Mazda Car 2002-04

Transaxle Removal & Installation 3

Print

G15m-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-2000-01 Protege with G15M-R transaxle



    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle assembly mounting-2002 Protege with G15M-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 65-86 ft. lbs. (89-116 Nm), the lower bolts except the lowest bolt to 28-38 ft. lbs. (38-51 Nm). Tighten the lowest bolt to 13-18 ft. lbs. (18-25 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 component 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-2000-01 Protégé with G15M-R transaxle



    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle assembly mounting-2002 Protégé with G15M-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 65-86 ft. lbs. (89-116 Nm), the lower bolts except the lowest bolt to 28-38 ft. lbs. (38-51 Nm). Tighten the lowest bolt to 13-18 ft. lbs. (18-25 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 component 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. Position the direction indicator on the mount member and bushings-Protégé with both manual and automatic transaxles



    Click image to see an enlarged view

    Fig. Location of the front mount member bolt locations-Protégé with both manual and automatic transaxles



    Click image to see an enlarged view

    Fig. Number 4 mount fastener locations-2000-01 Protégé with G15M-R transaxle



    Click image to see an enlarged view

    Fig. Number 4 mount fastener locations-2002 Protégé with G15M-R transaxle



    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-Protégé with both manual and automatic transaxles



    Click image to see an enlarged view

    Fig. Tighten the joint shaft bolts as shown-Protégé with both manual and automatic transaxles

     
    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.  

G35m-R Transaxle





Click image to see an enlarged view

Fig. Exploded view of the G35M-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
     
    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
     
    Back up light switch connector
     
    Neutral safety switch connector
     
    Harness bracket
     
    Vehicle speed sensor
     
    Shift cable and select cable
     
    Selector cable bracket
     
    Clutch release cylinder
     
    Starter
     
    Endplate cover
     
    Transaxle upper mount bolts
     
    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.

    Click image to see an enlarged view

    Fig. Exploded view of the joint shaft assembly-Mazda 6 models with the 2.3L (L3) engine

  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 bracket
     
    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
     

  18.  
  19. Remove the number 4 engine mount

    Click image to see an enlarged view

    Fig. Exploded view of the front crossmember, related components and their torque specifications-Mazda 3 and 6 models



    Dynamic damper
     
    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 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.  

  6.  
  7. 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.  

  8.  
  9. 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 G35M-R manual 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 G35M-R manual transaxle

  10.  
  11. Install the remaining components in the reverse order of removal.
  12.  
  13. Fill the transaxle with fluid. Road test the vehicle and check for leaks. Top off all fluids as needed.
  14.  

 
label.common.footer.alt.autozoneLogo