Mazda Car 2002-04

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transmission oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Shifter knob
     
    Center console
     
    Gearshift lever
     
    Engine undercover and the performance rod
     
    Exhaust pipe from the manifold
     
    Entire exhaust system as an assembly and matchmark the driveshaft flange at the rear
     
    Driveshaft
     
    Clutch release cylinder and set it aside, without disconnecting the hydraulic hose
     
    Starter
     
    Speedometer cable and wiring from the frame member
     

  6.  
  7. Support the transmission and differential with jacks.
  8.  
  9. Remove the transmission-to-differential frame, also called the Power Plant Frame (PPF), as follows:
    1. Remove the frame-to-transmission bracket.
    2.  
    3. Remove the bolts from the underside of the frame at the differential end, noting their location. Pry out the spacer from the frame.
    4.  
    5. Remove the differential mounting spacer from the underside of the differential.
    6.  
    7. Insert a 14 x 1.5mm bolt through the frame hole and turn it into the sleeve. Twist and pull the bolt downward.
    8.  
    9. Install a 6 x 1mm bolt in the side hole to hold the sleeve and remove the long bolt. Remove the short bolt.
      NOTE
      Do not remove the spacers from the end of the PPF. Doing so will reduce the performance of the frame. If the spacers are removed, the PPF must be replaced as an assembly.

    10.  
    11. Remove the transmission side bolts and the frame member.
    12.  

  10.  
  11. Remove or disconnect the following:

    Bolts from the clutch housing
     
    Transmission from the vehicle
     

  12.  

To install:

  1. Lightly lubricate the main shaft spline and the release bearing fork contact points with molybdenum grease and install the fork. Place a wood block on a floor jack and use it to tilt the engine up in front.
  2.  
  3. Install or connect the following:
    NOTE
    After the frame installation, position a straightedge between the body frame members on each side of the vehicle. Measure the distance between the bottom of the frame to the straightedge; it should be 2.403-2.797 in. (61-71mm). If the distance is not as specified, reposition the frame member at the transmission.



    Transmission. Torque the bolts alternately, in several passes, to 48-65 ft. lbs. (64-89 Nm)
     
    Transmission to the differential frame. Torque the bolts to 76-91 ft. lbs. (104-124 Nm)
     
    Bracket. Torque the bracket-to-transmission bolts to 27-40 ft. lbs. (37-54 Nm) and the bracket-to-frame bolts to 77-91 ft. lbs. (104-124 Nm)
     



    Speedometer cable and wiring
     
    Starter
     
    Clutch release cylinder
     
    Driveshaft. Torque the nuts to 22 ft. lbs. (30 Nm)
     
    Exhaust system using new gaskets. Torque the nuts to 34 ft. lbs. (46 Nm)
     
    Performance rod and engine undercover
     
    Shift lever
     
    Rear console
     
    Shift lever knob
     
    Negative battery cable
     

  4.  
  5. Fill the transmission with clean oil.
  6.  
  7. Verify proper operation of the transmission.

    Click image to see an enlarged view

    Fig. Measure distance -A- after installing the transmission-to-differential frame member-Miata with N4A-HL and NC4A-EL transmissions

  8.  

 
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