to 28-38 ft. lbs. (38-51 Nm). Refer to the exploded view illustration for bolt locations.
  4.  
  5. Install or connect the following:

    Number 1 engine mount bracket. Refer to the illustration for component location and torque specifications.
     
    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 boltsAB
    4.  
    5. Tighten boltsC
    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 boltDED
    8.  

  8.  
  9. Install or connect the following:

    Joint shaft. Install a new circlip with the opening facing up. Hand tighten the boltsA
     
    Halfshafts
     
    Lower control arm ball joint
     
    Tie rod ends to the knuckle
     
    Change control rod
     
    Extension bar
     
    Clutch release cylinder
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Speedometer connector
     
    Starter
     
    EGR pipe
     
    Splash shields
     
    Wheels
     
    Air cleaner assembly and fresh air duct
     
    Battery and battery box
     

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

  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
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Front exhaust pipe and three way catalytic converter
     
    Starter
     
    Speedometer sensor connector
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Clutch release cylinder
     
    Extension bar
     
    Change control rod
     
    Tie rod ends from the knuckle
     
    Lower control arm ball joint
     
    Halfshafts
     
    Joint shaft, install tool 49 B027 006 to hold the side gears after removal

    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle assembly mounting-Protégé with F25M-R transaxle

     

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

    Number 4 engine mount
     
    Engine mount member
     
    Number 2 engine mount
     
    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 48-65 ft. lbs. (64-89 Nm), the lower bolts to 28-38 ft. lbs. (38-51 Nm). Refer to the exploded view illustration for bolt locations.
  4.  
  5. Install or connect the following:

    Number 1 engine mount bracket. Refer to the illustration for component location and torque specifications.
     
    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 nuts B and tighten to 50-68 ft. lbs. (67-93 Nm).
    4.  
    5. Tighten bolts C to 50-68 ft. lbs. (67-93 Nm).
    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 D , then nuts E and bolt D to 50-68 ft. lbs. (67-93 Nm).
    8.  

  8.  
  9. Install or connect the following:

    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. Number 4 mount fastener locations-Protégé with F25M-R transaxle

     
    Halfshafts
     
    Lower control arm ball joint
     
    Tie rod ends to the knuckle
     
    Change control rod
     
    Extension bar
     
    Clutch release cylinder
     
    Neutral safety switch connector
     
    Back up light switch connector
     
    Speedometer connector
     
    Starter
     
    EGR pipe
     
    Splash shields
     
    Wheels
     
    Air cleaner assembly and fresh air duct
     
    Battery and battery box
     

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

 
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