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Home >> Mazda >> 2006 >> 6 s, 4D Wagon, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 32 (Automatic Transaxle - Overhaul (FS5A-El)) >> Automatic Transaxle Disassembly >> Disassembly >> Disassembly procedure

Disassembly procedure

WARNING: This page is about a different variant/trim than selected.
  1. Remove the torque converter, and immediately turn it so that the hole faces upward This will help to keep any remaining fluid from spilling.
  2. Remove the ATF dipstick and oil filler tube.
  3. Remove the O-ring from the oil filler tube.
  4. Remove the breather hose.
  5. Assemble the SST. 
    Fig 1: Identifying SST
    G05118619Courtesy of MAZDA MOTORS CORP.
  6. Lift the transaxle and mount it on the SST.
  7. Remove the input/turbine speed sensor.
  8. Remove the O-ring from the input/turbine speed sensor.
  9. Remove the oil pressure switch.
  10. Remove the transaxle range switch.
  11. Remove the vehicle speed sensor.
  12. Remove the O-ring from the vehicle speed sensor.
  13. Remove the intermediate sensor.
  14. Remove the O-ring from the intermediate sensor.
  15. Remove the connector pipe, connector bolt and oil pipe.
    Fig 2: Identifying SST For Mount
    G05118620Courtesy of MAZDA MOTORS CORP.
    WARNING:
    • Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
    CAUTION:
    • Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.
    • If any old sealant gets into the transaxle during installation of the oil cover, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil cover, and clean with cleaning fluids.
  16. Remove the oil cover.

    Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause.

    1. Clutch facing material
      • Drive plate and brake band wear
    2. Steel (magnetic)
      • Bearing, gear, and driven plate wear
    3. Aluminum (nonmagnetic)
      • Aluminum part wear
  17. Disconnect the solenoid valve connector.
    Fig 3: Identifying Transaxle Solenoid Connectors
    G05118621Courtesy of MAZDA MOTORS CORP.
  18. Remove the bolts as shown in the figure.
  19. Remove the secondary control valve body.
    Fig 4: Identifying Secondary Control Valve Body Bolts
    G05118622Courtesy of MAZDA MOTORS CORP.
  20. Remove the coupler component.
  21. Remove the O-rings and tubular pins from the transaxle case.
    WARNING:
    • Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
    CAUTION:
    • Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.
    • If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil pan, and clean with cleaning fluids.
    Fig 5: Locating O-Rings And Tubular Pins At Transaxle Case
    G05118623Courtesy of MAZDA MOTORS CORP.
  22. Remove the oil pan.

    Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause.

    1. Clutch facing material
      • Drive plate and brake band wear
    2. Steel (magnetic)
      • Bearing, gear, and driven plate wear
    3. Aluminum (nonmagnetic)
    • Aluminum part wear
  23. Disconnect the solenoid valve connector, ground, and TFT sensor.
  24. Remove the oil strainer.
    Fig 6: Identifying Solenoids And Connectors
    G05118624Courtesy of MAZDA MOTORS CORP.
  25. Remove the O-ring from the oil strainer.
    Fig 7: View Of O-Ring On Oil Strainer
    G05118625Courtesy of MAZDA MOTORS CORP.
  26. Remove the bolts as shown in the figure.
    NOTE:
    • Remove the control valve body by removing the head of the manual valve from the port of the parking assist lever component.
    Fig 8: Identifying Primary Control Valve Body Bolts
    G05118626Courtesy of MAZDA MOTORS CORP.
  27. Remove the Primary control valve body.
    Fig 9: View Of Primary Control Valve Body
    G05118627Courtesy of MAZDA MOTORS CORP.
  28. Remove the coupler component.
    Fig 10: View Of Coupler Component
    G05118628Courtesy of MAZDA MOTORS CORP.
  29. Remove the accumulator component.
    Fig 11: View Of Accumulator Component
    G05118629Courtesy of MAZDA MOTORS CORP.
  30. Remove the manual shaft.
    1. Remove the roll pin using a pin punch.
      Fig 12: Removing Roll Pin Using A Pin Punch
      G05118630Courtesy of MAZDA MOTORS CORP.
    2. Remove the manual shaft.
    3. Remove the O-ring from the manual shaft.
    Fig 13: View Of O-Ring And Manual Shaft
    G05118631Courtesy of MAZDA MOTORS CORP.
  31. Remove the parking rod lever component.
    Fig 14: View Of Parking Rod Lever Component
    G05118632Courtesy of MAZDA MOTORS CORP.
  32. Remove the band servo component.
    Fig 15: View Of Band Servo Bolts
    G05118633Courtesy of MAZDA MOTORS CORP.
  33. Remove the oil pump.
    Fig 16: View Of Oil Pump
    G05118634Courtesy of MAZDA MOTORS CORP.
  34. Remove the converter housing by tapping lightly with a plastic hammer.
    Fig 17: View Of Converter Housing
    G05118635Courtesy of MAZDA MOTORS CORP.
  35. Remove the forward clutch component.
    Fig 18: View Of Forward Clutch Component
    G05118636Courtesy of MAZDA MOTORS CORP.
  36. Remove the differential.
    Fig 19: View Of Differential
    G05118637Courtesy of MAZDA MOTORS CORP.
  37. Remove the actuator plate.
    Fig 20: View Of Actuator Plate
    G05118638Courtesy of MAZDA MOTORS CORP.
  38. Remove the support actuator.
    Fig 21: View Of Support Actuator
    G05118639Courtesy of MAZDA MOTORS CORP.
  39. Pull out the parking pawl shaft.
  40. Remove the parking pawl.
    Fig 22: View Of Parking Pawl
    G05118640Courtesy of MAZDA MOTORS CORP.
  41. Remove the pawl return spring.
    Fig 23: View Of Pawl Return Spring
    G05118641Courtesy of MAZDA MOTORS CORP.
  42. Remove the Output gear component.
    Fig 24: View Of Output Gear Component
    G05118642Courtesy of MAZDA MOTORS CORP.
  43. Remove the Secondary sun gear.
    Fig 25: View Of Secondary Sun Gear
    G05118643Courtesy of MAZDA MOTORS CORP.
  44. Remove the direct clutch component and one-way clutch No.2.
    Fig 26: View Of Direct Clutch Component And One-Way Clutch No.2
    G05118644Courtesy of MAZDA MOTORS CORP.
  45. Remove the Needle bearing, seal rings and spacer.
  46. Remove the reduction brake.(See REDUCTION BRAKE DISASSEMBLY/ ASSEMBLY .)
    Fig 27: View Of Needle Bearing, Seal Rings And Spacer
    G05118645Courtesy of MAZDA MOTORS CORP.
  47. Remove the end cover.
  48. Remove the O-rings from the transaxle case.
    Fig 28: View Of O-Rings From Transaxle Case
    G05118646Courtesy of MAZDA MOTORS CORP.
  49. Remove the band strut.
    Fig 29: View Of Band Strut
    G05118647Courtesy of MAZDA MOTORS CORP.
  50. Remove the 2-4 brake band, and hold it together using a piece of wire as shown in the figure.
    Fig 30: View Of 2-4 Brake Band
    G05118648Courtesy of MAZDA MOTORS CORP.
  51. Remove the clutch component.
    Fig 31: View Of Clutch Component
    G05118649Courtesy of MAZDA MOTORS CORP.
  52. Remove the snap ring.
    Fig 32: View Of Snap Ring
    G05118650Courtesy of MAZDA MOTORS CORP.
  53. Remove the rear planetary gear component.
    Fig 33: View Of Rear Planetary Gear Component
    G05118651Courtesy of MAZDA MOTORS CORP.
  54. Remove the front sun gear by tapping its end with a flathead screwdriver or similar tool, as shown in the figure.
  55. Remove the forward clutch hub.
    Fig 34: View Of Forward Clutch Hub
    G05118652Courtesy of MAZDA MOTORS CORP.
  56. Remove the front planetary gear component.
    Fig 35: View Of Front Planetary Gear Component
    G05118653Courtesy of MAZDA MOTORS CORP.
  57. Remove the front internal gear and one-way clutch component.
    Fig 36: View Of Front Internal Gear And One-Way Clutch Component
    G05118654Courtesy of MAZDA MOTORS CORP.
  58. Remove the locknut.
    1. Knock the crimped portion of the locknut outward by using a small chisel and a hammer.
      Fig 37: View Of Lock Nut
      G05118655Courtesy of MAZDA MOTORS CORP.
    2. Install the SST  to the primary gear in the order shown.

      Tightening torque 

      19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf} 

      Fig 38: View Of SST And Primary Gear
      G05118656Courtesy of MAZDA MOTORS CORP.
    3. Install the SST  to the locknut in the order shown.
      Fig 39: View Of SST
      G05118657Courtesy of MAZDA MOTORS CORP.
    4. Remove the locknut.
      Fig 40: View Of Locknut
      G05118658Courtesy of MAZDA MOTORS CORP.
  59. Remove the primary gear by tapping it with a flathead screwdriver, etc. as shown in the figure.
    Fig 41: View Of Primary Gear
    G05118659Courtesy of MAZDA MOTORS CORP.
  60. Remove the bearing and distance piece.
    Fig 42: View Of Bearing And Distance Piece
    G05118660Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Removing the bearing race using a flathead screwdriver can damage the inside of the bearing race. Handle the flathead screwdriver carefully.
  61. Remove torx screws from the converter housing side.
  62. Remove the bearing race.
    Fig 43: Identifying Torx Screws At Converter Housing
    G05118661Courtesy of MAZDA MOTORS CORP.
  63. Remove the bearing race using the SST  as shown in the figure.
    Fig 44: View Of Bearing Race
    G05118662Courtesy of MAZDA MOTORS CORP.
  64. Remove the bearing using the SST as shown in the figure.
    Fig 45: Removing Bearing Using SST
    G05118663Courtesy of MAZDA MOTORS CORP.
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