Mazda Car 2005-06

Transaxle Removal & Installation 2

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G35m-R Transaxle





Click image to see an enlarged view

Fig. Exploded view of the G35M-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
     
    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-Mazda6 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-Mazda3 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-Mazda6 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-Mazda6 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.  

 
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