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Manual Transaxle Removal/Installation: Installation

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WARNING:
  • Install the manual transaxle carefully, holding it steady. If the manual transaxle falls it could be damaged or cause injury.
  1. Set the manual transaxle on a jack and lift into place.
    Fig 1: Setting Manual Transaxle On Jack
    G10937050Courtesy of MAZDA MOTORS CORP.
  2. Install the manual transaxle to the engine, and tighten the transaxle mounting bolts.
    Fig 2: Locating Transaxle Mounting Bolts
    G10937051Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    • 38-52 N.m {3.9-5.3 kgf.m, 29-38 ft.lbf}
  3. Tighten the stud bolts for the manual transaxle.
    Fig 3: Identifying Manual Transaxle Stud Bolt With Torque Specifications
    G10937052Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • If the No. 4 engine mount bracket nut is loosened, tighten the stud bolts for the manual transaxle because they may be loosened.
  4. Install the No. 4 engine mount bracket to No. 4 engine mount rubber, and temporarily tighten the installation bolt.
    Fig 4: Installing Engine Mount Bracket To Engine Mount Rubber
    G10937053Courtesy of MAZDA MOTORS CORP.
  5. Pull up the manual transaxle using the SSTs  , pass the manual transaxle stud bolts through the No. 4 engine mount bracket, and temporarily tighten the No. 4 engine mount installation nuts.
    Fig 5: Pulling Up Manual Transaxle
    G10937054Courtesy of MAZDA MOTORS CORP.
  6. Install the No. 1 engine mount bracket and bracket plate to the manual transaxle, and temporarily tighten the installation bolts.
    Fig 6: Installing Engine Mount Bracket And Bracket Plate To Manual Transaxle
    G10937055Courtesy of MAZDA MOTORS CORP.
  7. Install the front crossmember component and No. 1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
  8. Temporarily tighten the No. 1 engine mount rubber installation bolts.
    Fig 7: Identifying Engine Mount Rubber Bolts
    G10937056Courtesy of MAZDA MOTORS CORP.
  9. Align the alignment marks on the No. 4 engine mount bracket and nuts, and temporarily tighten the nuts shown in the figure.
    Fig 8: Identifying Good And Bad Alignment Marks On Engine Mount Bracket
    G10937057Courtesy of MAZDA MOTORS CORP.
  10. Tighten the No. 4 engine mount bracket installation nuts and bolt in the order shown in the figure.
    Fig 9: Engine Mount Bracket Nuts Tightening Sequence
    G10937058Courtesy of MAZDA MOTORS CORP.
    No. Tightening torque
    1, 2, 3 92-116 N.m {9.4-11 kgf.m, 68-85 ft.lbf}
    4 81-99 N.m {8.3-10 kgf.m, 60-73 ft.lbf}
  11. Tighten the No. 1 engine mount bracket and bracket plate installation bolts in the order shown in the figure.
    Fig 10: Identifying Engine Mount Bracket And Bracket Plate
    G10937059Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    • 84-98 N.m {8.6-9.9 kgf.m, 62-72 ft.lbf}
  12. Remove the SST (49 C017 5A0)  .
  13. Tighten the No. 1 engine mount rubber installation bolts.
    Fig 11: Identifying Engine Mount Rubber Installation Bolts With Torque Specifications
    G10937060Courtesy of MAZDA MOTORS CORP.
  14. Connect and/or Install the following parts to the underside of the vehicle.
    1. Install the starter. (See STARTER REMOVAL/INSTALLATION .)
    2. Install the clutch release cylinder to the manual transaxle. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION .)
  15. Connect and/or Install the following parts related to the suspension and axle.
    1. Connect the drive shaft (RH) to the manual transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
    2. Connect the drive shaft (LH) to the manual transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
    3. Connect the front lower arms to the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
    4. Connect the stabilizer control links to the stabilizer. (See FRONT STABILIZER REMOVAL/INSTALLATION .)
    5. Connect the tie-rod end ball joints to the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
    6. Connect the ABS wheel-speed sensors to the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION .)
    7. Connect the clip securing the brake hose to the shock absorber. (See BRAKE HOSE (FRONT) REMOVAL/INSTALLATION .)
    8. Install the front tires. (See GENERAL PROCEDURES (FRONT AND REAR AXLES) .)
  16. Connect and/or install the following parts in the engine compartment.
    1. Install the fuel hose to the clip shown in the figure.
      Fig 12: Identifying Fuel Hose Clip
      G10937061Courtesy of MAZDA MOTORS CORP.
    2. Connect the clip shown in the figure.
      Fig 13: Identifying Intake Manifold Clip
      G10937062Courtesy of MAZDA MOTORS CORP.
    3. Install the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION .)
    4. Install the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
    5. Install the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION .)
    6. Install the lower radiator hose clip and bracket to the manual transaxle.
      Fig 14: Identifying Lower Radiator Hose Clip And Bracket Bolts With Torque Specifications
      G10937063Courtesy of MAZDA MOTORS CORP.
    7. Connect the back-up light switch connector. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION .)
    8. Connect the neutral switch connector. (See NEUTRAL SWITCH REMOVAL/INSTALLATION .)
    9. Install the bracket to the manual transaxle and the exhaust manifold using the following procedure:
      Fig 15: Identifying Manual Transaxle Bracket Bolts
      G10937064Courtesy of MAZDA MOTORS CORP.
      1. Tighten the bolt A.

        Tightening torque 

        • 8-10 N.m {82-101 kgf.cm, 71-88 in.lbf}
      2. ii. Temporarily tighten the bolt B and C.
      3. iii. Tighten the bolt B.

        Tightening torque 

        • 38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf}
      4. iv. Tighten the bolt C.

      Tightening torque 

      • 38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf}
    10. Connect the ground cable to the No. 4 engine mount bracket.
      Fig 16: Identifying Engine Mount Bracket Ground Cable Bolt With Torque Specifications
      G10937065Courtesy of MAZDA MOTORS CORP.
    11. Install the control cable bracket to the manual transaxle.
      Fig 17: Identifying Control Cable Bracket Bolt With Torque Specifications
      G10937066Courtesy of MAZDA MOTORS CORP.
    12. Connect the control cable to the manual transaxle. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
    13. Install the battery component (battery, battery tray and PCM component). (See BATTERY REMOVAL/INSTALLATION .)
    14. Install the air cleaner component (air cleaner, air hose). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  17. Install the splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
  18. Install the front under cover No. 1. (See FRONT UNDER COVER No. 1 REMOVAL/INSTALLATION .)
  19. Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT .)
  20. Install the front under cover No. 2. (See FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
  21. Connect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION .)
  22. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  23. If the manual transaxle is overhauled, perform the "INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL". (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL .)
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