Mazda Car 2005-06

Transaxle Removal & Installation 1

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Click image to see an enlarged view

Fig. Exploded view of the manual transmission assembly and related components-MX-5 Miata

  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. Remove the battery cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Loosen the starter installation bolts only enough that the starter is loose, but not removed.
  8.  
  9. Remove the shift lever knob.
  10.  
  11. Remove the console.
  12.  
  13. Remove the outer, then inner shift insulator components.
  14.  
  15. Remove the shift lever component.
  16.  
  17. Remove the member bracket
  18.  
  19. Remove the tunnel member.
  20.  
  21. Remove the catalytic converter and middle pipe.
  22.  
  23. Remove the clutch release pipe and cylinder.
  24.  
  25. Remove the power plant frame as follows:
    1. Support the transmission using a transmission jack.
    2.  
    3. Remove the power plant frame.
    4.  

  26.  
  27. Remove the hanger bracket.
  28.  
  29. Remove the propeller shaft as follows:
    NOTE
    When replacing with a new propeller shaft, mark the companion flange to match the position of the tag on the propeller shaft.

    1. Before removing the propeller shaft, make alignment marks on the yoke and differential companion flange.
    2.  
    3. Remove the retainers and the shaft.
    4.  
    5. Install the tools illustrated onto the to the extension housing.

      Click image to see an enlarged view

      Fig. Install the tools shown depending on transmission type, onto the to the extension housing-MX-5 Miata

    6.  

  30.  
  31. Disconnect the back-up light switch connector.
  32.  
  33. Disconnect the neutral switch connector.
  34.  
  35. Disconnect the vehicle speed sensor connector
  36.  
  37. Remove the wiring harness and any remaining electrical connections from the transmission.
    NOTE
    Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged or cause injury.

  38.  
  39. Support the transmission securely using a transmission jack.
  40.  
  41. Remove the transmission-to-engine bolts.
  42.  
  43. Remove the transmission.
    NOTE
    When removing/installing the transmission, be sure not to move the engine up and down more than necessary to prevent part interference with the engine.

  44.  

To install:

  1. Shift to any gear position.
  2.  
  3. Install tool 49 0259-44 onto the main shaft.
    WARNING
    Install the transmission carefully, holding it steady. If the transmission falls it could be damaged or cause injury.



    Click image to see an enlarged view

    Fig. Install tool 49 0259-44 onto the main shaft-MX-5 Miata

  4.  
  5. Place the transmission on the transmission jack and raise it.
  6.  
  7. Slowly rotate the tool 49 0259-44 to engage the clutch with the main drive gear spline, and install the transmission.
  8.  
  9. Tighten the transmission installation bolts and nuts to 37-52 Nm (28-38 Nm).

    Click image to see an enlarged view

    Fig. Location of the manual transmission bolts and nuts-MX-5 Miata

  10.  
  11. Installation of the remaining components is the reverse of removal, please note the following:
    1. When installing the propeller shaft:

      Align the marks and install the propeller shaft.
       
      When installing a new propeller shaft, align the differential companion flange mark with the tag on the propeller shaft and assemble.
       

    2.  
    3. When installing the power plant frame:

      Support the transmission and differential so that they are level using a transmission jack.
       
      Install the power plant frame.
       
      Temporarily tighten the nuts 1, 2, 3 in the order shown in the illustration.

      Click image to see an enlarged view

      Fig. Temporarily tighten the nuts 1, 2, 3 in the order shown-MX-5 Miata

       
      Tighten nut 2 until the power plant frame is seated in the rear differential.
       
      Temporarily tighten the nuts 4, 5 in order shown in the illustration.
       
      Install the middle pipe and tunnel member.
       
      Raise the front end of the power plant frame (transmission side) or the transmission with the transmission jack, and adjust dimension A to 26.7-34.7 mm (1.06-1.36 in) (lower surface of power plant frame-upper surface of the tunnel member) as shown in the illustration.

      Click image to see an enlarged view

      Fig. Raise the front end of the power plant frame (transmission side) or the transmission with the transmission jack, and adjust dimension A to 26.7-34.7 mm (1.06-1.36 in-MX-5 Miata

       
      Tighten the power plant frame installation nuts to 126-154 Nm (93-113.5 ft. lbs)
       
      Verify that dimension A is within the specification with the transmission jack and the adjustment bolt removed.
       
      If not within the specification, adjust dimension A again.
       

    4.  
    5. To position the plug hole plate, grasp rubber 1 and 2, as shown in the illustration, with your hands and press them in.

      Click image to see an enlarged view

      Fig. Install the plug hole plate by grasping rubber and pressing them in-MX-5 Miata

    6.  
    7. Apply grease to the areas of the shift lever component as shown in the illustration.
    8.  
    9. Align the shift lever component notch with the shift control case pin and install the shift lever component.

      Click image to see an enlarged view

      Fig. Apply grease to the areas of the shift lever component indicated-MX-5 Miata

    10.  

  12.  

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-Mazda6 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-Mazda6 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

    No. 4 engine mount bracket and rubber
     

  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. Remove the intake manifold and attach tool 49 UN30 3050 to the head as shown and remove the mount.
     

  16.  
  17. 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-Mazda6 models with the A65M-R manual transaxle

     
    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 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-Mazda6 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-Mazda6 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-Mazda6 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.  

 
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