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Final Assembly

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NOTE: Ensure all bearing preloads are set and appropriate shims are installed. See ADJUSTMENTS .
NOTE: For location of thrust bearings and races, refer to illustration. See Fig 1. For outer diameter identification of bearings and races, see THRUST BEARING & RACE SPECIFICATIONS  table. All bearings, except No. 1, are one-piece units.
Fig 1: Locating Thrust Bearings & Races
G00024943Courtesy of MAZDA MOTORS CORP.
THRUST BEARING & RACE SPECIFICATIONS

Application Location Outer Diameter - In. (mm)
Bearing No.
1 Between End Cover & Clutch 1.57 (40.0)
2 Between End Cover & Clutch 1.57 (40.0)
3 Between 3-4 Clutch Drum & Hub 1.54 (39.0)
4 Between 3-4 Clutch Hub & Rear Sun Gear Plate 3.08 (78.2)
5 Between Rear Planetary Gear & Front Sun Gear 2.05 (52.0)
6 Between Front Sun Gear & Front Planetary Gear 1.97 (50.0)
Race No.
1 Between End Cover & Clutch 1.58 (40.2)
  1. Measure front sun gear bushing. See Fig 2. Ensure bushing inner diameter is within specification. See TRANSAXLE SPECIFICATIONS . If not within specification, replace front sun gear.
  2. Measure end cover bushing. See Fig 3. Ensure bushing inner diameter is within specification. See TRANSAXLE SPECIFICATIONS . If not within specification, replace end cover.
  3. Mount transaxle case in appropriate holding fixture. Install oil pipe. Install funnel bearing and race. Tighten Torx screws to specification. See TORQUE SPECIFICATIONS . Install bearing race to transaxle case. Install locknut. Set primary gear in place. Install distance piece (spacer) and bearing. See Fig 4. Install lock nut and hand tighten.
  4. Secure primary gear with Holding Tool (49 B019 019). Using lock nut Socket (49 B019 021), tighten lock nut. Tighten the locknut from the end cover side to adjust the preload within specification. Preload: 4.42-7.96 INCH lbs. (0.50-0.90 N.m) is achieved. Stake lock nut. Remove SSTs.
  5. Install front internal gear and one-way clutch. Apply petroleum jelly to the bearing and secure bearing to the front planetary gear. Install front planetary gear. Apply petroleum jelly to the bearing and secure to front sun gear. See Figure.
  6. Install front sun gear with thrust bearing. Install rear planetary gear. Rotate case so that the oil pan faces downward. Pull the front internal gear and one-way clutch a little until the groove for the snap ring appears. See Fig 5. Install snap ring.
  7. Rotate case so that the end cover faces upward, and verify that the snap ring is installed accurately. Install 2-4 brake band servo return spring, piston and seal lubricated with ATF into transaxle case. Install servo retainer (cover) and tighten bolts to specification. See TORQUE SPECIFICATIONS .
  8. Install 2-4 brake band. Apply petroleum jelly to the bearing and install to 2-4 brake drum. Install 2-4 brake drum with thrust bearing. Install an alternate bolt in place of brake band strut. Bolt must be 2.36-2.75" (60-70 mm) in length. Tighten bolt to 43 INCH lbs. (4.9 N.m). Measure and record distance between case and head of bolt (dimension "A"). See Fig 6.
  9. Remove bolt. Measure and record total length of bolt from below head (dimension "B"). Calculate as follows:
    • B - A = C (The middle of the under head length)
    • C - 4 = D (The lower limit of under head length)
    • C - 4.7 = E (The upper limit of under head length)

    Select a brake band strut whose length should be between "D" and "E". Available lengths are:

    • 1.417" (36.0 mm)
    • 1.437" (36.5 mm)
    • 1.457" (37.0 mm)
    • 1.476" (37.5 mm)
    • 1.496" (38.0 mm)
    • 1.516" (38.5 mm)
    • 1.535" (39.0 mm)
    Install selected strut and tighten to specification. See TORQUE SPECIFICATIONS .

  10. Place .102" (2.6 mm) thrust bearing race (thickest) on end cover. Install end cover without gasket on 2-4 brake drum and case. Measure clearance between cover and transaxle case. See Fig 7. Calculate according to the formula:
    • A - 0.102 (2.6 mm) (Bearing thickness) = B
    • B - 0.25 = C (The lower limit of bearing thickness)
    • B - 0.50 = D (The upper limit of bearing thickness)

    Select an appropriate bearing race whose bearing thickness matches the calculated limits. Select a bearing race whose thickness is between "D" and "E". Bearing races are available in the following sizes:

    • 0.071" (1.8 mm)
    • 0.079" (2.0 mm)
    • 0.087" (2.2 mm)
    • 0.094" (2.4 mm)
    • 0.102" (2.6 mm)

    11. CAUTION: The bearing race and end cover may be damaged if the end cover is not installed correctly to the transaxle case. Align the projection of the bearing race within the area of the arrows shown in the figure, and then install the end cover to the transaxle case. See Fig 8.
  11. Select proper bearing race and install on end cover. See Fig 7. Ensure tab on bearing race is installed in correct location. See Fig 8. Install "O" rings coated with ATF in end cover. See Fig 9. Seal ring inner diameter:
    • A: 1.854" (47.1 mm)
    • B: 2.197" (55.8 mm)
    Apply a light coat of silicone sealant to contact surfaces of the transaxle case and end cover. Apply ATF to the "O" ring and install to transfer case. Install end cover to transaxle case. Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS .
  12. Install parking pawl spring, parking pawl and shaft to transaxle case. See Figure. Install support plate into transaxle case. Install actuator plate to transaxle case. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  13. Install secondary gear, and output gear and differential. Install forward clutch assembly. Apply light coating of silicone sealant to transaxle case and converter case. Install converter housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  14. Install differential side gear Holders (49 G030 455) into differential side gears. Install oil pump. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install parking rod lever assembly. Apply ATF to "O" ring and install on manual shaft. Install manual shaft to manual plate and detent bracket. Install roll/knock pin.
  15. Install accumulators. See ACCUMULATORS  under COMPONENT DISASSEMBLY & REASSEMBLY for identification.
  16. Install coupler. Ensure that the head of the manual valve and the parking rod are assembled properly. If they are not, the ranges cannot be charged.
  17. Install internal solenoid harness. Install valve body. Install valve body bolts in correct location. See Figure. All bolts are same length except bolts with no markings:
    • Bolt "B" - 1.575" (40 mm)
    • No Mark - 2.756" (70 mm)

    Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS .

  18. Connect harness connectors to solenoids. Match the harness colors, then connect the solenoid connector and transaxle fluid temperature sensor. See SOLENOID HARNESS CONNECTOR IDENTIFICATION  table. See Fig 10.
    SOLENOID HARNESS CONNECTOR IDENTIFICATION

    Shift Solenoid Connector Color
    A White
    B Blue
    C Green
    D White
    E Black
    Pressure Control Black
  19. Connect ground. See Fig 10. Tighten to specification. See TORQUE SPECIFICATIONS .
  20. Apply a light coat of silicone to the contact surfaced of the oil pan and transaxle case. Install oil pan. Tighten to specification. See TORQUE SPECIFICATIONS .
  21. Install oil pipe. Apply ATF to the "O" ring and install it to the vehicle speed sensor. Install vehicle speed sensor. Tighten to specification. See TORQUE SPECIFICATIONS .
  22. Apply ATF to the new "O" ring and install it to the input/turbine speed sensor. Install the oil pressure switch. Tighten to specification. See TORQUE SPECIFICATIONS .
  23. Install the input/turbine speed sensor. Tighten to specification. See TORQUE SPECIFICATIONS .
  24. Install Transaxle Range (TR) switch. Rotate the manual shaft to the "N" position. Turn the protrusion till the resistance between TR switch connector terminals "B" and "C" becomes 750 ohms. See Fig 11. Install the TR switch while aligning the protrusion and groove. Hand tighten the TR switch mounting bolts. See Fig 12.
    • Inspect resistance between TR switch terminals "B" and "C". See Fig 11. Resistance should be 750 ohms. Adjust as necessary. Tighten TR switch mounting bolts to specification. See TORQUE SPECIFICATIONS .
      • CAUTION: Do NOT use an impact wrench. Hold the manual shaft lever when removing the manual shaft nut or the transaxle may be damaged.
    • Install manual shaft lever and washer. Using an adjustable wrench, hold the manual shaft lever and tighten manual shaft nut to specification. See TORQUE SPECIFICATIONS .
  25. Apply ATF to NEW "O" ring and install on the oil filler tube. Install oil filler tube and dipstick to the transaxle. Tighten to specification. See TORQUE SPECIFICATIONS .
    26. NOTE: If re-using torque converter, drain any ATF remaining in torque converter. Pour about 0.53 qt. (0.5 L) of solvent into torque converter. Shake torque converter to clean the inside. Drain out the solvent.
  26. Align torque converter to oil pump and install torque converter. See Fig 13. Check installed depth. See Fig 14. Installed distance "A" depth:
    • Mazda3 - 1.24" (31.4 mm)
    • Mazda6 & Protege - 0.84" (21.4 mm)
Fig 2: Identifying Front Sun Gear Bushing
G00380249Courtesy of MAZDA MOTORS CORP.
Fig 3: Identifying End Cover Bushing
G00380250Courtesy of MAZDA MOTORS CORP.
Fig 4: Installing Distance Piece & Bearing
G00380251Courtesy of MAZDA MOTORS CORP.
Fig 5: Identifying Groove For Snap Ring
G00380252Courtesy of MAZDA MOTORS CORP.
Fig 6: Determining 2-4 Brake Band Strut Length
G00024948Courtesy of MAZDA MOTORS CORP.
Fig 7: Measuring End Play
G00024949Courtesy of MAZDA MOTORS CORP.
Fig 8: Identifying End Cover Thrust Bearing Race Location
G00024950Courtesy of MAZDA MOTORS CORP.
Fig 9: Locating End Cover "O" Rings
G00380253Courtesy of MAZDA MOTORS CORP.
Fig 10: Locating Ground & Solenoid Connections
G00380255Courtesy of MAZDA MOTORS CORP.
Fig 11: Installing Transaxle Range Switch
G00380256Courtesy of MAZDA MOTORS CORP.
Fig 12: Aligning Manual Shaft Groove To TR Switch Protrusion
G00380257Courtesy of MAZDA MOTORS CORP.
Fig 13: Aligning Torque Converter To Oil Pump
G00380258Courtesy of MAZDA MOTORS CORP.
Fig 14: Measuring Distance "A"
G00380259Courtesy of MAZDA MOTORS CORP.
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