CX-7 Transmission Manual

1874-1U-06B(INDEX).
fm 1
Automatic
Transaxle and
Transfer
Workshop
Manual
AW6AEL
AW6AXEL
FOREWORD
This manual explains the service points for
the above-indicated automotive system.
This manual covers all models with the
above-indicated automotive system, not any
one specific model.
In order to do these procedures safely,
quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers.
This manual should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual without obligation or
advance notice.
All rights reserved.
No part of this book may be reproduced or
used in any form or by any means, electronic
or mechanical-including
photocopying and recording and the use of
any kind of information storage and retrieval
system-without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
CONTENTS
Title
Section
FEATURES
SERVICE
GENERAL INFORMATION
00
00
DRIVELINE/AXLE
03
03
TRANSMISSION/TRANSAXLE
05
05
2006 Mazda Motor Corporation

PRINTED IN U.S.A., FEBRUARY 2006
Form No. 18741U06B
Part No. 9999950AW607
FEATURES(cover).fm
FEATURES
FEATURES_1874-1U-06B(03-00).fm
03
DRIVELINE/AXLE
SECTION
03-00
Toc
of SCT . . . . . . . . . . . . . . . . . . 03-00
OUTLINE
TRANSFER . . . . . . . . . . . . . . . 03-16
Toc of SCT
03-00
OUTLINE
DRIVELINE/AXLE FEATURES . . . . . . . . 03-001
DRIVELINE/AXLE SPECIFICATIONS. . . 03-001
End of Toc
DRIVELINE/AXLE FEATURES
NG: DRIVELINE/AXLE
Improved reliability
id030000100100
Separate oil pump and oil cooler have been adopted to the transfer
End Of Sie
DRIVELINE/AXLE SPECIFICATIONS
id030000100200
Item
Type
Transfer oil
Specification
API service GL-5
SAE 80W-90
Grade
Viscosity
Oil capacity
(approx. quantity)
(L {US qt, Imp qt})
1.2 {1.3,1.1}
End Of Sie
03-001
TRANSFER
03-16
TRANSFER
TRANSFER STRUCTURAL VIEW . . . . . 03-161

TRANSFER CROSS-SECTIONAL
VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-161
TRANSFER POWER FLOW . . . . . . . . . . . 03-162

TRANSFER OIL COOLER
CONSTRUCTION . . . . . . . . . . . . . . . . . 03-162
End of Toc
03-16
TRANSFER STRUCTURAL VIEW

NG: TRANSFER
id031600100100
OIL COOLER
DRIVE PINION GEAR
RING GEAR
OIL PUMP
DRIVE GEAR SHAFT
DRIVE GEAR
acxuun00000598
End Of Sie
TRANSFER CROSS-SECTIONAL VIEW
id031600100200
DRIVE GEAR CASE

DRIVE GEAR
DRIVE GEAR SHAFT
OIL PUMP
RING GEAR
OIL LEVEL PLUG
FRONT CARRIER
DRIVE PINION GEAR

acxuun00000599
End Of Sie
03-161
TRANSFER
TRANSFER POWER FLOW
id031600100300
acxuun00000600
End Of Sie
TRANSFER OIL COOLER CONSTRUCTION
WATER IN
id031600100400
VIEW A
WATER OUT
VIEW FROM A
acxuun00000601
End Of Sie
03-162
05
SECTION
Toc
of SCT . . . . . . . . . . . . . . . . . . 05-00
OUTLINE
AUTOMATIC TRANSAXLE . . . 05-17
Toc of SCT
05-00
OUTLINE
FEATURES . . . . . . . . . . . . . . . . . . . . . . 05-001
AUTOMATIC TRANSAXLE
SPECIFICATIONS . . . . . . . . . . . . . . . . 05-001
End of Toc
TRANSMISSION/TRANSAXLE FEATURES
NG: TRANSMISSION/TRANSAXLE
ATX [AW6A-EL, AW6AX-EL]

Superior shift quality
id050000100200
Centrifugal hydraulic pressure cancel clutch has been adopted.
End Of Sie
AUTOMATIC TRANSAXLE SPECIFICATIONS

Item
Transaxle type
Gear ratio
1GR
2GR
3GR
4GR
5GR
6GR
Reverse
Final gear ratio

ATF
Type
Capacity (approx. quantity)
(L {US qt, Imp qt})
id050000100300
Specifications
AW6A-EL, AW6AX-EL
4.148
2.370
1.555
1.154
0.859
0.685
3.393
3.749
JWS3309
Torque converter stall torque ratio

C1 clutch
C2 clutch
Hydraulic system
(Number of drive/driven plates)
C3 clutch
B2 brake
Band servo
Servo diameter (piston outer dia./retainer
(mm {in})
outer dia.)
Ring gear
Front planetary gear
Sun gear
(Number of teeth)
Pinion gear
Ring gear
Middle sun gear
Rear planetary gear
Rear sun gear
(Number of teeth)
Long pinion gear
Short pinion gear
Counter drive gear (Number of teeth)
Driven gear
Counter gear (Number of teeth)
Drive gear
Ring gear (Number of teeth)
7.0 {7.4, 6.2}

2.15
7/7
4/4
4/4
7/6
61.3/66.0
{2.41/2.60}
81
45
17
72
33
27
18
17
52
49
15
53
The example of automatic transaxle specifications. (specifications of the CX-7)

End Of Sie
05-001
05-00
AUTOMATIC TRANSAXLE
05-17
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE OUTLINE . .

AUTOMATIC TRANSAXLE
CROSS-SECTIONAL VIEW . . . . . . . . .
POWERFLOW STRUCTURE . . . . . . . . .
Description of Components . . . . . . . . .
POWERFLOW OPERATION . . . . . . . . . .
1GR (D range) . . . . . . . . . . . . . . . . . . .
1GR (M range) . . . . . . . . . . . . . . . . . . .
2GR . . . . . . . . . . . . . . . . . . . . . . . . . . .
05-171
05-172
05-174
05-174
05-175
05-176
05-177
05-178
3GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-179
4GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1710
5GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1711
6GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1712
R position . . . . . . . . . . . . . . . . . . . . . . . 05-1713
CENTRIFUGAL HYDRAULIC PRESSURE
CANCEL CLUTCH OUTLINE . . . . . . . . 05-1715
TORQUE CONVERTER OUTLINE. . . . . . 05-1717
End of Toc
AUTOMATIC TRANSAXLE OUTLINE
NG: AUTOMATIC TRANSAXLE
id051700101700
The AW6A (X) -EL automatic transaxle is a compact, lightweight, next-generation electronically controlled FF 6speed automatic transaxle that employs a Ravigneaux-type planetary gear. It employs a high-precision clutch
hydraulic control system for smooth, highly responsive gear shift feel.
End Of Sie
05-171
05-17
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE CROSS-SECTIONAL VIEW
id051700101900
AW6A-EL
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
TORQUE
CONVERTER
COUNTER
DRIVE GEAR
COUNTER GEAR
(DRIVEN)
COUNTER GEAR
(DRIVE)
DIFFERENTIAL
acxuun00000612
05-172
AUTOMATIC TRANSAXLE
AW6AX-EL
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
TORQUE
CONVERTER
05-17
COUNTER
DRIVE GEAR
COUNTER GEAR
(DRIVEN)
COUNTER GEAR
(DRIVE)
DIFFERENTIAL
acxuun00000613
End Of Sie
05-173
AUTOMATIC TRANSAXLE
POWERFLOW STRUCTURE
id051700102200
Description of Components
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
C3 CLUTCH
B1 BRAKE
OIL PUMP
INPUT
SHAFT
DIFFERENTIAL
COUNTER GEAR
REAR PLANETARY GEAR
FRONT PLANETARY GEAR

SUN GEAR
SUN GEAR
PINION GEAR
PINION GEAR
INPUT
SHAFT
RING GEAR
: LOCK
RING GEAR
acxuun00000680
The number of pinion gears differs depending on the engine displacement and vehicle.
Mazda6
Front: 3 pinions
Rear: 3 pinions
CX-7
Front: 5 pinions
Rear: 3 pinions
05-174
AUTOMATIC TRANSAXLE
ONE-WAY CLUTCH
B1 BRAKE
C3 CLUTCH
C1 CLUTCH
B2 BRAKE
C2 CLUTCH
REAR PLANETARY
RING GEAR
REAR PLANETARY
LONG PINION
GEAR
REAR
PLANETARY
CARRIER
COUNTER
DRIVE GEAR
FRONT
PLANETARY
CARRIER
FRONT
PLANETARY
RING GEAR
FRONT
PLANETARY
PINION GEAR
05-17
REAR PLANETARY
MIDDLE SUN GEAR
REAR PLANETARY SHORT
PINION GEAR
REAR PLANETARY REAR SUN GEAR
FRONT PLANETARY SUN GEAR

acxuun00000681
End Of Sie
POWERFLOW OPERATION
id051700102300
List of operating components

Clutch / Brake
C1 clutch
C2 clutch
C3 clutch
B1 brake
B2 brake
One-way clutch
Operation
Connects front planetary carrier to rear planetary rear sun gear
Connects intermediate shaft to rear planetary carrier
Connects front planetary carrier to rear planetary middle sun gear
Locks rear planetary middle sun gear
Locks rear planetary carrier
Locks counterclockwise rotation of rear planetary carrier
05-175
AUTOMATIC TRANSAXLE
1GR (D range)
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000620
Power transmission pathway

[Operating components: C1 clutch, One-way clutch]
Operating components:
C1 clutch, One-way clutch (counterclockwise rotation is locked), B2 brake (ON when engine brake is operating)
Planetary gear unit
Front
Rear
Input, Locked, Output

Input: Ring gear
Locked: Sun gear
Output: Carrier
Input: Rear sun gear
Locked: Carrier
Output: Ring gear
1. Input shaft (rotates clockwise) [same revolutions as the torque converters turbine runner]
2. Front planetary ring gear (rotates clockwise) [same revolutions as the input shaft]
3. Front planetary pinion gear (rotates clockwise on its axis, orbits clockwise)
[because the front planetary sun gear is locked by the oil pump, it is pressed against the front planetary ring
gear and orbits the sun gear while rotating on its axis (because the front planetary ring gear has internal gears,
the rotational direction does not change)]
4. Front planetary carrier (rotates clockwise)
[reduction: same revolution as the front planetary pinion gear orbit revolution]
5. C1 clutch (rotates clockwise) [connects the front planetary carrier and the rear planetary rear sun gear]
6. Rear planetary rear sun gear (rotates clockwise) [same revolution as the front planetary carrier]
7. Rear planetary short pinion gear (rotates counterclockwise on its axis)
[the rear planetary carrier tries to rotate counterclockwise, but the counterclockwise rotation is locked by oneway clutch.]
8. Rear planetary long pinion gear (rotates clockwise on its axis)
[the rear planetary middle sun gear rotates counterclockwise (idling)]
05-176
AUTOMATIC TRANSAXLE
9. Rear planetary ring gear (rotates clockwise)
[the rear planetary ring gear is rotated by the rear planetary long pinion gear (because the rear planetary ring
gear has internal gears, the rotational direction does not change)]
10. Counter drive gear (rotates clockwise)
[because the rear planetary ring gear is installed on the counter drive gear, the rotational direction and the
revolution are the same as the rear planetary ring gear]
11. Counter gear (rotates counterclockwise)
12. Differential ring gear (rotates clockwise)
1GR (M range)
05-17
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000621
[Operating components: C1 clutch, B2 brake]

When the engine brake is operating, driving force is transmitted from the tires. Because the rear planetary
carrier, which is locked in its counterclockwise rotation by the one-way clutch, tries to rotate clockwise, B2 brake
is turned ON and the rear planetary carrier is locked, and kinematic energy is transmitted from the tires to the
engine.
05-177
AUTOMATIC TRANSAXLE
2GR
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000622

Planetary gear unit
Front
Rear

Input: Ring gear
Locked: Sun gear
Output: Carrier
Input: Rear Sun gear
Locked: Middle Sun gear
Output: Ring gear
1. Input shaft (rotates clockwise) [same revolutions as the torque converters turbine runner]
2. Front planetary ring gear (rotates clockwise) [same revolution as the input shaft]
6. Rear planetary rear sun gear (rotates clockwise) [same revolution as the front planetary carrier]
7. Rear planetary middle sun gear is locked by B1 brake
8. Rear planetary short pinion gear (rotates counterclockwise on its axis, orbits clockwise)
9. Rear planetary long pinion gear (rotates clockwise on its axis, orbits clockwise)
05-178
AUTOMATIC TRANSAXLE
Engine brake
When the engine brake is operating, driving force is transmitted from the tires.
3GR
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
05-17
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000623

[Operating components: C1 clutch, C3 clutch]
Planetary gear unit
Front
Rear

Input: Ring gear
Locked: Sun gear
Output: Carrier
Input: Rear Sun gear, Middle Sun gear
Locked: Output: Ring gear
1. Input shaft (rotates clockwise) [same revolution as the torque converters turbine runner]
6. C3 clutch (rotates clockwise) [connects the front planetary carrier and the rear planetary middle sun gear]
7. Rear planetary gear component (rotates clockwise)
[because the rear planetary short pinion gear and the rear planetary long pinion gear are engaged, both the
pinion gears are locked due to the difference in the rotational directions, and kinematic energy of the rear
planetary sun gear and rear planetary middle sun gear is transmitted to the rear planetary ring gear]
8. Rear planetary ring gear (rotates clockwise) [same revolution as the rear planetary carrier]
revolution are same as the rear planetary ring gear]
05-179
FEATURES_1874-1U-06B(05-17).fm 10
AUTOMATIC TRANSAXLE
Engine brake
4GR
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000624

Planetary gear unit
Front
Rear

Input: Ring gear
Locked: Sun gear
Output: Carrier
Input: Rear Sun gear, Carrier
6. Intermediate shaft (rotates clockwise) [same revolution as the input shaft]
7. C2 clutch (rotates clockwise) [same revolution as the intermediate shaft]
8. Rear planetary carrier (rotates clockwise) [same revolution as the intermediate shaft]
9. Rear planetary short pinion gear (rotates clockwise on its axis, orbits clockwise)
[because the rear planetary carrier rotates faster than the rear planetary sun gear]
05-1710
FEATURES_1874-1U-06B(05-17).fm 11
AUTOMATIC TRANSAXLE
10. Rear planetary long pinion gear (rotates counterclockwise on its axis, orbits clockwise)
[because the rear planetary long pinion gears rotation is subtracted from the rear planetary carrier revolution,
the rear planetary ring gear revolution is slower than those of the rear planetary carrier]
revolution is the same as the rear planetary ring gear]
05-17
Engine brake
5GR
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000625

Planetary gear unit
Front
Rear

Input: Ring gear
Locked: Sun gear
Output: Carrier
Input: Carrier, Middle Sun gear
1. Input shaft (rotates clockwise) [same revolutions as torque converters turbine runner]
05-1711
FEATURES_1874-1U-06B(05-17).fm 12
AUTOMATIC TRANSAXLE
6. Rear planetary middle sun gear (rotates clockwise)
[same revolution as C3 clutch (decelerates by the front planetary gear, so the revolutions are slower than the
input shaft)]
7. Intermediate shaft (rotates clockwise) [same revolution as the input shaft]
8. C2 clutch (rotates clockwise) [same revolution as the intermediate shaft]
9. Rear planetary carrier (rotates clockwise) [same revolutions as intermediate shaft]
10. Rear planetary long pinion gear (rotates clockwise on its axis, orbits clockwise)
[because the rear planetary carrier rotates faster than the rear planetary middle sun gear, the rear planetary
middle pinion gear is pushed out by the speed difference, and orbits clockwise while rotating clockwise on its
axis.]
[because the rear planetary long pinion gears rotation is added to the rear planetary carrier revolutions, rear
planetary ring gear revolution is faster than those of the rear planetary carrier]
[because the rear planetary ring gear is installed on the counter drive gear, the rotational direction and
revolution is the same as the rear planetary ring gear]
Engine brake
6GR
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000626
05-1712
FEATURES_1874-1U-06B(05-17).fm 13
AUTOMATIC TRANSAXLE
[Operating components: B1 brake, C2 clutch]
Planetary gear unit
Front

Input: Carrier
Locked: Middle Sun gear
Output: Ring gear
Rear
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Input shaft (rotates clockwise) [same revolution as the torque converters turbine runner]
Intermediate shaft (rotates clockwise) [same revolution as the torque converters turbine runner]
B1 brake [locks the rear planetary middle sun gear]
C2 clutch [connects the intermediate shaft and the rear planetary carrier]
Rear planetary carrier (rotates clockwise) [same revolution as the intermediate shaft]
Rear planetary long pinion gear (rotates clockwise on its axis, orbits clockwise)
[because the rear planetary middle sun gear is locked, it is always in a speed increasing condition]
Rear planetary ring gear (rotates clockwise)
[because the rear planetary long pinion gears rotation is added to the rear planetary carrier revolution, the rear
planetary ring gear revolution is faster than those of the rear planetary carrier]
Counter drive gear (rotates clockwise)
Counter gear (rotates counterclockwise)
Differential ring gear (rotates clockwise)
Engine brake
R position
C2 CLUTCH
B2 BRAKE
ONE-WAY
CLUTCH
COUNTER DRIVE GEAR
C1 CLUTCH
B1 BRAKE
C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000627
05-1713
05-17
FEATURES_1874-1U-06B(05-17).fm 14
AUTOMATIC TRANSAXLE
Planetary gear unit
Front
Rear

Input: Ring gear
Locked: Sun gear
Output: Carrier
Input: Middle Sun gear
Locked: Carrier
Output: Ring gear
6. Rear planetary middle sun gear (rotates clockwise)
[same revolutions as the C3 clutch (rotates slower than the input shaft)]
7. B2 brake [locks the rear planetary carrier]
8. Rear planetary long pinion gear (rotates counterclockwise)
9. Rear planetary ring gear (rotates counterclockwise)
10. Counter drive gear (rotates counterclockwise)
11. Counter gear (rotates clockwise)
12. Differential ring gear (rotates counterclockwise)
Engine brake
End Of Sie
05-1714
FEATURES_1874-1U-06B(05-17).fm 15
AUTOMATIC TRANSAXLE
CENTRIFUGAL HYDRAULIC PRESSURE CANCEL CLUTCH OUTLINE
id051700102400
When the rotation of the clutch rises, centrifugal force operates on the oil inside the clutch, hydraulic pressure
rises, and the clutch is engaged at an earlier timing. Because of this, a difference arises in rotation between the
input shaft and the output shaft, and shift shock may occur. To solve this, an additional chamber has been
provided opposite the piston hydraulic pressure chamber. This causes centrifugal hydraulic pressure to operate
in the opposite direction with the same force as the piston, counteracting that pressure.
C2 CLUTCH
C1 CLUTCH
C3 CLUTCH
05-17
B
B
A : PISTON HYDRAULIC PRESSURE CHAMBER
B : CENTRIFUGAL HYDRAULIC PRESSURE CANCEL CHAMBER
acxuun00000628
05-1715
FEATURES_1874-1U-06B(05-17).fm 16
AUTOMATIC TRANSAXLE
WITH CENTRIFUGAL HYDRAULIC
PRESSURE CANCEL CLUTCH
PISTON HYDRAULIC
PRESSURE CHAMBER
WITHOUT CENTRIFUGAL HYDRAULIC

PRESSURE CANCEL CLUTCH
PISTON HYDRAULIC
PRESSURE CHAMBER
CENTRIFUGAL HYDRAULIC
PRESSURE CANCEL CHAMBER
PISTON HYDRAULIC
PRESSURE
PRESSURE
PRESSURE CANCEL
acxuun00000629
End Of Sie
NG: TORQUE CONVERTER
05-1716
FEATURES_1874-1U-06B(05-17).fm 17
AUTOMATIC TRANSAXLE
TORQUE CONVERTER OUTLINE
id051700100700
The torque converter is composed of the converter cover, pump impeller, turbine runner, stator, one-way clutch,
and TCC. The torque converter transmits and amplifies torque by means of the ATF inside it. In addition, the
use of the TCC is intended to improve fuel economy as a direct coupling between the engine and automatic
transaxle.
TCC PISTON
CONVERTER
COVER
05-17
TURBINE
RUNNER
PUMP
IMPELLER
STATER
OIL PUMP
INPUT SHAFT
acxuun00000605
End Of Sie
05-1717
SERVICE(cover).fm 1
SERVICE
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
00
SECTION
Toc
of SCT INFORMATION . . . . 00-00
GENERAL
Toc of SCT
00-00
GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00-002

Range of Topics . . . . . . . . . . . . . . . . . . 00-002
Service Procedure . . . . . . . . . . . . . . . . 00-002
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-004
Advisory Messages. . . . . . . . . . . . . . . . 00-004
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-005
Conversion to SI Units (Systme
International d'Units) . . . . . . . . . . . . 00-005
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-005
Upper and Lower Limits . . . . . . . . . . . . 00-005
FUNDAMENTAL PROCEDURES. . . . . . . 00-006
Preparation of Tools and Measuring
Equipment . . . . . . . . . . . . . . . . . . . . . 00-006
Special Service Tools . . . . . . . . . . . . . . 00-006
Disassembly . . . . . . . . . . . . . . . . . . . . . 00-006
Inspection During Removal,

Disassembly . . . . . . . . . . . . . . . . . . . .
Arrangement of Parts . . . . . . . . . . . . . .
Cleaning of Parts . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . .
Rubber Parts and Tubing . . . . . . . . . . .
Hose Clamps . . . . . . . . . . . . . . . . . . . .
Torque Formulas . . . . . . . . . . . . . . . . .
Vise . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM. . . . . . . . . . . . . .
Connectors . . . . . . . . . . . . . . . . . . . . . .
SAE STANDARDS. . . . . . . . . . . . . . . . . .
ABBREVIATIONS . . . . . . . . . . . . . . . . . .
00-006
00-007
00-007
00-007
00-008
00-008
00-008
00-008
00-009
00-009
00-009
00-0010
00-0011
End of Toc
WM: GENERAL INFORMATION
00-001
00-00
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000800100
Range of Topics
This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
Inspection and adjustment procedures are
divided into steps. Important points regarding the
location and contents of the procedures are
explained in detail and shown in the illustrations.
SHOWS PROCEDURE ORDER

FOR SERVICE
Fluid Pressure Inspection

1. Assemble the SSTs as shown in the figure.
Tightening torque
3949 Nm {4.05.0 kgfm, 2936 ftlbf}
49 1232 670A
49 H002 671
49 H032 322
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
acxuuw00000434
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
00-002
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
SHOWS SERVICE
ITEM (S)
Procedure
1
"Removal/Installation"
Portion
"Inspection After
Installation" Portion
INDICATES RELEVANT
REFERENCES THAT NEED
TO BE FOLLOWED DURING
INSTALLATION
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION

1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the undercover. (See 01-10-4 Undercover Removal)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the rear wheel alignment and adjust it if necessary.
11
12 SST
10
4460 {4.46.2, 3244}
GREASE
SHOWS PROCEDURE ORDER

FOR SERVICE
INSTALL THE PARTS BY
PERFORMING STEPS
1 3 IN REVERSE ORDER
SHOWS SPECIAL
SERVICE TOOL (SST)
FOR SERVICE OPERATION
9 SST
4356 {4.35.8, 3241}
SHOWS APPLICATION
POINTS OF GREASE, ETC.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS EXPENDABLE PARTS
SST
SHOWS DETAILS
6
SST
GREASE
4
94116 {9.511.9, 6986}
2
1
SHOWS REFERRAL
NOTES FOR SERVICE
1
2
3
4
5
6
118156 {12.016.0, 87115}
SHOWS TIGHTENING
TORQUE UNITS
Nm {kgfm, ftlbf}
Split pin
Nut
Lower trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note)
Bolt
Lower trailing link
Dust boot (lower trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link

Ball Joint Removal Note
Remove the ball joint using the SSTs.
7
8
9
10
11
12
Split pin
Nut
Upper trailing link ball joint
(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
Nut
Upper trailing link
Dust boot (upper trailing link)
49 T028 304
49 T028 305
UPPER TRAILING LINK

LOWER TRAILING LINK
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
acxuuw00000435
00-003
00-00
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
Symbols
There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol
Meaning
Kind
Apply oil
New appropriate
engine oil or gear
oil
Apply brake fluid
New appropriate
brake fluid
Apply automatic
transaxle/
transmission fluid
New appropriate
automatic
transaxle/
transmission fluid
Apply grease
Appropriate
grease
Apply sealant
Appropriate
sealant
Apply petroleum
jelly
Appropriate
petroleum jelly
Replace part
O-ring, gasket,
etc.
SST
Use SST or
equivalent
Appropriate tools
OIL
BRAKE
FLUID
ATF
GREASE
SEALANT
Advisory Messages
You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
A Note provides added information that will help you to complete a particular procedure.
Specification
The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits
The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie
NG: GENERAL INFORMATION
00-004
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
UNITS
Electrical current
Electric power
Electric resistance
Electric voltage
Length
Negative pressure
Positive pressure
Number of
revolutions
Torque
Volume
Weight
id000000100400
A (ampere)
W (watt)
ohm
V (volt)
mm (millimeter)
in (inch)
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
00-00
kgf/cm2 (kilogram force per square

centimeter)
psi (pounds per square inch)
rpm (revolutions per minute)
Nm (Newton meter)
kgfm (kilogram force meter)
kgfcm (kilogram force centimeter)
ftlbf (foot pound force)
inlbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
oz (ounce)
Conversion to SI Units (Systme International d'Units)

All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
Rounding Off
Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits
When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit, and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:
210 260 kPa {2.1 2.7 kgf/cm2, 30 38 psi}
270 310 kPa {2.7 3.2 kgf/cm2, 39 45 psi}
The actual converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
WM: GENERAL INFORMATION
00-005
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
id000000810000
Preparation of Tools and Measuring Equipment

Be sure that all necessary tools and measuring
equipment are available before starting any work.
acxuuw00000006
Special Service Tools

Use special service tools or the equivalent when
they are required.
49 SE01 310
acxuuw00000007
Disassembly
If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance, and
identified so that reassembly can be performed
easily and efficiently.
acxuuw00000010
Inspection During Removal, Disassembly

When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
acxuuw00000011
00-006
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
Arrangement of Parts
All disassembled parts should be carefully
arranged for reassembly.
Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
00-00
acxuuw00000012
Cleaning of Parts
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
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.
acxuuw00000013
Reassembly
Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with
new ones:
Oil seals
Gaskets
O-rings
Lock washers
Cotter pins
Nylon nuts
acxuuw00000014
Depending on location:
Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
Oil should be applied to the moving
components of parts.
Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
acxuuw00000326
00-007
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
Adjustment
Use suitable gauges and testers when making
adjustments.
acxuuw00000016
Rubber Parts and Tubing

Prevent gasoline or oil from getting on rubber
parts or tubing.
acxuuw00000017
Hose Clamps
When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
acxuuw00000018
Torque Formulas
When using a torque wrench-SST or equivalent
combination, the specified torque must be
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
2
3
00-008
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
Formula
Nm [L/(L+A)]
kgfm [L/(L+A)]
kgfcm [L/(L+A)]
ftlbf [L/(L+A)]
inlbf [L/(L+A)]
Torque Unit
Nm
kgfm
kgfcm
ftlbf
inlbf
SST
L
acxuuw00000019
SERVICE_1874-1U-06B(00-00).fm
GENERAL INFORMATION
Vise
When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
00-00
PROTECTIVE PLATES
acxuuw00000020
ELECTRICAL SYSTEM
Connectors
Disconnecting connectors
When disconnecting a connector, grasp the
connectors, not the wires.
id000000800400
GOOD
NO GOOD
acxuuw00000454
Connectors can be disconnected by pressing or

pulling the lock lever as shown.
acxuuw00000455
Locking connector
When locking connectors, listen for a click
indicating they are securely locked.
acxuuw00000456
00-009
SERVICE_1874-1U-06B(00-00).fm
10
GENERAL INFORMATION
Inspection
Caution
To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into
terminal.
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
GOOD
NO GOOD
acxuuw00000457
Inspect the terminals of waterproof connectors

from the connector side since they cannot be
accessed from the wiring harness side.
GOOD
NO GOOD
End Of Sie
acxuuw00000458
SAE STANDARDS
id000000800900
In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations
are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda
manuals up to now and their SAE equivalents.
SAE Standard
Remark
Abbreviation
Name
AP
Accelerator Pedal
APP
Accelerator Pedal Position
ACL
Air Cleaner
A/C
Air Conditioning
BARO
Barometric Pressure
B+
Battery Positive Voltage
CMP sensor Camshaft Position Sensor
CAC
Charge Air Cooler
CLS
Closed Loop System
CTP
Closed Throttle Position
CPP
Clutch Pedal Position
CIS
Continuous Fuel Injection System
CKP sensor Crankshaft Position Sensor
DLC
Data Link Connector
DTM
Diagnostic Test Mode
#1
DTC
Diagnostic Test Code(s)
DI
Distributor Ignition
DLI
Distributorless Ignition
EI
Electronic Ignition
#2
ECT
Engine Coolant Temperature
EM
Engine Modification
EVAP
Evaporative Emission
00-0010
SAE Standard
Abbreviation
Name
MAP
Manifold Absolute Pressure
MAF sensor Mass Air Flow Sensor
MFL
Multiport Fuel Injection
OBD
On-board Diagnostic System
OL
Open Loop
OC
Oxidation Catalytic Converter
O2S
Oxygen sensor
PNP
Park/Neutral Position
PSP
Power Steering Pressure
PCM
Powertrain Control Module
Remark
#3
PAIR
Pulsed Secondary Air Injection
Pulsed
injection
AIR
Secondary Air Injection
Injection
with air
pump
SAPV
SFI
3GR
TWC
TB
TP sensor
Secondary Air Pulse Valve

Sequential Multiport Fuel
Injection
Third Gear
Three Way Catalytic Converter
Throttle Body
Throttle Position Sensor
SERVICE_1874-1U-06B(00-00).fm
11
GENERAL INFORMATION
Abbreviation
EGR
FC
FF
4GR
GEN
GND
HO2S
IAC
IAT
KS
MIL
SAE Standard
Name
Exhaust Gas Recirculation
Fan Control
Flexible Fuel
Fourth Gear
Generator
Ground
Heated Oxygen Sensor
Idle Air Control
Intake Air Temperature
Knock Sensor
Malfunction Indicator Lamp
Remark
With
heater
SAE Standard
Abbreviation
Name
TCC
Torque Converter Clutch
Remark
TCM
Transmission (Transaxle) Control

Module
TR
TC
VSS
VR
VAF sensor
Transmission (Transaxle) Range

Turbocharger
Vehicle Speed Sensor
Voltage Regulator
Volume Air Flow Sensor
WU-TWC
WOP
Warm Up Three Way Catalytic

Converter
00-00
#4
Wide Open Throttle
#1: Diagnostic trouble codes depend on the diagnostic test mode.

#2: Controlled by the PCM
#3: Device that controls engine and powertrain
#4: Directly connected to exhaust manifold
End Of Sie
ABBREVIATIONS
ATF
LH
RH
SST
TFT
2WD
id000000801000
Automatic Transaxle Fluid

Left Hand
Right Hand
Special Service Tool
Transaxle Fluid Temperature
2 Wheel Drive
End Of Sie
00-0011
SERVICE_1874-1U-06B(03-16).fm
DRIVELINE/AXLE
03
SECTION
03-16
Toc of SCT
TRANSFER . . . . . . . . . . . . . . . . 03-16
TECHNICAL DATA . . . . . . . . . . 03-50
SERVICE TOOLS . . . . . . . . . . . 03-60
Toc of SCT
03-16
TRANSFER
TRANSFER CLEANING. . . . . . . . . . . . . . 03-161

Cleaning Precautions . . . . . . . . . . . . . . 03-161
TRANSFER DISASSEMBLY . . . . . . . . . . 03-161
Before Service Precautions. . . . . . . . . . 03-161
Transfer Component Disassembly . . . . 03-162
Transfer Component Disassembling
Procedure . . . . . . . . . . . . . . . . . . . . . . 03-163
Drive Gear Case Component
Disassembly . . . . . . . . . . . . . . . . . . . . 03-164
Disassembly Procedure . . . . . . . . . . . 03-165
Front Carrier Component
Disassembly . . . . . . . . . . . . . . . . . . . . 03-169
Front Carrier Component Disassembling
Procedure . . . . . . . . . . . . . . . . . . . . . 03-1610
TRANSFER ASSEMBLY . . . . . . . . . . . . . 03-1613

Before Service Precautions . . . . . . . . . 03-1613
Assembly. . . . . . . . . . . . . . . . . . . . . . 03-1614
Drive Gear Case Component Assembly
Procedure . . . . . . . . . . . . . . . . . . . . . 03-1615
Front Carrier Component Assembly . . . 03-1621
Front Carrier Component Assembly
Procedure . . . . . . . . . . . . . . . . . . . . . 03-1622
Transfer Component Assembly . . . . . . 03-1628
Transfer Component Assembly
Procedure . . . . . . . . . . . . . . . . . . . . . 03-1629
End of Toc
TRANSFER CLEANING
AT: TRANSFER
id031600500100
Cleaning Precautions
1. Clean the surface of the transfer using steam and cleaning fluids when disassembly.
Warning
Always wear safety glasses when using compressed air since the foreign material could be blown
by the compression air and damage your eyes.
2. Clean removed components with cleaning fluids and use compressed air to blow off the oil. Clean the oil holes
and passages with compressed air.
End Of Sie
TRANSFER DISASSEMBLY
id031600500200
Before Service Precautions

To prevent foreign material from entering the transfer, perform disassembly and servicing in a clean, dust-free
environment.
Inspect the each part while disassembling.
Warning
The engine stand is equipped with a self-lock mechanism. However, if the transfer is tilted, the
self-lock mechanism could become inoperative. This could cause the transfer to rotate
accidentally, resulting in injury. Therefore, make sure that the transfer is not tilted when it is on the
engine stand. When turning the transfer, grasp the rotation handle firmly.
03-161
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
Transfer Component Disassembly
4
R
1
bawuua00000167
.
1
2
3
Drain plug
Oil level plug
Oil cooler
03-162
4
5
Drive gear case component

Front carrier component
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
Transfer Component Disassembling Procedure
1. Assemble the SSTs.
49 0107 680A
03-16
49 M005 561
bawuua00000168
2. Install the transfer component to the SSTs.

3. Remove the oil cooler.
4. Remove the drive gear case component.
49 M005 561
49 0107 680A
bawuua00000169
03-163
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
Drive Gear Case Component Disassembly
RH
5
3
8
9 SST
7
SST
11
SST
1 R
12 R
10 SST
15
SST
R 13
LH
SST
R 14
16
bawuua00000170
.
1
2
3
4
5
6
7
8
Oil seal (RH outer)

Drive gear shaft
Bearing cap
Adjustment shim
Spacer
Drive gear component
Bearing outer race (LH)
Bearing outer race (RH)
03-164
9
10
11
12
13
14
15
16
Bearing (RH)
Bearing (LH)
Drive gear
Oil seal (RH inner)
Oil seal (LH outer)
Oil seal (LH inner)
Baffle plate
Drive gear case
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
Drive Gear Case Component Disassembly Procedure
1. Install the drive gear case component to the SST.
49 M005 561
03-16
bawuua00000171
2. Tap the drive gear shaft using a suitable rod and

hammer.
bawuua00000172
3. Take out the drive gear shaft from the drive gear
case.
bawuua00000173
4. Make alignment marks on the bearing cap and

drive gear case.
5. Remove the bearing cap.
ALIGNMENT MARK
bawuua00000174
03-165
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
6. Insert a flathead screwdriver into spacer notch
and remove the adjustment shim.
bawuua00000175
Caution
Place a rag on the case to protect it from
damage.
RAG
bawuua00000176
7. Remove the spacer.
bawuua00000177
8. Remove the drive gear component.
bawuua00000178
9. Using the SST, remove the oil seal (LH outer).
49 0839 425C
49 W032 201
bawuua00000179
03-166
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
10. Using the SST, remove the oil seal (LH inner).
49 0839 425C
03-16
49 W032 201
bawuua00000179
11. Using a suitable rod and hammer, remove the oil

seal (RH outer).
bawuua00000180
12. Using the SST, remove the oil seal (RH inner).
49 W032 201
49 0839 425C
bawuua00000181
13. Using the SST, remove the bearing outer race

(LH).
BEARING RACE
bawuua00000182
(1) Install the SSTs (49 W032 202, 49 S019 005).

49 W032 202
49 S019 005
bawuua00000183
03-167
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
(2) Connect the SST (49 T032 316, 49 T032 317)
to the SSTs (49 W032 202, 49 S019 005).
49 W032 202
49 T032 316
49 T032 317
49 S019 005
bawuua00000184
14. Remove the baffle plate.
bawuua00000185
15. Using the SST, remove the bearing (RH).

49 0839 425C
bawuua00000186
16. Using a flathead screwdriver, deform the bearing

roller guide (LH) and remove it.
bawuua00000187
17. Using the SST, remove the bearing inner race

(LH).
49 0636 145
bawuua00000188
03-168
SERVICE_1874-1U-06B(03-16).fm
TRANSFER
Front Carrier Component Disassembly
R
16
R
15 SST
17 SST
5
03-16
20
25
R
SST
24
21
18 R
22
23
SST R
19
LEFTHAND SCREW
10
9
11
SST 12
SST 14
13
SST
12
SST
11
8
SST
9
bawuua00000189
1
2
3
4
5
6
7
8
9
10
11
12
13
Oil pipe
Oil strainer
Side cover
Ring gear lockbolt
Oil pump
Oil pump shaft
Bearing cap
Ring gear component
Adjustment shim
Spacer
Bearing outer race (side)
Bearing (side)
Ring gear
14
15
16
17
18
19
20
21
22
23
24
25
Ring gear shaft

Locknut
Washer
Companion flange
Oil seal
Drive pinion gear
Bearing (rear)
Distance piece
Bearing (front)
Spacer
Bearing outer race (front)
Bearing outer race (rear)
03-169
SERVICE_1874-1U-06B(03-16).fm
10
TRANSFER
Front Carrier Component Disassembling Procedure
1. Install the front carrier component to the SST.
2. Remove the oil strainer.
3. Remove the oil pipe.
4. Remove the side cover.
49 M005 561
bawuua00000190
5. Remove the oil pump by turning it using pliers as

shown in the figure.
If the oil pump shaft remains in the gear shaft
side, remove the oil pump shaft.
bawuua00000191
6. Make alignment marks on the bearing caps and

front carrier.
7. Remove the bearing caps.
MARK
bawuua00000192
8. Using a suitable wrench, secure the ring gear

shaft, and remove the ring gear lockbolt.
bawuua00000193
03-1610
SERVICE_1874-1U-06B(03-16).fm
11
TRANSFER
9. Using the SST, secure the companion flange, and
remove the locknut and washer.
49 S120 710
03-16
bawuua00000546
10. Using the SST, remove the companion flange.
49 0839 425C
bawuua00000536
11. Using the SSTs, remove the ring gear

component.
12. Remove the adjustment shims and spacer.
49 T032 316
49 T032 317
49 L027 004
bawuua00000196
13. Install an appropriate nut to the drive pinion to

prevent the thread from being damaged.
14. Lightly tap the drive pinion using a copper
hammer and remove the drive pinion gear.
bawuua00000537
03-1611
SERVICE_1874-1U-06B(03-16).fm
12
TRANSFER
15. Using a flathead screwdriver, remove the oil seal.
16. Remove the bearing (rear) and distance piece.
bawuua00000198
17. Using the SST, remove the bearing (front).

18. Remove the spacer.
49 H027 002
bawuua00000199
19. Attach the brass stick to the notch, tap the race
end lightly and evenly, then remove the bearing
outer races.
bawuua00000200
bawuua00000201
20. Using the SSTs, remove the bearing (side)

(opposite ring gear side).
49 0839 425C
(ATTACHMENT
39.5 mm {1.56 in})
49 0710 520
bawuua00000202
03-1612
SERVICE_1874-1U-06B(03-16).fm
13
TRANSFER
21. Using a SST, remove the bearing (side) (ring gear
side) together with ring gear.
Substitution SST
49 T032 302
Outer diameter: 25 30 mm {0.99 1.18 in}
Plate thickness: 1 mm {0.04 in} or more
49 T032 302
End Of Sie
03-16
bawuua00000203
TRANSFER ASSEMBLY
id031600500300
Before Service Precautions

Assemble with bare hands or using vinyl gloves. To prevent foreign material from entering the transfer, do not
use cotton work gloves or a rag.
Apply sufficient gear oil to the sliding surfaces and O-rings, and be careful not to damage when assembling.
Replace the transfer with a new one if the case alignment surface is damaged. Be careful not to damage it
since it may cause oil leakage.
When installing silicone sealant, clean off the old sealant adhering to the sealing area and clean the sealing
area with cleaning fluids.
After installing a seal, leave the parts alone for 2 h or more. Do not add oil or operate the vehicle during this
time.
Warning
The engine stand is equipped with a self-lock mechanism. However, if the transfer is tilted, the
self-lock mechanism could become inoperative. This could cause the transfer to rotate
accidentally, resulting in injury. Therefore, make sure that the transfer is not tilted when it is on the
engine stand. When turning the transfer, grasp the rotation handle firmly.
03-1613
SERVICE_1874-1U-06B(03-16).fm
14
TRANSFER
Drive Gear Case Component Assembly
RH
3751 Nm
{3.85.2 kgfm, 27.337.6 ftlbf}
8
10
4
3 SST
5
6.99.8 Nm
{7099 kgfcm, 6186 inlbf}
1
2 SST
SST
SST
LH
11
R
SST
R
SST
15
R 12
R 13
16
14
bawuua00000204
.
1
2
3
4
5
6
7
8
Drive gear
Bearing (LH)
Bearing (RH)
Bearing outer race (RH)
Bearing outer race (LH)
Oil seal (RH inner)
Drive gear component
Spacer
03-1614
9
10
11
12
13
14
15
16
Adjustment shim
Bearing cap
Oil seal (RH outer)
Oil seal (LH inner)
Oil seal (LH outer)
Drive gear shaft
Baffle plate
Drive gear case
SERVICE_1874-1U-06B(03-16).fm
15
TRANSFER
Drive Gear Case Component Assembly Procedure
1. Install the drive gear case to the SST.
49 M005 561
03-16
bawuua00000205
2. Install the baffle plate.

Tightening torque
6.9 9.8 Nm {70 99 kgfcm, 61 86 inlbf}
bawuua00000206
3. Using a press, assemble the bearing (RH).

Substitution SST
49 H028 202
Inner diameter: 56 mm {2.20 in} or more
49 H028 202
bawuua00000207
4. Using a press, assemble the bearing (LH).

Substitution SST
49 H028 202
5. Temporarily assemble the bearing outer race
(RH) and spacer to the drive gear.
49 H028 202
bawuua00000208
03-1615
SERVICE_1874-1U-06B(03-16).fm
16
TRANSFER
6. Place the drive gear component on the surface
plate as shown in the figure, and measure the
height using a vernier caliper or height gauge.
This is dimension A.
A
bawuua00000209
7. Measure the width of the drive gear installation

area in the drive gear case. This is dimension B.
8. The maximum and minimum thickness C of the
adjustment shim can be expressed by the
following formula:
C = B - A - (0.01 0.03 mm {0.00039

0.00118 in})
9. If the thickness of the installed adjustment shim is
within the C range, use the shim as it is.
10. If the thickness of the installed adjustment shim is
not within the C range, select the appropriate
adjustment shim from the table below and use it.
bawuua00000210
Adjustment shim
Identification mark
350
355
360
365
370
375
380
385
390
395
400
405
410
415
Thickness (mm {in})

3.50 {0.1378}
3.55 {0.1398}
3.60 {0.1417}
3.65 {0.1437}
3.70 {0.1457}
3.75 {0.1476}
3.80 {0.1496}
3.85 {0.1516}
3.90 {0.1535}
3.95 {0.1555}
4.00 {0.1575}
4.05 {0.1594}
4.10 {0.1614}
4.15 {0.1634}
Identification mark
420
425
430
435
440
445
450
455
460
-
Thickness (mm {in})

4.20 {0.1654}
4.25 {0.1673}
4.30 {0.1693}
4.35 {0.1713}
4.40 {0.1732}
4.45 {0. 1752}
4.50 {0.1772}
4.55 {0.1791}
4.60 {0. 1811}
-
11. Using the plastic hammer, install the bearing

outer race (LH).
bawuua00000211
03-1616
SERVICE_1874-1U-06B(03-16).fm
17
TRANSFER
12. Install the drive gear component.
03-16
bawuua00000212
13. Install the spacer with its notch facing the bearing,
and also facing upward, as shown in the figure.
bawuua00000213
14. Using a plastic hammer, assemble the adjustment

shim.
bawuua00000214
15. Align the bearing cap alignment marks, assemble

the bearing cap.
Tightening torque
37 51 Nm {3.8 5.2 kgfm, 27.3 37.6
ftlbf}
ALIGNMENT MARK
bawuua00000215
16. Assemble the SST to the drive gear shaft, and

hand-tighten the nut.
SST tightening torque
2.1 Nm {21 kgfcm, 19 inlbf}
49 L011 201
bawuua00000216
03-1617
SERVICE_1874-1U-06B(03-16).fm
18
TRANSFER
17. Install the drive gear shaft with the SST
assembled and verify that the preload is within the
specification using the torque wrench as shown in
the figure.
Standard drive gear bearing preload
0.6 2.1 Nm {6.2 21.4 kgfcm, 5.4 18.5
inlbf}
If the drive gear rotational torque is not within
the specification, adjust it by selecting the
proper spacer.
18. Remove the drive gear shaft.
19. Using a SSTs, install the oil seals.
bawuua00000217
Note
Mark the press-in depth of each oil seal to the SST and press fit oil seals to the specified position.
LH inner
Substitution SST
49 S019 006
49 G030 797
49 S019 006
15.717.3
{0.620.68}
mm {in}
bawuua00000218
03-1618
SERVICE_1874-1U-06B(03-16).fm
19
TRANSFER
LH outer
49 G030 797
49 L019 301
03-16
OIL SEAL
5.06.0
{0.200.23}
mm {in}
bawuua00000219
RH inner
Substitution SST
49 B025 001
49 G030 797
49 B025 001
18.720.3
{0.740.79}
mm {in}
bawuua00000220
03-1619
SERVICE_1874-1U-06B(03-16).fm
20
TRANSFER
RH outer
Substitution SST
49 T034 201A
Length: 5 mm {0.20 in} or more
49 T034 201A
-0.80.8
{-0.030.03}
mm {in}
bawuua00000221
20. Install the C-ring to the drive gear shaft and insert
the drive gear shaft until it is secured by the Cring.
Caution
Be careful not to damage the oil seal
when installing the drive gear shaft.
bawuua00000222
21. Pull the drive gear shaft by hand and verify that
the drive gear shaft is secured by the C-ring at the
specified position.
bawuua00000223
03-1620
SERVICE_1874-1U-06B(03-16).fm
21
TRANSFER
Front Carrier Component Assembly
127284
{13.028.9, 93.7209.4}
11 SST
R
OIL
10
9
GREASE
03-16
21
20
SST 1
2 SST
R
SST
SST
25
8 R
4
3
SST R
LEFTHAND SCREW
22 150200 {15.320.3, 110.7147.4}
SST 7
A
23
24
6.99.8 Nm
{70100 kgfcm, 6186 inlbf}
17
16
15
14 R
SST
12
A
SST 13
R 14
SST
19
15
18
16
6393 {6.59.4, 46.468.5}
Nm {kgfm, ftlbf}
bawuua00000224
.
1
2
3
4
5
6
7
8
9
10
11
12
13
Bearing outer race (rear)

Bearing outer race (front)
Spacer
Bearing (front)
Distance piece
Bearing (rear)
Drive pinion gear
Oil seal
Companion flange
Washer
Locknut
Ring gear shaft
Ring gear
14
15
16
17
18
19
20
21
22
23
24
25
Bearing (side)
Bearing outer race (side)
Adjustment shim
Spacer
Ring gear component
Bearing cap
Oil pump shaft
Oil pump
Ring gear lockbolt
Side cover
Oil strainer
Oil pipe
03-1621
SERVICE_1874-1U-06B(03-16).fm
22
TRANSFER
Front Carrier Component Assembly Procedure
1. Using a press, assemble the opposite ring gear
side bearing (side) to the ring gear shaft.
Substitution SST
49 G033 105 (A)
Outer diameter: 25 mm {0.99 in} or more
49 G033 105 (B)
(A)
49 G033 105
(B)
bawuua00000225
2. Using a press, assemble the ring gear to the ring

gear shaft
Substitution SST
49 G033 105
49 G033 105
bawuua00000226
3. Using a press, assemble the ring gear side

bearing (side).
Substitution SST
49 G033 105 (A)
49 G033 105 (B)
4. Temporarily assemble the bearing outer races
(side).
49 G033 105
(A)
(B)
bawuua00000227
5. Place the ring gear component on the surface

plate as shown in the figure, and measure the
height using a vernier caliper or height gauge.
This is dimension A.
A
bawuua00000228
03-1622
SERVICE_1874-1U-06B(03-16).fm
23
TRANSFER
6. Measure the width of the front carrier ring gear
installation area with the spacer installed. This is
dimension B.
7. The maximum and minimum total thickness C of
the adjustment shims on both sides can be
expressed by the following formula:
B
SPACER
C = B - A - (0.01 0.03 mm {0.00039 0.00118

in})
03-16
8. If the total thickness of the installed adjustment

shims is within the C range, use the shims as they
bawuua00000229
are.
9. If the total thickness of the installed adjustment
shims is not within the C range, select the appropriate number of adjustment shims from the table below and
use them.
Adjustment shim
Identification mark
350
355
360
365
370
375
380
385
390
395
400
405
Thickness (mm {in})

3.50 {0.1378}
3.55 {0.1398}
3.60 {0.1417}
3.65 {0.1437}
3.70 {0.1457}
3.75 {0.1476}
3.80 {0.1496}
3.85 {0.1516}
3.90 {0.1535}
3.95 {0.1555}
4.00 {0.1574}
4.05 {0.1594}
Identification mark
410
415
420
425
430
435
440
445
450
455
460
-
Thickness (mm {in})

4.10 {0.1614}
4.15 {0.1634}
4.20 {0.1654}
4.25 {0.1673}
4.30 {0.1693}
4.35 {0.1713}
4.40 {0.1732}
4.45 {0.1752}
4.50 {0.1772}
4.55 {0.1791}
4.60 {0.1811}
-
Note
When reusing adjustment shims, do not mix up the left and right shims.
Do not mix up the left and right side bearing races and spacers.
10. Install the front carrier to the SST.
11. Install the adjustment shim chosen for the front
carrier ring gear side and spacer on opposite
side.
12. Assemble the ring gear component to the front
carrier.
49 M005 561
bawuua00000230
13. Using the plastic hammer, assemble the selected

adjustment shim in between the spacer and
bearing race as shown in the figure.
bawuua00000231
03-1623
SERVICE_1874-1U-06B(03-16).fm
24
TRANSFER
14. Align the alignment marks of the bearing caps,
assemble the bearing caps, and tighten the bolts
temporarily.
MARK
Caution
Locking compound is applied to a new
ring gear lockbolt. Reuse the old ring
gear lock bolt when inspecting the
preload.
15. Install the ring gear lockbolt and inspect the ring
gear bearing preload.
bawuua00000232
Standard ring gear bearing preload

0.6 2.1 Nm {6.2 21.4 kgfcm, 5.4 18.5 inlbf}
If the rotational torque is not within the specification, select the suitable adjustment shim and reinstall so
that the rotational torque is within the specification.
16. Follow the disassembling procedure in Step 11 to remove the ring gear component.
Note
Identify the left and right side of the adjustment shim for reinstallation.
17. Using the SSTs, assemble the bearing outer
races.
Substitution SST
49 F027 005
Outer diameter: 61 61.8 mm {2.41 2.43
in}
49 F027 007
in}
49 F027 003
49 F027 003
49 F027 005
49 F027 007
bawuua00000233
18. Using the SSTs, adjust the drive pinion height as

follows:
(1) Install the SSTs to the removed spacer and
bearing.
(2) Assemble the spacer, bearing and SSTs.
Using an O-ring, secure the SST.
(3) Assemble the bearing, SSTs, washer, and
nut.
(4) Tighten the nut to the SST to where it can still
be rotated by hand.
49 8531 565
49 H025 003A
bawuua00000234
(5) Place the SSTs on the plate surface and set

the dial gauge to 0.
49 0727 570
49 8531 555
49 0305 555
bawuua00000235
03-1624
SERVICE_1874-1U-06B(03-16).fm
25
TRANSFER
(6) Position the SST (49 0727 570) on the driver
pinion model.
(7) Attach the dial gauge head to where the
carrier bearing outer race (side) is installed
and measure the lowest position. Also,
measure the value of where the side bearing
outer race (side) is installed on the opposite
side.
(8) Measure the average value between the
values of both sides measured in Step 7. This
value is the spacer thickness which
determines the pinion height.
49 0727 570
bawuua00000236
Pinion height error factor within allowance

limit
0.032 mm { 0.00126 in}
Spacer
Identification mark
08
09
11
12
14
15
17
18
20
21
23
24
26
27
Thickness (mm {in})

3.08 {0.1213}
3.095 {0.1219}
3.11 {0.1224}
3.125 {0.1230}
3.14 {0.1236}
3.155 {0.1242}
3.17 {0.1248}
3.185 {0.1254}
3.20 {0.1260}
3.215 {0.1266}
3.23 {0.1272}
3.245 {0.1278}
3.26 {0.1283}
3.275 {0.1289}
Identification mark
29
30
32
33
35
36
38
39
41
42
44
45
47
-
Thickness (mm {in})

3.29 {0.1295}
3.305 {0.1301}
3.32 {0.1307}
3.335 {0.1313}
3.35 {0.1319}
3.365 {0.1325}
3.38 {0.1331}
3.395 {0.1335}
3.41 {0.1343}
3.425 {0.1348}
3.44 {0.1354}
3.455 {0.1360}
3.47 {0.1366}
-
19. Assemble the spacer selected for pinion height adjustment with the rounded off side facing the gears.
20. Using the SST, assemble the bearing (front) to
the drive pinion gear.
SPACER
Substitution SST
49 F401 331
49 F401 331, 49 F401 337A
Outer diameter: 37.2 43.3 mm {1.47 1.70
in}
Inner diameter: 35.2 mm {1.39 in} or more
Inner diameter depth: 140 mm {5.51 in} or
49 F401 337A
more
21. Assemble a new distance piece to the drive pinion
gear.
bawuua00000237
22. Assemble the drive pinion gear to the front carrier.
23. Install the bearing (rear), companion flange,
washer, and new locknut to the drive pinion and temporarily tighten.
24. Rotate the companion flange by hand and seat the bearing.
03-1625
03-16
SERVICE_1874-1U-06B(03-16).fm
26
TRANSFER
25. Using the SST, tighten the locknut from the lower
limit of the specified tightening torque and set to
the preload value. Note the tightening torque
when the specified preload value is obtained.
49 S120 710
Tightening torque
127 284 Nm {13.0 28.9 kgfm, 93.7
209.4 ftlbf}
Drive pinion preload value
0.88 1.37 Nm {9.0 14.0 kgfcm, 7.9 12.1
inlbf}
26. Remove the locknut, washer, and companion
flange.
27. Apply oil to the lip area of a new oil seal.
28. Using the SST, assemble the oil seal.
Substitution SST
49 U027 003
in}
Inner diameter depth: 50 mm {1.97 in} or
more
29. Apply the grease to the bearing contact surface of
the companion flange.
30. Assemble the companion flange.
31. Using the SST, tighten the new locknut to the
tightening torque noted when the preload was
adjusted.
32. Reverify the preload.
bawuua00000546
49 U027 003
bawuua00000538
49 S120 710

0.88 1.37 Nm {9.0 14.0 kgfcm, 7.9 12.1
inlbf}
33. Assemble the ring gear component following the
procedure in Step 11 to 14.
34. Set the dial gauge with the measuring probe
attached perpendicularly to the end of one of the
ring gear teeth.
35. Secure the drive pinion and measure the
backlash from when the ring gear is moved.
bawuua00000546
Standard drive pinion backlash

0.09 0.11 mm {0.0035 0.0043 in}
Caution
Perform the backlash measurement on
the ring gear circumference at four
points.
36. If the backlash is not within the specified range
above, adjust it by sliding the ring gear in the shaft
direction.
bawuua00000539
Note
Slide the ring gear in the shaft direction by replacing the adjustment shim. If the right side adjustment shim
is replaced with one that is 0.05 mm {0.002 in} thicker, the left side shim must be replaced with one that is
0.05 mm {0.002 in} thinner.
03-1626
SERVICE_1874-1U-06B(03-16).fm
27
TRANSFER
37. Tighten the bearing cap bolts.
Tightening torque
63 93 Nm {6.5 9.4 kgfm, 46.4 68.5 ftlbf}
38. Perform the drive pinion and ring gear tooth
contact inspection.
(1) Apply tooth marking compound evenly to both
surfaces of the ring gear.
(2) Rotate the ring gear back and forth several
times.
(3) Inspect for gear tooth contact at four points on
the ring gear circumference and verify that the
gear tooth contact indicated by the tooth
marking compound is as indicated in the
figure.
If the tooth contact points are normal,
wipe off the marking compound.
If the tooth contact points are not normal,
adjust the pinion height, then adjust the backlash.
(4) If toe and flank contact is indicated as shown
in the figure, replace the drive pinion spacer
with a thinner one to maintain the drive pinion
further away.
03-16
bawuua00000540
TOE CONTACT
FLANK CONTACT
bawuua00000242
(5) If heal and face contact is indicated as shown

in the figure, replace the drive pinion spacer
with a thicker one to bring the drive pinion
closer.
39. Using a suitable wrench, secure the ring gear
shaft and tighten the new ring gear lockbolt to the
specified tightening torque.
Caution
Before installing the new ring gear
lockbolt, remove the old thread-locking
compound remaining on the thread of the
ring gear shaft.
TOE CONTACT
FLANK CONTACT
bawuua00000243
Tightening torque
150 200 Nm {15.3 20.3 kgfm, 110.7
147.4 ftlbf}
40. Align the cast hexagon of the oil pump shaft and
assemble the oil pump and oil pump shaft.
bawuua00000244
03-1627
SERVICE_1874-1U-06B(03-16).fm
28
TRANSFER
41. Align the oil holes of the oil pump and front
carrier.
42. Assemble the oil strainer.
43. Assemble the oil pipe.
44. Apply oil to a new O-ring and assemble the side
cover.
45. Assemble the side cover to the front carrier.
Tightening torque
6.9 9.8 Nm {70 100 kgfcm, 61 86
inlbf}
OIL HOLE
bawuua00000245
46. Remove the front carrier component from the

SST.
Transfer Component Assembly
23.529.4
{2.42.9, 17.421.6}
GREASE
GREASE
SEALANT
2
39.258.8
{4.05.9, 29.043.3}
1927
{2.02.7, 14.119.9}
1927
{2.02.7, 14.119.9}
39.258.8
{4.05.9, 29.043.3}
Nm {kgfm, ftlbf}
bawuua00000246
1
2
3
Front carrier component

Drive gear case component
Oil cooler
03-1628
4
5
Drain plug
Oil level plug
SERVICE_1874-1U-06B(03-16).fm
29
TRANSFER
Transfer Component Assembly Procedure
Note
Before applying silicone sealant, completely clean off any old silicone sealant and remove any oil or
grease.
After applying silicone sealant, install the drive gear case within 10 min.
After connecting the sealing area, leave it for 30 min. or more, then add transfer oil.
1. Clean the alignment surface of the front carrier and drive gear case, and lightly apply silicone sealant.
2. Assemble the transfer component.
Tightening torque
19 27 Nm {2.0 2.7 kgfm, 14.1 19.9 ftlbf}
3. Install the oil cooler.
4. Tighten the oil cooler installation bolt with a O-ring.
Tightening torque
23.5 29.4 Nm {2.4 2.9 kgfm, 17.4 21.6 ftlbf}
5. Tighten the drain plug with a new washer.
Tightening torque
39.2 58.8 Nm {4.0 5.9 kgfm, 29.0 43.3 ftlbf}
End Of Sie
03-1629
03-16
SERVICE_1874-1U-06B(03-50).fm
TECHNICAL DATA
03-50
TECHNICAL DATA
DRIVELINE/AXLE TECHNICAL DATA . . 03-501
End of Toc
DRIVELINE/AXLE TECHNICAL DATA
WM: DRIVELINE/AXLE
Item
Standard drive gear bearing preload
Standard ring gear bearing preload
Pinion height error factor within allowance limit
Standard drive pinion backlash
id035000800100
Specification
0.62.1 Nm {6.221.4 kgfcm, 5.418.5 inlbf}
0.62.1 Nm {6.221.4 kgfcm, 5.418.5 inlbf}
0.032 mm { 0.00126 in}
0.881.37 Nm {9.014.0 kgfcm, 7.912.1 inlbf}
0.090.11 mm {0.00350.0043 in}
End Of Sie
03-501
03-50
SERVICE_1874-1U-06B(03-60).fm
SERVICE TOOLS
03-60
SERVICE TOOLS
SERVICE TOOLS . . . . . . . . . . . . . . . . . . 03-601
End of Toc
SERVICE TOOLS
AT: DRIVELINE/AXLE
id036000500100
49 0107 680A
49 M005 561
49 W032 201
Engine stand
Differential
carrier hanger
Body
49 B025 001
49 T032 316
49 T032 317
(Dust Seal
Installer) Body
Shaft
Weight
49 S019 005
49 W032 202
49 0839 425C
Oil seal puller
Attachment
Bearing puller
set
49 0636 145
49 S120 710
49 L027 004
Water pump
pulley boss
puller
Coupling flange
holder
Gear case
remover
49 H027 002
49 T034 201A
49 T032 302
Bearing
remover
Dust boot
installer
Bearing installer
49 G033 105
49 F027 003
49 F027 005
Attachment
Handle
Attachment for
62
49 F027 007
49 8531 565
49 L019 301
Attachment for
72
Drive pinion
model
Installer
03-601
03-60
SERVICE_1874-1U-06B(03-60).fm
SERVICE TOOLS
49 H025 003A
49 0727 570
49 0305 555
Bearing installer
Pinion height
gauge body
Block Gauge
(20mm)
49 8531 555
49 F401 331
49 F401 337A
Block Gauge
(11mm)
Body
Attachment C
49 U027 003
49 H028 202
49 L011 201
Oil seal installer
Block L
Shaft
49 G030 797
49 0710 520
49 S019 006
Handle
Universal
bearing puller
Oil seal installer
End Of Sie
03-602
SERVICE_1874-1U-06B(05-17).fm
05
SECTION
Toc of SCT
AUTOMATIC TRANSAXLE . . . . 05-17

TECHNICAL DATA . . . . . . . . . . 05-50
SERVICE TOOLS . . . . . . . . . . . 05-60
Toc of SCT
05-17
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-172
Precaution . . . . . . . . . . . . . . . . . . . . . . . 05-172
Disassembly . . . . . . . . . . . . . . . . . . . . . 05-173
Disassembly procedure. . . . . . . . . . . . . 05-179
OIL PUMP
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-1726
Components . . . . . . . . . . . . . . . . . . . . . 05-1726
Disassembly Procedure . . . . . . . . . . . . 05-1727
Assembly Procedure . . . . . . . . . . . . . . . 05-1728
B1 BRAKE PISTON
Components . . . . . . . . . . . . . . . . . . . . . 05-1729
C3 CLUTCH COMPONENT
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-1731
Components . . . . . . . . . . . . . . . . . . . . . 05-1731
C3 CLUTCH INSPECTION. . . . . . . . . . . . 05-1733
C3 CLUTCH COMPONENT
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 05-1734
Components . . . . . . . . . . . . . . . . . . . . . 05-1734
FRONT PLANETARY GEAR
COMPONENT INPUT SHAFT
Components . . . . . . . . . . . . . . . . . . . . . 05-1737
C1 CLUTCH COMPONENT
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-1742
Components . . . . . . . . . . . . . . . . . . . . . 05-1742
C1 CLUTCH INSPECTION. . . . . . . . . . . . 05-1744
C1 CLUTCH COMPONENT
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 05-1745
Components . . . . . . . . . . . . . . . . . . . . . 05-1745
COUNTER DRIVE GEAR
Components . . . . . . . . . . . . . . . . . . . . . 05-1749
ONE-WAY CLUTCH COMPONENT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-1755
REAR PLANETARY GEAR COMPONENT

AND ONE-WAY CLUTCH COMPONENT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05-1756
Components . . . . . . . . . . . . . . . . . . . . . 05-1756
REAR PLANETARY GEAR
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-1757
REAR PLANETARY GEAR COMPONENT
AND ONE-WAY CLUTCH COMPONENT
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-1758
Components . . . . . . . . . . . . . . . . . . . . . 05-1758
Assembly Procedure . . . . . . . . . . . . . . 05-1759
C2 CLUTCH COMPONENT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05-1760
Components . . . . . . . . . . . . . . . . . . . . . 05-1760
C2 CLUTCH INSPECTION . . . . . . . . . . . 05-1763
C2 CLUTCH COMPONENT
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-1764
Components . . . . . . . . . . . . . . . . . . . . . 05-1764
TRANSAXLE CASE AND B2 BRAKE
Low and Reverse Brake Piston
Disassembly Note . . . . . . . . . . . . . . . 05-1769
Low and Reverse Brake Piston
Assembly Note . . . . . . . . . . . . . . . . . . 05-1770
Low and Reverse Brake Return Spring
Assembly Note . . . . . . . . . . . . . . . . . . 05-1770
TRANSAXLE CASE AND B2 BRAKE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-1771
CONTROL VALVE BODY
Components . . . . . . . . . . . . . . . . . . . . . 05-1772
AUTOMATIC TRANSAXLE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-1775
Assembly . . . . . . . . . . . . . . . . . . . . . . . 05-1775
Components . . . . . . . . . . . . . . . . . . . . . 05-1777
AUTOMATIC TRANSAXLE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17104
B2 Brake Inspection . . . . . . . . . . . . . . . 05-17104
End of Toc
05-171
05-17
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE DISASSEMBLY
AT: AUTOMATIC TRANSAXLE
id051700502100
Precaution
The following are precautions that must be followed when performing removal/installation.
1. Handle electronic parts with care
Do not pull the wiring harness forcibly when disconnecting the connector. Unlock the lock first and pull the
connector.
When connecting the connector, verify to insert it until it is properly locked. (Verify that a click sound is
heard.)
Do not shock electronic parts. Replace with new parts if they have been dropped or subjected to shock.
2. Prevent foreign matter from penetrating
Be sure to remove foreign matter such as dust and sand from the automatic transaxle before removing
parts.
Protect removed parts from dust with an object such as a vinyl sheet.
Do not use cotton work gloves or shop rags as frayed strings might get caught in the unit. Thus work with
bare hands or use vinyl gloves.
3. Prevent scratching
Do not pry with a screwdriver forcibly. Slightly hit the case with a plastic hammer when separating
component cases at seams.
Do not pull the valve forcibly.
Be careful not to get the wire harness caught between parts during installation.
4. Prevent incorrect installation and lack of or missing parts
Be careful not to install parts incorrectly or lose parts since there are similar types of O-rings, snap rings,
bearings and races. Take great care for straightening parts and checking installation direction.
Be careful not to drop small parts such as check balls or lose them during installation.
5. Wash parts and apply oil
Wash each part before installing and dry using compressed air, and then apply the specified ATF type
JWS3309.
Soak disks in ATF type JWS3309 before installing. In particular, soak new disks for 2 h or more so that the
oil seeps into the lining.
If the thrust bearing or race falls during installation, use a small amount of yellow petrolatum grease.
Apply ATF type JWS3309 to contact and rotating surfaces.
Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave it for one
hour or more.
Do not wash aluminum parts or rubber parts with alkaline chemicals.
Do not wash the rubber parts with white gasoline.
6. Handling ATF with care
If you spill ATF on the floor, wipe it off immediately, as it is quite slippery and dangerous.
Be sure to use JWS3309 type ATF.
05-172
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
Disassembly
Components
R 21
15 R
20 R
05-17
R
R 22
13 R
18
14
16 R
12
19
11
10
3
17
*1
2
bawuua00000279
.
1
2
3
4
5
6
Oil pipe and O-ring

Torque converter
Drain plug
Gasket
Filler plug
O-ring
7
8
9
10
11
12
TCM
Control valve body cover
Lock plate
Suction cover
Gasket
Control valve body component
05-173
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
13
14
15
16
17
*1
Coupler component lock plate

Coupler component
O-ring
Gasket
Input/turbine speed sensor
: The figure shows Mazda6 specification.
05-174
18
19
20
21
22
Oil seal (converter housing side)

O-ring (converter housing side) (2WD)
Oil seal (transaxle case side)
O-ring (transaxle case side)
Oil seal (manual shaft)
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
3
1
22
R
10
23
05-17
15
6
14
13
12
37
35
38
29
7
36
34
24 R
33
39
32
31
21
30
20
19
28
27
25
17
16
26
11
18
9
8
bawuua00000280
.
1
2
3
Breather pipe
O-ring
Transaxle case gasket
4
5
6
Gasket
Gasket
Oil Pump component
05-175
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Oil strainer
C3 clutch component
Front planetary gear component and input shaft
Brake band anchor bolt
B1 brake band
Snap ring
Brake piston cover
B1 brake piston
Piston return spring
Thrust bearing
Bearing race
C1 clutch component
Thrust bearing
Bearing race
Sun gear input drum
Counter gear component
Differential component
05-176
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Lock washer
Counter drive gear
Vehicle speed sensor (VSS)
Spacer
Snap Ring
Rear planetary gear component and one-way clutch
component
Bearing race
Thrust bearing
Bearing race
Snap ring
Retaining plate
Drive plate
Driven plate
Retaining plate
C2 clutch component
Thrust bearing
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
1
2
05-17
3
4
bawuua00000281
.
1
2
Tube clamp
Oil reservoir lock plate
3
4
Magnet
Oil pipe
05-177
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
10
12
8
7
6
20
11
19
3
R 17
18
14
17 R
13
15
16
bawuua00000282
.
05-178
SERVICE_1874-1U-06B(05-17).fm
AUTOMATIC TRANSAXLE
1
2
3
4
5
6
7
8
9
10
Stud bolt
Detent spring cover
Detent spring
Parking pawl shaft
Pawl return spring
Spring guide sleeve
Torsion spring
Parking pawl bracket
Parking pawl
Manual valve lever
11
12
13
14
15
16
17
18
19
20
Parking rod
Parking pin
Pipe clamp
Transaxle case No.1 plate
Wiring harness clip
Oil cooler outlet tube
O-ring
Seal ring
Transaxle case plate No.2
05-17
Disassembly procedure
1. Remove the oil pipes and O-rings. (Refer to Workshop Manual.)
Caution
Do not damage the oil seal.
Do not drop the torque converter.
2. Remove the torque converter.
bawuua00000283
3. Remove the drain plug and gasket.

4. Drain the ATF.
Caution
Do not repair the threads using a tap or
other tools.
bawuua00000284
05-179
SERVICE_1874-1U-06B(05-17).fm
10
AUTOMATIC TRANSAXLE
5. Remove the stud bolts.
bawuua00000285
Caution
Do not touch the terminals.
bawuua00000286
6. Remove the TCM.
TCM
MOUNTING
BOLT
TCM
bawuua00000287
7. Set the SST as shown in the figure.

Caution
When installing the SST to the transaxle,
use bolts (M121.25) with a thread length
of 90 mm {3.54 in}.
49 L010 1A0
49 0107 680A
bawuua00000288
05-1710
SERVICE_1874-1U-06B(05-17).fm
11
AUTOMATIC TRANSAXLE
8. Install the SST to the position where the transaxle
stud bolts were removed.
05-17
bawuua00000289
9. Remove the control valve body cover installation

bolt.
Caution
Do not damage the fitting surface of the
transaxle case and the control valve body
cover.
Do not deform the control valve body
cover.
bawuua00000290
10. Using a plastic hammer, tap the control valve

body cover to remove it.
Caution
Be careful not to damage the solenoid
valves and connectors.
Do not pull the wiring harnesses when
removing the connector.
Note
Disconnect the solenoid connector
according to the following procedure:
bawuua00000291
(1) Insert a precision screwdriver from the

backside into the connector as shown in the
figure.
bawuua00000292
05-1711
SERVICE_1874-1U-06B(05-17).fm
12
AUTOMATIC TRANSAXLE
(2) Pry the screwdriver in the direction of the
arrow and disconnect the connector.
Caution
Do not damage the solenoid valves and
connectors with the screwdriver.
When disconnecting connectors, grasp
the connectors, not the wiring harnesses.
Otherwise, the wiring harnesses may be
pulled out of the connector causing poor
contact.
bawuua00000293
11. Disconnect the solenoid connectors, VSS

connector and the input/turbine speed sensor
connector.
12. Disconnect the coupler component from the
clamp.
CLAMP
CLAMP
bawuua00000294
13. Remove the lock plate, and pull out the TFT
sensor from the control valve body.
14. Remove the O-ring from the TFT sensor.
Note
Be sure to secure the coupler component
with tape so that it will not interfere with the
control valve body component.
bawuua00000295
15. Fix the coupler component with tape to the

transaxle case as shown in the figure.
bawuua00000296
05-1712
SERVICE_1874-1U-06B(05-17).fm
13
AUTOMATIC TRANSAXLE
16. Remove the VSS connector and input/turbine speed sensor connector from the solenoid clamp.
05-17
VSS CONNECTOR
INPUT/TURBINE SPEED SENSOR

CONNECTOR
bawuua00000297
Note
Be sure to secure the VSS and input/turbine speed sensor with tape so that they do not interfere with the
17. Secure the VSS wiring harness and input/turbine
speed sensor wiring harness with tape to the
transaxle case as shown in the figure.
bawuua00000298
18. Remove the suction cover and the gasket.

Caution
Loosen the bolts evenly a little at a time
in the order shown in the figure.
bawuua00000299
05-1713
SERVICE_1874-1U-06B(05-17).fm
14
AUTOMATIC TRANSAXLE
19. Remove the control valve body installation bolts.
Caution
Do not drop the control valve body
component.
2
3
6
5
bawuua00000300
20. Disconnect the manual valve link and remove the

bawuua00000301
21. Remove the coupler component lock plate.

Caution
Do not damage the wiring harness.
Do not pull hard on the wiring harness.
22. Remove the coupler component from the
transaxle case.
bawuua00000302
23. Remove the O-ring and the gasket from the

coupler component.
Caution
Do not damage the input/turbine speed
sensor.
O-RING
GASKET
bawuua00000303
05-1714
SERVICE_1874-1U-06B(05-17).fm
15
AUTOMATIC TRANSAXLE
24. Remove the input/turbine speed sensor.
25. Remove the bolts as shown in the figure.
05-17
bawuua00000304
bawuua00000305
Caution
Do not damage the fitting surface of the converter housing and the transaxle case.
26. Using a plastic hammer, tap the converter
housing to remove it.
bawuua00000306
05-1715
SERVICE_1874-1U-06B(05-17).fm
16
AUTOMATIC TRANSAXLE
27. Remove the transaxle case gaskets as shown in
the figure.
bawuua00000307
28. Remove the gaskets as shown in the figure.

Caution
Do not damage the oil reservoir lock
plate.
bawuua00000308
29. Remove the tube clamp and the oil reservoir lock
plate.
bawuua00000309
30. Remove the magnets from the oil reservoir lock

plate.
Caution
Do not damage the differential gear lube
apply tube.
bawuua00000310
31. Using a flathead screwdriver, remove the oil pipe.

Caution
Do not damage the converter housing.
If using a screwdriver, use a wooden
block or equivalent to avoid damaging
the fitting surface of the converter
housing.
32. Remove the oil seal lip using a razor.
bawuua00000311
05-1716
SERVICE_1874-1U-06B(05-17).fm
17
AUTOMATIC TRANSAXLE
33. Using a tape-wrapped flathead screwdriver,
remove the oil seal (converter housing side).
05-17
bawuua00000312
34. Remove the oil pump component.
bawuua00000313
35. Remove the oil seal and the oil strainer from the
oil pump component.
bawuua00000314
36. Remove the C3 clutch component, input shaft and

the front planetary gear component.
Note
In some cases, the input shaft may be
detached with the thrust roller bearing
attached.
bawuua00000315
37. Remove the C3 clutch component from the input

shaft and the front planetary gear component.
Note
In some cases, the C3 clutch component
may be detached with the thrust washer
attached.
bawuua00000316
05-1717
SERVICE_1874-1U-06B(05-17).fm
18
AUTOMATIC TRANSAXLE
38. Remove the brake band anchor bolt.
bawuua00000317
39. Remove B1 the brake band.
bawuua00000318
40. Inspect the lining of the brake band.

If the lining is flaking or has changed color, or
if it is worn or the print mark is wearing away,
replace with a new brake band and C3 clutch.
When replacing, inspect the contact surfaces
between the C3 clutch drum and B1 brake
band. If they are scratched or have changed
color, replace with new parts.
Note
Before replacing with a new B1 brake band,
soak it at least 2 h in ATF.
PRINT
bawuua00000319
41. Remove the snap ring using snap ring pliers.

Caution
The brake piston cover will fly off due to
the force of the piston return spring.
Do not drop the brake piston cover.
Do not drop the B1 brake piston.
bawuua00000320
42. Remove the brake piston cover, B1 brake piston

and the piston return spring.
bawuua00000321
05-1718
SERVICE_1874-1U-06B(05-17).fm
19
AUTOMATIC TRANSAXLE
43. Remove the thrust bearing, bearing race and the
C1 clutch component.
Note
In some cases, the C1 clutch component
may be detached with the thrust bearing
attached.
05-17
bawuua00000322
44. Remove the thrust bearing, bearing race and the

sun gear input drum.
bawuua00000323
45. Remove the detent spring cover and detent

spring.
Caution
Be careful not to apply too much force to
the pawl return spring.
bawuua00000324
46. Remove the pawl return spring and the parking

pawl shaft.
Caution
Be careful not to apply too much force to
the torsion spring.
bawuua00000325
47. Remove the torsion spring and the spring guide

sleeve.
bawuua00000326
05-1719
SERVICE_1874-1U-06B(05-17).fm
20
AUTOMATIC TRANSAXLE
48. Remove the parking pawl and the parking pawl
bracket.
bawuua00000327
49. Disconnect the parking rod from the manual valve

lever.
bawuua00000328
50. Remove the manual valve lever from the transaxle

case.
bawuua00000329
51. Remove the parking rod from the transaxle case.
bawuua00000330
05-1720
SERVICE_1874-1U-06B(05-17).fm
21
AUTOMATIC TRANSAXLE
52. Remove the parking pin from the transaxle case.
Note
Inspect the direction of the parking pin.
05-17
bawuua00000331
53. Remove the counter gear component.

Note
For easy removal, tilt the counter gear
component slightly.
bawuua00000332
54. Remove the differential component.

Caution
Do not damage the VSS wiring harness.
Do not pull hard on the VSS wiring
harness.
bawuua00000333
55. Disconnect the VSS wiring harness from the tube

wiring clamp.
Caution
Do not damage the oil cooler outlet tube.
bawuua00000334
05-1721
SERVICE_1874-1U-06B(05-17).fm
22
AUTOMATIC TRANSAXLE
56. Remove the pipe clamp, transaxle case No.1
plate, wiring harness clip and the oil cooler outlet
tube.
57. Remove the O-rings from the oil cooler outlet
tube.
bawuua00000335
58. Using a flathead screwdriver and a hammer, pry

back the crimp on the lockwashers.
Caution
If the lockwasher crimp is not completely
pried back, the tool cannot fit over the
bolt properly and the bolt cannot be
loosened.
bawuua00000336
59. Remove the lockwashers, washers and the

counter drive gear.
Caution
harness.
Do not damage the VSS.
bawuua00000337
60. Remove the VSS and spacer from the counter

drive gear.
bawuua00000338
05-1722
SERVICE_1874-1U-06B(05-17).fm
23
AUTOMATIC TRANSAXLE
61. Using a flathead screwdriver, remove the snap
ring.
Caution
Do not drop the sun gear.
05-17
bawuua00000339
62. Remove the rear planetary gear component and

the one-way clutch.
Note
In some cases, the sun gear may be
detached with the bearing race attached.
Note
Remove the sun gear in the center while
holding it.
The thrust washer of the rear planetary gear
on the rear side might remain on the
transaxle case side when removing the rear
planetary gear component.
bawuua00000340
63. Remove the thrust bearing and the bearing races.
bawuua00000341

ring.
bawuua00000342
05-1723
SERVICE_1874-1U-06B(05-17).fm
24
AUTOMATIC TRANSAXLE
65. Remove the retaining plates, drive and driven
plates.
Note
Inspect the number of drive plates and
driven plates.
bawuua00000343
66. Inspect the lining of all drive plates.

replace with a new drive plate. When
replacing, inspect the contact surfaces
between the retaining plate, driven plate and
drive plate. If they are scratched or have
changed color, replace with new parts.
Note
Before replacing with new drive plates, soak
them at least 2 h in ATF.
PRINT
bawuua00000344
67. Remove the C2 clutch component and the thrust

bearing.
bawuua00000345
68. Remove the seal rings from the transaxle case.
bawuua00000346
69. Remove the transaxle case plate No.2.
bawuua00000347
05-1724
SERVICE_1874-1U-06B(05-17).fm
25
AUTOMATIC TRANSAXLE
70. Remove the transaxle case plate No.3.
Caution
Do not damage the transaxle case.
the fitting surface of the transaxle case.
71. Remove the oil seal lip using a razor.
05-17
bawuua00000348

remove the oil seal (transaxle case side).
Caution
the fitting surface of the transaxle case.
bawuua00000349

remove the oil seal (manual shaft).
End Of Sie
AT: OIL PUMP
bawuua00000350
05-1725
SERVICE_1874-1U-06B(05-17).fm
26
AUTOMATIC TRANSAXLE
OIL PUMP DISASSEMBLY/ASSEMBLY
id051700500100
Components
GREASE
R
SST
ATF
3
GREASE
ATF
:NON SUPPLY PART

bawuua00000001
.
1
2
O-ring
Thrust washer
05-1726
3
4
Seal ring
Oil seal
SERVICE_1874-1U-06B(05-17).fm
27
AUTOMATIC TRANSAXLE
Disassembly Procedure
1. Remove the O-ring from the oil pump.
05-17
bawuua00000002
2. Remove the thrust washer from the oil pump.
bawuua00000003
3. Remove the seal rings from the oil pump.

Caution
Do not damage the bushing on the oil
pump body.
bawuua00000004

remove the oil seal from the oil pump body.
bawuua00000005
05-1727
SERVICE_1874-1U-06B(05-17).fm
28
AUTOMATIC TRANSAXLE
Assembly Procedure
Caution
1. Using the SST and a hammer, install the new oil
seal to the oil pump body.
Substitution SST
49 U027 003
Inner diameter: 54 61 mm {2.13 2.40 in}
2. Apply grease to the oil seal lip.
3. Apply ATF to the new seal rings and sliding
surface of the oil pump component.
49 U027 003
-0.20.2 mm
{-0.007880.00788 in}
Caution
Do not expand the seal rings too much.
Be careful not to shorten the seal rings
too much, when installing the seal rings.
4. Compress the seal rings as shown in the figure.
Then install the seal rings to the oil pump
component.
bawuua00000006
5 mm {0.197 in}
Note
Verify that oil seal rings rotate smoothly after
installing them.
5. Apply grease to the thrust washer.
Caution
Apply grease to the mounting surface of
the thrust washer so that it does not drop
when installed.
bawuua00000007
6. Install the thrust washer to the oil pump

component.
7. Apply ATF to a new O-ring.
bawuua00000003
8. Install the O-ring to the oil pump component.

Caution
Do not damage the oil seal lip.
bawuua00000002
05-1728
SERVICE_1874-1U-06B(05-17).fm
29
AUTOMATIC TRANSAXLE
9. Turn the drive gear with flathead screwdrivers and
verify it rotates smoothly.
End Of Sie
AT: AUTOMATIC TRANSAXLE CLUTCH COMPONENT
05-17
bawuua00000008
B1 BRAKE PISTON DISASSEMBLY/ASSEMBLY
id051700500200
Components
1
ATF
ATF
bawuua00000351
.
O-ring
O-ring
05-1729
SERVICE_1874-1U-06B(05-17).fm
30
AUTOMATIC TRANSAXLE
1. Remove the O-ring from the B1 brake piston.
bawuua00000352
2. Remove the O-rings from the brake piston cover.
bawuua00000353
Assembly Procedure
1. Apply ATF to the new O-rings.
2. Install the O-rings to the brake piston cover.
Number of O-ring
AJ: 3
L3 with TC: 2
3. Apply ATF to a new O-ring.
bawuua00000353
4. Install the O-ring to the B1 brake piston.
End Of Sie
bawuua00000352
05-1730
SERVICE_1874-1U-06B(05-17).fm
31
AUTOMATIC TRANSAXLE
C3 CLUTCH COMPONENT DISASSEMBLY
id051700500300
Components
5
SST
6
8
9
12
05-17
R 11
R 10
2 SELECTIVE
3
bawuua00000354
.
1
2
3
4
5
6
Snap ring
Retaining plate
Drive plate
Driven plate
Snap ring
C3 clutch balancer
7
8
9
10
11
12

Spring retainer
C3 clutch piston
O-ring
O-ring
C3 clutch drum
05-1731
SERVICE_1874-1U-06B(05-17).fm
32
AUTOMATIC TRANSAXLE
ring from the C3 clutch drum.
bawuua00000355
2. Remove the retaining plate, drive and driven

plates from the C3 clutch drum.
Note
Inspect the number of drive and driven
plates.
bawuua00000356
3. Place the SST on the clutch balancer and

compress the return spring with a press.
49 G025 001
Caution
Be careful not to expand the snap ring
too much.
Caution
Do not damage the seal on the clutch
balancer.
bawuua00000357
5. Remove the clutch balancer, return spring and the

retainer from the C3 clutch drum.
bawuua00000358
05-1732
SERVICE_1874-1U-06B(05-17).fm
33
AUTOMATIC TRANSAXLE
6. While pushing the C3 clutch piston by hand, apply
compressed air into the oil passage as shown in
the figure and remove the C3 clutch piston from
the C3 clutch drum.
Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}
Note
When applying compressed air, shut the 3
oil passages of the C3 clutch drum as shown
in the figure.
05-17
bawuua00000359
7. Remove the O-rings from the C3 clutch drum.
End Of Sie
bawuua00000360
C3 CLUTCH INSPECTION
Note
id051700500400
PRINT
bawuua00000495
2. Using vernier calipers, measure the free length of

the piston return spring.
C3 clutch return spring free length
Standard: 12.91 mm {0.5083 in}
If it is less than the specification, replace the
piston return spring with a new one.
End Of Sie
bawuua00000496
05-1733
SERVICE_1874-1U-06B(05-17).fm
34
AUTOMATIC TRANSAXLE
C3 CLUTCH COMPONENT ASSEMBLY
id051700500500
Components
8 SST
7
5
4
ATF
ATF
ATF
ATF
12
11 SELECTIVE
10
bawuua00000361
.
1
2
3
4
5
6
C3 clutch drum
O-ring
O-ring
C3 clutch piston
Spring retainer
05-1734
7
8
9
10
11
12
C3 clutch balancer
Snap ring
Driven plate
Drive plate
Retaining plate
Snap ring
SERVICE_1874-1U-06B(05-17).fm
35
AUTOMATIC TRANSAXLE
Assembly Procedure
1. Apply ATF to the new O-rings and the C3 clutch drum.
2. Install the O-rings to the C3 clutch drum.
3. Apply ATF to the sliding surface of the C3 clutch
piston.
Caution
Do not damage the seal on the piston and
O-rings.
05-17
bawuua00000362
4. Install the C3 clutch piston to the C3 clutch drum.

5. Apply ATF to the seal on the clutch balancer.
Caution
balancer.
bawuua00000363
6. Install the retainer, return spring and the clutch

balancer to the C3 clutch drum.
bawuua00000364

compress the piston return spring with a press.
49 G025 001
Caution
When installing the snap ring, set the end
gap of the snap ring as shown in the
figure.
Do not expand the snap ring too much.
8. Install the snap ring in the groove using snap ring
pliers.
bawuua00000365
05-1735
SERVICE_1874-1U-06B(05-17).fm
36
AUTOMATIC TRANSAXLE
9. Install the driven plates, drive plates and the
retaining plate in the following order to the C3
clutch drum as shown in the figure.
Driven Drive Driven Drive Driven
Drive Driven Drive Retaining
bawuua00000366
Caution
Inspect the number and order of the
retaining plate, drive and driven plates.
RETAINING PLATE
DRIVE PLATE
DRIVEN PLATE
bawuua00000367
10. Using a flathead screwdriver, install the snap ring

in the groove.
Caution
figure.
bawuua00000368
11. Install the C3 clutch component to the oil pump

and set a dial indicator as shown in the figure.
12. Apply compressed air as shown in the figure and
measure the C3 clutch piston stroke.
Air pressure
200 kPa {2.0 kgf/cm2, 29 psi}
C3 clutch piston stroke
0.6 0.8 mm {0.024 0.031 in}
If not within the specification, select an
appropriate retaining plate.
05-1736
bawuua00000369
SERVICE_1874-1U-06B(05-17).fm
37
AUTOMATIC TRANSAXLE
Retaining plate size
Identification mark
1
A
2
B
3
C
4
5
6
7
8
Thickness (mm {in})

2.8 {0.110}
2.85 {0.112}
2.9 {0.114}
2.95 {0.116}
3.0 {0.118}
3.05 {0.120}
3.1 {0.122}
3.2 {0.126}
3.3 {0.130}
3.4 {0.134}
3.5 {0.138}
05-17
End Of Sie
FRONT PLANETARY GEAR COMPONENT INPUT SHAFT DISASSEMBLY/ASSEMBLY
id051700500600
Components
3
ATF
ATF
7 R
6
5
ATF
ATF
4
bawuua00000497
.
1
2
3
4
5
Thrust washer
Front planetary gear component
Thrust washer
Front planetary sun gear
Thrust bearing
6
7
8
9
Bearing race
Seal ring
Seal ring
Input shaft
05-1737
SERVICE_1874-1U-06B(05-17).fm
38
AUTOMATIC TRANSAXLE
1. Remove the thrust washer from the front
bawuua00000498
2. Remove the front planetary gear component from

the input shaft.
bawuua00000499
3. Remove the thrust washer from the front

Note
In some cases, the thrust washer may be
detached with the input shaft attached.
bawuua00000500
4. Remove the front planetary sun gear, thrust

bearing and the bearing race from the input shaft.
Note
If it is difficult to remove the bearing race, pry
it off gently using a flathead screwdriver.
bawuua00000501
05-1738
SERVICE_1874-1U-06B(05-17).fm
39
AUTOMATIC TRANSAXLE
5. Remove the seal rings from the input shaft.
05-17
bawuua00000502
6. Remove the seal rings from the input shaft.
bawuua00000503
Assembly Procedure
1. Apply ATF to the new seal rings and sliding surface of the input shaft.
Caution
Do not expand the seal ring too much.
Be careful not to shorten the seal rings too much, when installing the seal rings.
Then install the seal rings to the input shaft.
5 mm {0.197 in}
Note
Verity that seal rings rotate smoothly after
installing them.
3. Apply ATF to the bearing race.
bawuua00000504
4. Install the bearing race to the input shaft.

Caution
when the front planetary gear component
is installed.
Do not apply grease to the oil holes of the
thrust washer.
Do not drop the thrust washer.
bawuua00000505
05-1739
SERVICE_1874-1U-06B(05-17).fm
40
AUTOMATIC TRANSAXLE
6. Install the thrust washer to the front planetary
gear component.
bawuua00000500
7. Install the front planetary gear component to the

input shaft.
8. Apply ATF to the thrust bearing.
bawuua00000506
9. Install the thrust bearing to the input shaft as

bawuua00000507
10. Install the front planetary sun gear to the input

shaft as shown in the figure.
surface of the input shaft.
Caution
Do not expand the oil seal rings too
much.
bawuua00000508
05-1740
SERVICE_1874-1U-06B(05-17).fm
41
AUTOMATIC TRANSAXLE
Then install the seal rings to the input shaft.
5 mm {0.197 in}
Note
Verify that seal rings rotate smoothly after
installing them.
Caution
when the front planetary gear component
is installed.
Do not coat grease to the oil holes of the
thrust washer.
05-17
bawuua00000509

14. Install the thrust washer to the front planetary
gear component.
End Of Sie
bawuua00000510
05-1741
SERVICE_1874-1U-06B(05-17).fm
42
AUTOMATIC TRANSAXLE
id051700500700
Components
4
SELECTIVE
10 R
11
9
8
7
6
SST
bawuua00000370
1
2
3
4
5
6
Snap ring
Retaining plate
Drive plate
Driven plate
Snap ring
C1 clutch balancer
05-1742
7
8
9
10
11

Spring retainer
C1 clutch piston
O-ring
C1 clutch drum
SERVICE_1874-1U-06B(05-17).fm
43
AUTOMATIC TRANSAXLE
ring from the C1 clutch drum.
05-17
bawuua00000371

plates from the C1 clutch drum.
Note
plates.
bawuua00000372

Caution
49 G025 001

Caution
balancer.
bawuua00000373

retainer from the C1 clutch drum.
bawuua00000374
05-1743
SERVICE_1874-1U-06B(05-17).fm
44
AUTOMATIC TRANSAXLE
the figure and remove the forward clutch piston
from the C1 clutch drum.
Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}
Note
When applying compressed air, block the
one oil passage of the C1 clutch drum as
bawuua00000375
7. Remove the O-rings from the C1 clutch drum.
End Of Sie
bawuua00000376
Note
id051700500800
PRINT
bawuua00000511

End Of Sie
bawuua00000512
05-1744
SERVICE_1874-1U-06B(05-17).fm
45
AUTOMATIC TRANSAXLE
id051700500900
Components
8
SELECTIVE
05-17
10
11
2 R
3
ATF
ATF
4
5
ATF
SST
bawuua00000377
1
2
3
4
5
6
C1 clutch drum
O-ring
C1 clutch piston
Spring retainer
C1 clutch balancer
7
8
9
10
11
Snap ring
Driven plate
Drive plate
Retaining plate
Snap ring
05-1745
SERVICE_1874-1U-06B(05-17).fm
46
AUTOMATIC TRANSAXLE
Assembly Procedure
1. Apply ATF to the new O-rings and the C1 clutch drum.
2. Install the O-rings to the C1 clutch drum.
3. Apply ATF to the sliding surface of the forward
clutch piston.
Caution
O-ring.
bawuua00000378
4. Install the C1 clutch piston to the C1 clutch drum.

5. Apply ATF to the seal on the clutch balancer.
Caution
balancer.
bawuua00000379
6. Install the retainer, return spring and the clutch

balancer to the C1 clutch drum.
bawuua00000380

compress the return spring component with a
press.
49 G025 001
Caution
figure.
8. Install the snap ring in the groove using snap ring
pliers.
05-1746
bawuua00000381
SERVICE_1874-1U-06B(05-17).fm
47
AUTOMATIC TRANSAXLE
retaining plate in the following order to the C1
clutch drum as shown in the figure.
Six drive plates type
Drive Driven Drive Driven Drive
Driven Drive Retaining
Seven drive plates type
Driven Drive Driven Drive Retaining
05-17
bawuua00000382
Caution
RETAINING PLATE
DRIVE PLATE
DRIVEN PLATE
bawuua00000383

in the groove.
Caution
figure.
bawuua00000384
11. Install the C1 clutch component on the input shaft

and set a dial indicator as shown in the figure.
Air pressure
200 kPa {2.0 kgf/cm2, 29 psi}
1.2 1.4 mm {0.047 0.055 in}
bawuua00000385
05-1747
SERVICE_1874-1U-06B(05-17).fm
48
AUTOMATIC TRANSAXLE
Identification mark
1
2
3
4
A
5
B
6
C
7
8
End Of Sie
05-1748
Thickness (mm {in})

2.8 {0.110}
2.9 {0.114}
3.0 {0.118}
3.1 {0.122}
3.15 {0.124}
3.2 {0.126}
3.25 {0.128}
3.3 {0.130}
3.35 {0.132}
3.4 {0.134}
3.5 {0.138}
SERVICE_1874-1U-06B(05-17).fm
49
AUTOMATIC TRANSAXLE
COUNTER DRIVE GEAR DISASSEMBLY/ASSEMBLY
id051700501000
Components
9
11
R
SST
8 SST
10
13
R
SST
05-17
12
1
2
3
6
4 SST
5
SST
R
bawuua00000386
1
2
3
4
5
6
7
Rear planetary ring gear

Snap ring
Rear planetary ring gear flange
Nut
Washer
Snap ring
Tapered roller bearing
8
9
10
11
12
13
Counter drive gear

Bearing race
Bearing race
Snap ring
Center support
Tapered roller bearing
05-1749
SERVICE_1874-1U-06B(05-17).fm
50
AUTOMATIC TRANSAXLE
1. Using the snap ring pliers, loosen the snap ring
and remove the rear planetary ring gear.
bawuua00000387

ring from the rear planetary ring gear.
3. Remove the ring gear flange from the rear
planetary ring gear.
bawuua00000388
4. Using a flathead screwdriver and hammer, pry

back the crimps locking the washer.
Caution
If the lockwasher crimps are not
completely pried back, the tool cannot fit
over the bolt properly and the bolt cannot
be loosened.
bawuua00000389
5. Using the SST, remove the nut and the washer.

49 G019 040
bawuua00000390
05-1750
SERVICE_1874-1U-06B(05-17).fm
51
AUTOMATIC TRANSAXLE
ring from the counter drive gear.
Caution
Do not drop the tapered roller bearing.
05-17
bawuua00000391
7. Using the SST, remove the counter drive gear

and tapered roller bearing.
49 G019 026
49 B032 317
bawuua00000392
8. Using a flathead screwdriver and hammer,

remove the bearing race inner from the counter
drive gear.
bawuua00000393
9. Using a flathead screwdriver and hammer,

remove the bearing race outer from the counter
drive gear.
bawuua00000394
05-1751
SERVICE_1874-1U-06B(05-17).fm
52
AUTOMATIC TRANSAXLE
ring from the counter drive gear.
bawuua00000395
Note
The tapered roller bearing cannot be
removed from the center support.
The tapered roller bearing and center
support must be replaced as a set.
bawuua00000396
Assembly Procedure
Note
The tapered roller bearing and bearing race outer must be replaced as a set.
1. Using the SST and a press, install the tapered
roller bearing to the center support.
Substitution SST
49 L033 101
STEEL PLATE
49 L033 101
bawuua00000397
2. Using a flathead screwdriver, install the hole snap

ring to the counter drive gear.
bawuua00000395
05-1752
SERVICE_1874-1U-06B(05-17).fm
53
AUTOMATIC TRANSAXLE
3. Using the old bearing race and the steel plate as
shown in the figure, install the new bearing race
outer to the counter drive gear.
STEEL PLATE
05-17
OLD BEARING
RACE
NEW BEARING
RACE
bawuua00000398
4. Using the old bearing race and the steel plate as

shown in the figure, install the new bearing race
inner to the counter drive gear.
Caution
Do not press fit the bearing too deeply.
Verify that the bearing is press fit to allow
the installation of the nut.
STEEL PLATE
OLD BEARING
RACE
NEW BEARING
RACE
bawuua00000399
5. Using the SST and a press, install the counter

drive gear with the tapered roller bearing.
Substitution SST
49 W027 001
49 W027 001
Note
Verify that the claw of the washer is fit into
the groove on the center support.
Verify that the nut is installed in the correct
direction.
bawuua00000400
6. Install the washer and nut.

7. Using the SST, tighten the nut.
NUT
WASHER
bawuua00000401
05-1753
SERVICE_1874-1U-06B(05-17).fm
54
AUTOMATIC TRANSAXLE
8. Using a spring balance, measure the starting and
rotating torque of the counter drive gear.
49 G019 040
bawuua00000402
Counter drive gear starting and rotating torque

Nm {kgfcm, inlbf}
Bearing
New
Reused
Starting torque
0.40 0.50 {4.08 5.09, 3.55 4.41}
0.20 0.25 {2.04 2.54, 1.77 2.20}
Rotating torque
0.40 0.48 {4.08 4.89, 3.55 4.24}
0.20 0.24 {2.04 2.44, 1.77 2.11}
Adjust the starting and rotating torque by tightening the nut.

If the starting and rotating torque does not fall within the specification, loosen the nut and retighten the nut
to adjust torque.
9. Using a flathead screwdriver and hammer, crimp
down the washer.
bawuua00000403
10. Using a flathead screwdriver, install the hole snap

ring to the counter drive gear.
11. Install the rear planetary ring gear flange to the
rear planetary ring gear.
bawuua00000391

in the groove.
13. Install the rear planetary ring gear to the counter
drive gear.
bawuua00000388
05-1754
SERVICE_1874-1U-06B(05-17).fm
55
AUTOMATIC TRANSAXLE
14. Using the snap ring pliers, while loosening the
snap ring, install the rear planetary ring gear.
End Of Sie
05-17
bawuua00000387
ONE-WAY CLUTCH COMPONENT INSPECTION

1. Hold the one-way clutch component in place.
Verify that the rear planetary gear rotates when
turned clockwise and does not rotate when turned
counterclockwise.
End Of Sie
id051700501100
LOCK
FREE
bawuua00000513
05-1755
SERVICE_1874-1U-06B(05-17).fm
56
AUTOMATIC TRANSAXLE
REAR PLANETARY GEAR COMPONENT AND ONE-WAY CLUTCH COMPONENT DISASSEMBLY
id051700501200
Components
3
4
5
6
7
8
bawuua00000514
.
1
2
3
4
5
One-way clutch component

Thrust washer
Thrust washer
Bearing race
Thrust bearing
6
7
8
9
Bearing race
Planetary sun gear
Bearing race
Rear planetary gear component
1. Remove the one-way clutch component from the
rear planetary gear component.
bawuua00000515
05-1756
SERVICE_1874-1U-06B(05-17).fm
57
AUTOMATIC TRANSAXLE
2. Remove the thrust washer from the rear planetary
gear component.
05-17
bawuua00000516
3. Remove the thrust washer from the rear planetary

gear component.
bawuua00000517
4. Remove the planetary sun gear and bearing

races from the rear planetary gear component.
Note
If it is difficult to remove the bearing race,
remove it gently using a flathead
screwdriver.
End Of Sie
bawuua00000518
REAR PLANETARY GEAR INSPECTION
id051700501300
Note
Measure at different places and take an average.
1. Using a dial indicator, measure the inner diameter
of the rear planetary gear bushings.
Rear planetary gear bushing inner diameter
Front side: 33.26 33.286 mm {1.3095
1.3104 in}
Rear side: 33.26 33.286 mm {1.3095
1.3104 in}
If it exceeds the specification, replace the rear
planetary gear component with a new one.
When the rear planetary gear component is
bawuua00000519
replaced, inspect the contact surface opposed
to the planetary sun gear.
If the surface of it is scratched or has changed color, replace the planetary sun gear with a new one.
05-1757
SERVICE_1874-1U-06B(05-17).fm
58
AUTOMATIC TRANSAXLE
2. Using a dial indicator, measure the inner diameter
of the planetary sun gear bushings.
Rear planetary sun gear bushing inner
diameter
Front side: 24.2 24.226 mm {0.9528
0.9537 in}
Rear side: 24.2 24.226 mm {0.9528
0.9537 in}
If it exceeds the specification, replace the
planetary sun gear component with a new
bawuua00000520
one.
When the planetary sun gear component is
replaced, inspect the contact surface opposed to the intermediate shaft.
If the surface of it is scratched or has changed color, replace the intermediate shaft with a new one.
End Of Sie
REAR PLANETARY GEAR COMPONENT AND ONE-WAY CLUTCH COMPONENT ASSEMBLY
id051700501400
Components
GREASE
GREASE
7
6
5
ATF
ATF
ATF
ATF
bawuua00000521
.
1
2
3
4
Rear planetary gear component

Thrust washer
Thrust washer
Bearing race
05-1758
5
6
7
8
Bearing race
Thrust bearing
Bearing race
Planetary sun gear
SERVICE_1874-1U-06B(05-17).fm
59
AUTOMATIC TRANSAXLE
Assembly Procedure
Caution
Apply grease to the mounting surface of the thrust washer so that it will not drop when the rear
planetary gear component is installed.
Do not apply grease to the oil holes of the thrust washer.
2. Install the thrust washer to the rear planetary gear
component.
05-17
Caution
the thrust washer so that it will not drop
when the rear planetary gear component
is installed.
thrust washer.
bawuua00000522
4. Install the thrust washer to the rear planetary gear

component.
Caution
the thrust washer so that it will not drop
when the rear planetary gear component
is installed.
thrust washer.
5. Apply ATF to the bearing races and the thrust
bearing.
6. Install the bearing races to the planetary sun gear
as shown in the figure.
7. Install the planetary sun gear to the rear planetary
gear component.
bawuua00000523
End Of Sie
bawuua00000524
05-1759
SERVICE_1874-1U-06B(05-17).fm
60
AUTOMATIC TRANSAXLE
id051700501500
Components
4
3 SELECTIVE
9
8
7
SST
11 R
12 R
13
10
bawuua00000045
.
1
2
3
Thrust bearing
Snap ring
Retaining plate
05-1760
4
5
6
Drive plate
Driven plate
Snap ring
SERVICE_1874-1U-06B(05-17).fm
61
AUTOMATIC TRANSAXLE
7
8
9
10
C2 clutch balancer
Spring retainer
C2 clutch piston
11
12
13
O-ring
O-ring
Intermediate shaft
1. Remove the thrust bearing from the intermediate
shaft.
05-17
Note
If the bearing is difficult to remove, blow air
between the bearing and the intermediate
shaft.
bawuua00000046

ring from the intermediate shaft.
bawuua00000047

plates from the intermediate shaft.
Note
plates.
bawuua00000048

Caution
Do not contract the return spring too
much.
49 G025 001

Caution
balancer.
bawuua00000049
05-1761
SERVICE_1874-1U-06B(05-17).fm
62
AUTOMATIC TRANSAXLE
spring retainer from the intermediate shaft.
Caution
Do not damage the seal on the piston.
bawuua00000050

the figure and remove the C2 clutch piston from
the intermediate shaft.
Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}
Note
When applying compressed air, block the
three oil passages of the intermediate shaft
bawuua00000051
8. Remove the O-rings from the intermediate shaft.
End Of Sie
bawuua00000052
05-1762
SERVICE_1874-1U-06B(05-17).fm
63
AUTOMATIC TRANSAXLE
Note
id051700501600
PRINT
05-17
bawuua00000525

End Of Sie
bawuua00000526
05-1763
SERVICE_1874-1U-06B(05-17).fm
64
AUTOMATIC TRANSAXLE
id051700501700
Components
10
12
11 SELECTIVE
5
6
8 SST
ATF
13
3 R
1
ATF
ATF
ATF
bawuua00000086
.
1
2
3
Intermediate shaft
O-ring
O-ring
05-1764
4
5
6
C2 clutch piston
Spring retainer
SERVICE_1874-1U-06B(05-17).fm
65
AUTOMATIC TRANSAXLE
7
8
9
10
C2 clutch balancer
Snap ring
Driven plate
Drive plate
11
12
13
Retaining plate
Snap ring
Thrust bearing
Assembly Procedure
1. Apply ATF to the new O-rings and the intermediate shaft.
2. Install the O-rings to the intermediate shaft.
05-17
bawuua00000087
O-ring size
mm {in}
Upper
Lower
Inner diameter
51.90 {2.043}
50.40 {1.984}
Thickness
1.60 {0.0630}
2.62 {0.1031}
3. Apply ATF to the sliding surface of the C2 clutch piston.

Caution
Do not damage the seal on the piston and O-ring.
4. Install the C2 clutch piston to the intermediate
shaft.
5. Apply ATF to the seal on the clutch balancer and
sliding surface.
Caution
balancer.
Do not damage the O-ring.
bawuua00000088
6. Install the spring retainer, return spring and the

clutch balancer to the intermediate shaft.
Caution
Be careful not to shorten the spring too
much. If it is too short, it will bite into the
O-ring.
bawuua00000089
05-1765
SERVICE_1874-1U-06B(05-17).fm
66
AUTOMATIC TRANSAXLE
49 G025 001
Caution
8. Install the snap ring into the groove using snap
ring pliers.
bawuua00000090

retaining plate in the following order to the
intermediate shaft as shown in the figure.
Three drive plates type
Drive Retaining
Four drive plates type
bawuua00000091
Caution
RETAINING PLATE
DRIVE PLATE
DRIVEN PLATE
bawuua00000092

into the groove.
11. Apply ATF to the thrust bearing.
Note
Install the bearing in the correct direction as
bawuua00000093
12. Install the thrust bearing to the intermediate shaft.
bawuua00000094
05-1766
SERVICE_1874-1U-06B(05-17).fm
67
AUTOMATIC TRANSAXLE
13. Install the intermediate shaft on the transaxle
case and set a dial indicator as shown in the
figure.
Air pressure
400 kPa {4.1 kgfcm2, 58 psi}
0.45 0.65 mm {0.0178 0.0255 in}
05-17

bawuua00000095

Identification mark
1
2
3
4
A
5
B
6
C
7
8
Thickness (mm {in})

2.5 {0.0984}
2.6 {0.102}
2.7 {0.106}
2.8 {0.110}
2.85 {0.112}
2.9 {0.114}
2.95 {0.116}
3.0 {0.118}
3.05 {0.120}
3.1 {0.122}
3.2 {0.126}
End Of Sie
05-1767
SERVICE_1874-1U-06B(05-17).fm
68
AUTOMATIC TRANSAXLE
TRANSAXLE CASE AND B2 BRAKE DISASSEMBLY/ASSEMBLY
id051700501800
1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.
3
1 SST
R
ATF
ATF
bawuua00000404
.
1
2
Snap ring
Low and reverse brake return spring
(See 05-17-70 Low and Reverse Brake Return
Spring Assembly Note.)
4
5
05-1768
Low and reverse brake piston

(See 05-17-69 Low and Reverse Brake Piston
Disassembly Note.)
(See 05-17-70 Low and Reverse Brake Piston
Assembly Note.)
O-ring
O-ring
SERVICE_1874-1U-06B(05-17).fm
69
AUTOMATIC TRANSAXLE
Low and Reverse Brake Piston Disassembly Note
ring from the transaxle case.
05-17
bawuua00000405
2. Remove the low and reverse brake return spring

from the transaxle case.
Caution
Do not damage the seal on the piston.
bawuua00000406
3. While pushing the low and reverse brake piston

by hand, apply compressed air into the oil
passage of the transaxle case as shown in the
figure and remove the low and reverse brake
piston.
Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}
bawuua00000407
4. Remove the O-rings from the low and reverse

brake piston.
bawuua00000408
05-1769
SERVICE_1874-1U-06B(05-17).fm
70
AUTOMATIC TRANSAXLE
Low and Reverse Brake Piston Assembly Note
2. Install the O-ring to the low and reverse brake
piston.
3. Apply ATF to the sliding surface of the transaxle
case.
Caution
O-ring.
bawuua00000408
4. Install the low and reverse brake piston to the

transaxle case.
bawuua00000409
Low and Reverse Brake Return Spring Assembly Note

1. Install the low and reverse brake return spring to
the transaxle case.
bawuua00000406
2. Using the SST, press the return spring into the

position where the snap ring groove is visible.
49 G019 0A9
bawuua00000410
05-1770
SERVICE_1874-1U-06B(05-17).fm
71
AUTOMATIC TRANSAXLE
in the groove.
Caution
figure.
End Of Sie
05-17
bawuua00000411
TRANSAXLE CASE AND B2 BRAKE INSPECTION
id051700501900
Note
Measure at different places and take an average.
1. Using a dial indicator, inspect the transaxle case
bushing.
Transaxle case bushing inner diameter
Standard: 21.932 21.953 mm {0.86347
0.86429 in}
If it exceeds the specification, replace the
transaxle case with a new one.
When the transaxle case is replaced, inspect
the contact surface of the intermediate shaft
bushing.
If the surface is scratched or has changed
color, replace the intermediate shaft with a
new one.
Note
bawuua00000527
PRINT
bawuua00000528

B2 brake return spring free length
End Of Sie
AT: CONTROL VALVE BODY
bawuua00000529
05-1771
SERVICE_1874-1U-06B(05-17).fm
72
AUTOMATIC TRANSAXLE
CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY
id051700502000
Components
5
ATF
3
bawuua00000530
.
1
2
3
Manual valve
E-ring
Manual valve connecting rod
05-1772
4
5
Shift solenoid A
Shift solenoid B
SERVICE_1874-1U-06B(05-17).fm
73
AUTOMATIC TRANSAXLE
Caution
Do not pull the manual valve strongly.
1. Remove the manual valve from the control valve
body.
05-17
bawuua00000531
2. Using a flathead screwdriver, remove the E-ring.

3. Remove the manual valve connecting rod from
the manual valve.
Caution
Do not damage the solenoid.
bawuua00000532
4. Remove the solenoids from the control valve

body.
bawuua00000533
05-1773
SERVICE_1874-1U-06B(05-17).fm
74
AUTOMATIC TRANSAXLE
Assembly Procedure
Caution
Do not damage the solenoid.
1. Install the solenoids to the front control valve
body.
Tightening torque
8.0 12.0 Nm {81.6 122.3 kgfcm, 70.9
106.1 inlbf}
2. Install the manual valve connecting rod to the
manual valve.
bawuua00000533
3. Install the E-ring.

4. Apply ATF to the manual valve.
Caution
Do not damage the manual valve.
bawuua00000534
5. Install the manual valve to the control valve body.
End Of Sie
AT: AUTOMATIC TRANSAXLE
bawuua00000531
05-1774
SERVICE_1874-1U-06B(05-17).fm
75
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE ASSEMBLY
id051700502200
Assembly
Bearing and race locations
C2 CLUTCH COMPONENT
PLANETARY SUN GEAR
REAR PLANETARY
GEAR COMPONENT
05-17
ONE-WAY CLUTCH
COMPONENT
11
10
9
8
7
SUN GEAR INPUT DRUM
C1 CLUTCH COMPONENT
INPUT SHAFT
FRONT PLANETARY SUN GEAR
FRONT PLANETARY GEAR COMPONENT

C3 CLUTCH COMPONENT
OIL PUMP COMPONENT

bawuua00000412
05-1775
SERVICE_1874-1U-06B(05-17).fm
76
AUTOMATIC TRANSAXLE
Thrust washer (mm {in})
1
2
3
64.0 101.0 85.0
Outer
{2.52} {3.98} {3.35}
51.0
75.3
72.7
Inner
{2.01} {2.96} {2.86}
7
8
79.8 104.2
{3.14} {4.10}
68.3
69.0
{2.69} {2.72}
10
11
Outer
Inner
Outer
Outer
Inner
45.6
{1.80}
33.2
{1.31}
47.0
{1.85}
35.2
{1.39}
52.6
{2.07}
39.2
{1.54}
48.5
{1.91}
38.1
{1.50}
Inner
61.3
{2.41}
43.7
{1.72}
68.8
{2.71}
46.9
{1.85}
Bearing race (front) (mm {in})
Bearing (mm {in})
Bearing race (rear) (mm {in})
05-1776
48.7
{1.92}
35.0
{1.38}
45.6
{1.80}
33.2
{1.31}
43.7
{1.72}
25.6
{1.01}
43.8
75.0
{1.72} {2.95}
24.25
50.5
{0.9547} {1.99}
41.7
{1.64}
24.2
{0.953}
SERVICE_1874-1U-06B(05-17).fm
77
AUTOMATIC TRANSAXLE
Components
05-17
17
20 R
16
12
11
13
14
15
19
18
R
10
4
3
ATF
8
6
5
bawuua00000413
.
05-1777
SERVICE_1874-1U-06B(05-17).fm
78
AUTOMATIC TRANSAXLE
1
2
3
4
5
6
7
8
9
10

Seal ring
O-ring
Oil cooler outlet tube
Wiring harness clip
Transaxle case No.1 plate
Pipe clamp
Parking pin
Parking rod
05-1778
11
12
13
14
15
16
17
18
19
20
Manual valve lever

Parking pawl
Parking pawl bracket
Torsion spring
Spring guide sleeve
Pawl return spring
Parking pawl shaft
Detent spring
Detent spring cover
Stud bolt
SERVICE_1874-1U-06B(05-17).fm
79
AUTOMATIC TRANSAXLE
4
3
05-17
2
1
bawuua00000414
.
1
2
Oil pipe
Magnet
3
4
Oil reservoir lock plate

Tube clamp
05-1779
SERVICE_1874-1U-06B(05-17).fm
80
AUTOMATIC TRANSAXLE
ATF
39
18
37
ATF
R 38
35
17
30
ATF
ATF
25
34
26
36
27
ATF
SST
28
ATF
ATF
ATF
11
33
ATF
16 R
ATF
ATF
8
9
ATF
ATF
10
ATF
19
ATF
ATF
20
ATF
ATF
12
13
15
21
ATF
23
ATF
24
14
29
22
31
32
ATF
bawuua00000415
.
1
2
Thrust bearing
C2 clutch component
05-1780
3
4
Retaining plate
Driven plate
SERVICE_1874-1U-06B(05-17).fm
81
AUTOMATIC TRANSAXLE
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Drive plate
Retaining plate
Snap ring
Bearing race
Thrust bearing
Bearing race
Rear planetary gear component and one-way clutch
component
Snap Ring
Spacer
Vehicle speed sensor (VSS)
Counter drive gear
Lock washer
Differential component
Counter gear component
Sun gear input drum
Bearing race
Thrust bearing
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
C1 clutch component
Bearing race
Thrust bearing
B1 brake piston
Brake piston cover
Snap ring
B1 brake band
Brake band anchor bolt
Front planetary gear component and input shaft
C3 clutch component
Oil strainer
Oil Pump component
Gasket
Gasket
Transaxle case gasket
O-ring
Breather pipe
05-1781
05-17
SERVICE_1874-1U-06B(05-17).fm
82
AUTOMATIC TRANSAXLE
18
3
ATF
R
SST
16
SST
R
17
1
10 R
R
SST
9
7
ATF
11
4
R
SEALANT
ATF
14
R 19
12
13
15 R
20
6
*1
22
21
bawuua00000416
.
1
2
3
4
5
6
7
Oil seal (manual shaft)

O-ring (transaxle case side)
Oil seal (transaxle case side)
O-ring (converter housing side) (2WD)
Oil seal (converter housing side)
Input/turbine speed sensor
Gasket
05-1782
8
9
10
11
12
13
14
O-ring
Coupler component
Coupler component lock plate
Control valve body component
Gasket
Suction cover
Lock plate
SERVICE_1874-1U-06B(05-17).fm
83
AUTOMATIC TRANSAXLE
15
16
17
18
*1
Control valve body cover

TCM
O-ring
Filler plug
19
20
21
22
Gasket
Drain plug
Torque converter
Oil pipe and O-ring
: The figure shows Mazda6 specification.
Assembly Procedure
05-17
Caution
1. Using the SST and a hammer, install a new oil
seal to the transaxle case.
Substitution SST
49 F026 102
Inner diameter: 15 18 mm {0.60 0.70 in}
surface of the transaxle case.
49 G030 797
-0.30.4 mm
{-0.01180.0157 in}
49 F026 102
bawuua00000417

Then install the seal rings in the transaxle case.
5 mm {0.197 in}
Caution
Do not expand the seal rings too much.
Note
Inspect that seal rings rotate smoothly after
installing them.
bawuua00000418
4. Install the transaxle case plate No.3.

Tightening torque
3.9 6.9 Nm {40 70 kgfcm, 26 60
inlbf}
bawuua00000419
05-1783
SERVICE_1874-1U-06B(05-17).fm
84
AUTOMATIC TRANSAXLE
5. Install the transaxle case plate No.2.
Tightening torque
3.9 6.9 Nm {40 70 kgfcm, 26 60
inlbf}
bawuua00000420
6. Apply ATF or grease to the thrust bearing and

install it to the C2 clutch component.
7. Apply ATF to the seal ring and rubbing surface of
the C2 clutch component where the bushing is fit.
Caution
Do not damage the seal ring.
bawuua00000421
8. Install the C2 clutch component to the transaxle

case.
9. Apply ATF to the driven plates, drive plates and
retaining plates.
Note
Replace with new drive plates after soaking
bawuua00000422
10. Install driven plates, drive plates and the retaining

plate in the following order to the transaxle case
Retaining Drive Driven Drive
Retaining
Caution
retaining plates, drive and driven plates.
bawuua00000423
RETAINING PLATE
DRIVE PLATE
DRIVEN PLATE
RETAINING PLATE
bawuua00000424
05-1784
SERVICE_1874-1U-06B(05-17).fm
85
AUTOMATIC TRANSAXLE
in the groove.
Caution
Align the opening of the snap ring with
the position as shown in the figure.
05-17
bawuua00000425
12. Apply ATF to the thrust bearing and the bearing

races and install them to the transaxle case.
Note
Align the spline of the C2 clutch drive plates
and B2 brake drive plates before installing
the rear planetary gear component.
bawuua00000426
13. Apply ATF to each gear and the bushing, and

then install the rear planetary gear component to
the transaxle case.
14. Apply ATF to the sliding surface of the one-way
clutch.
Note
For easy installation, while turning the rear
planetary gear component, install it.
bawuua00000427
15. Install the one-way clutch to the transaxle case.
bawuua00000428

in the groove.
Caution
the position shown in the figure.
bawuua00000429
05-1785
SERVICE_1874-1U-06B(05-17).fm
86
AUTOMATIC TRANSAXLE
17. While holding the one-way clutch component,
inspect that the planetary gear turns to right
(clockwise) but does not turn to left
(counterclockwise).
LOCK
FREE
Caution
Do not damage the VSS.
bawuua00000430
18. Install the VSS and spacer to the counter drive

gear.
Tightening torque
3.9 6.9 Nm {40 70 kgfcm, 26 60
inlbf}
SPACER
19. Apply ATF to the spline on the counter drive gear

and spline on the ring gear.
Caution
harness.
bawuua00000431
20. Install the counter drive gear to the transaxle case.

Note
Verify that the claws of the lockwashers are facing upward.
21. Install the new lockwashers and washers with
new bolts.
Tightening torque
82.7 93.6 Nm {8.5 9.5 kgfcm, 61.0
69.0 ftlbf}
Bolt length (measured from below the head)

A: 28 mm {1.102 in}
B: 35 mm {1.378 in}
A
B
B
bawuua00000432
05-1786
SERVICE_1874-1U-06B(05-17).fm
87
AUTOMATIC TRANSAXLE
22. Using a flathead screwdriver and a hammer, pry
back the crimp locking the lockwashers.
24. Install the O-rings to the oil cooler outlet tube.
05-17
bawuua00000433
25. Install the oil cooler outlet tube, pipe clamp,

transaxle case No.1 plate and the wiring harness
clip to the converter housing.
Caution
harness.
Tightening torque
7.8 11.8 Nm {82 122 kgfcm, 72 105
inlbf}
bawuua00000434
26. Connect the VSS wiring harness to the wiring

harness clip.
27. Apply ATF to the bearing and gear of the
differential component.
bawuua00000435
28. Install the differential component to the transaxle

case.
29. Apply ATF to the bearing and gear of the counter
gear component.
bawuua00000436
05-1787
SERVICE_1874-1U-06B(05-17).fm
88
AUTOMATIC TRANSAXLE
30. Install the counter gear component to the
transaxle case.
Note
If it is difficult to install the counter driven
gear, remove the differential component and
then install the counter driven gear. Install
the differential component again.
For easy installation, tilt the counter gear
slightly.
bawuua00000437
31. Install the parking pin to the transaxle case.

Caution
Verify to install the parking pin as shown
in the figure.
bawuua00000438
32. Insert the parking rod to the transaxle case.
bawuua00000439
33. Install the manual valve lever to the transaxle

case.
bawuua00000440
34. Connect the parking rod to the manual valve

lever.
bawuua00000441
05-1788
SERVICE_1874-1U-06B(05-17).fm
89
AUTOMATIC TRANSAXLE
35. Install the parking pawl, parking pawl bracket and
the parking rod to the transaxle case.
Caution
Do not apply too much force to the
torsion spring.
Tightening torque
7.8 11.8 Nm {82 122 kgfcm, 72 105
inlbf}
05-17
bawuua00000442
36. Install the spring guide sleeve and the torsion

spring.
Tightening torque
7.8 11.8 Nm {82 122 kgfcm, 72 105
inlbf}
Note
Install the torsion spring to the position of the
parking lock pawl and parking lock pawl
bracket shown in the figure together with the
spring guide sleeve and torsion spring
installed.
bawuua00000443
Caution
Do not apply too much force to the pawl return spring.
37. Install the pawl return spring to the parking pawl shaft.
38. Install the pawl return spring and the parking pawl
shaft to the transaxle case.
Caution
Do not apply too much force to the detent
spring.
Note
When installing the pawl return spring to
transaxle case, install the parking pawl side
of the spring, then install the parking pawl
shaft.
bawuua00000444
05-1789
SERVICE_1874-1U-06B(05-17).fm
90
AUTOMATIC TRANSAXLE
39. Install the detent spring cover and detent spring
to the transaxle case.
Tightening torque
7.8 11.8 Nm {82 122 kgfcm, 72 105
inlbf}
bawuua00000445
Note
When installing, ensure that the center of the
detent springs roller fits the center of the
manual valve lever.
bawuua00000446
40. Install the sun gear input drum to the transaxle

case.
41. Apply ATF to the bearing race and the thrust
bearing, and then install them to the transaxle
case.
bawuua00000447

case.
43. Apply ATF to the bearing race and the thrust
bearing, and then install them to the transaxle
case.
Caution
If the input shaft is not hold during
installation, the thrust washer might be
come off.
Note
Align the spline of the C1 clutch drive plates
bawuua00000448
before installing the input shaft and front
planetary gear.
Hold the C1 clutch component and install the front planetary gear while holding the input shaft.
05-1790
SERVICE_1874-1U-06B(05-17).fm
91
AUTOMATIC TRANSAXLE
44. Install the input shaft and the front planetary gear
to the transaxle case.
45. Apply ATF to the bushing of the C3 clutch
component.
Note
Before installing the C3 clutch component,
align the spline of the C3 clutch drive plates
and the spline of the B1 brake drive plates.
05-17
bawuua00000449

case.
bawuua00000450
Note
Install the C3 clutch component so that it
engages with the sun gear drum as shown in
the figure.
C3 CLUTCH COMPONENT
SUN GEAR
INPUT DRUM
bawuua00000451
47. Install the B1 brake band to the transaxle case.
bawuua00000452
48. Install the brake band anchor bolt to the transaxle

case.
Tightening torque
133.3 199.9 Nm {13.6 20.3 kgfm, 98.3
147.4 ftlbf}
bawuua00000453
05-1791
SERVICE_1874-1U-06B(05-17).fm
92
AUTOMATIC TRANSAXLE
49. Install the piston return spring, B1 brake piston
and the brake piston cover to the transaxle case.
bawuua00000454
50. Using the SST, press the brake piston cover into
the position where the snap ring groove is visible.
51. Apply ATF to the oil seal.
BRAKE PISTON COVER
49 T019 0A1
bawuua00000455
52. Install the oil strainer and the oil seal to the oil
pump component.
53. Apply ATF to each rubbing surface of the oil pump
component.
Caution
Do not drop the thrust washer.
bawuua00000456
54. Install the oil pump component to the transaxle

case.
Tightening torque
19.6 29.4 Nm {2.0 2.9 kgfm, 14.5
21.6 ftlbf}

A: 22 mm {0.866 in}
B: 35 mm {1.378 in}
B
A
bawuua00000457
05-1792
SERVICE_1874-1U-06B(05-17).fm
93
AUTOMATIC TRANSAXLE
55. Verify that the input shaft turns smoothly.
05-17
bawuua00000458
56. Using a dial indicator, measure the input shaft

end play.
Input shaft end play
0.349 1.081 mm {0.01374 0.04255 in}
bawuua00000459
57. Put a mark on the piston rod at the point where it

intersects with the case.
MARK
bawuua00000460
58. Measure the stroke between the transaxle case

and the mark on the piston rod when applying
compressed air into the oil hole as shown in the
figure.
Air pressure
400 kPa {4.1 kgf/cm2, 58 psi}
B1 brake piston stroke
5.50 6.00 mm {0.217 0.236 in}
appropriate piston rod.
bawuua00000461
05-1793
SERVICE_1874-1U-06B(05-17).fm
94
AUTOMATIC TRANSAXLE
Piston rod size
Identification mark
1
2
3
4
5
6
7
8
9
10
Length (mm {in})

102.80 {4.0473}
103.05 {4.0571}
103.30 {4.0669}
103.55 {4.0768}
103.80 {4.0866}
104.05 {4.0965}
104.30 {4.1063}
104.55 {4.1161}
104.80 {4.1260}
105.05 {4.1358}
105.30 {4.1457}
Caution
Do not damage the differential gear lube
apply tube.
MARK
bawuua00000462
59. Install the differential gear lube apply tube to the

converter housing.
bawuua00000463
60. Install the magnets to the oil reservoir lock plate.

Caution
Do not damage the oil reservoir lock
plate.
bawuua00000464
05-1794
SERVICE_1874-1U-06B(05-17).fm
95
AUTOMATIC TRANSAXLE
61. Install the oil reservoir lock plate and the tube
clamp to the converter housing.
Tightening torque
3.9 6.9 Nm {40 70 kgfcm, 26 60
inlbf}
62. Apply ATF to the new gaskets.
05-17
bawuua00000465
63. Install the gaskets to the transaxle case as shown

in the figure.
64. Apply ATF to the new transaxle case gaskets.
bawuua00000466
65. Install the transaxle case gaskets to the transaxle

case as shown in the figure.
Caution
Verify to install the transaxle case gasket
66. Remove any packing material and be careful not
to get oil on the contact surface of the transaxle
case and the converter housing.
67. Clean the contact surface of the transaxle case
and the converter housing and the bolt holes.
bawuua00000467
Note
Completely remove sealant and oil with white gasoline or equivalent.
68. Apply ATF to a O-ring of the oil pump.
69. Apply sealant to the converter housing as shown
in the figure.
Note
Spread sealant over the contact surface.
Do not apply sealant to the transaxle case.
Caution
Do not damage the O-ring on the oil
pump component.
Do not damage the housing oil seal.
bawuua00000468
05-1795
SERVICE_1874-1U-06B(05-17).fm
96
AUTOMATIC TRANSAXLE
70. Install the converter housing to the transaxle
case.
Note
Tap all around the contact surface with a
plastic hammer during installation.
71. Temporarily tighten the bolts by hand as shown in
the figure.
bawuua00000469
B
B
B
A
B
A
C
B
B
B
B
A
B
B
C
bawuua00000470
Bolt number
A
B
C
D
E
Bolt size
M8 1.25
M8 1.25
M8 1.25
M10 1.25
M10 1.25
Length (measured from below the head) (mm {in})

30 {1.18}
35 {1.38}
39 {1.54}
25 {0.984}
40 {1.57}
72. Tighten the bolts.

Tightening torque
A, B, C: 23.5 35.3 Nm {2.4 3.5 kgfm, 17.4 26.0 ftlbf}
D, E: 29.4 41.2 Nm {3.0 4.2 kgfm, 21.7 30.3 ftlbf}
Caution
Do not damage the input/turbine speed sensor.
05-1796
SERVICE_1874-1U-06B(05-17).fm
97
AUTOMATIC TRANSAXLE
73. Install the input/turbine speed sensor to the
transaxle case.
Tightening torque
3.9 6.9 Nm {40 70 kgfcm, 26 60
inlbf}
05-17
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74. Apply ATF to a new gasket as shown in the figure.

75. Install the gasket to the coupler component.
Caution
Do not apply ATF to the O-ring.
O-RING
76. Install a new O-ring to the coupler component.

GASKET
Caution
Do not apply too much force to the
coupler component.
Do not damage the coupler component.
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77. Install the coupler component to the transaxle

case.
Note
Install the coupler component to the transaxle case by engaging its claw.
78. Install a new coupler component lock plate.
Caution
When installing the control valve body
component, do not put the coupler
component in the open space of the
separate plate in the control valve body
component.
Do not pinch the coupler component
between the separate plate and the
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79. Connect the manual valve link and install the

SEPARATE PLATE
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05-1797
SERVICE_1874-1U-06B(05-17).fm
98
AUTOMATIC TRANSAXLE
80. Temporarily install the control valve body
component with the bolts.
A: 31 mm {1.220 in}
B: 17 mm {0.669 in}
C: 21 mm {0.827 in}
Note
Aligning the bolt holes, temporarily tighten
the bolts by hand.
B
B
B
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81. Temporarily install the suction cover and a new

gasket with the bolts.
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82. Tighten the bolts in the order shown in the figure.

Tightening torque
8 12 Nm {82 122 kgfcm, 72 105
inlbf}
5
4
1
2
7
8
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05-1798
SERVICE_1874-1U-06B(05-17).fm
99
AUTOMATIC TRANSAXLE
83. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.
05-17
INPUT/TURBINE SPEED SENSOR

CONNECTOR
VSS CONNECTOR
bawuua00000478
Caution
If the control valve body cover is installed with the wiring harnesses overlapped, the wiring
harnesses may be pinched between the cover and valve body causing the wiring harnesses to be
damaged. Therefore, verify that the wiring harnesses are not overlapped when installing the
control valve body cover.
NO GOOD
GOOD
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84. Apply ATF to a new O-ring and install it on the TFT sensor.
85. Install the TFT sensor with the lock plate and a
bolt to the control valve body component as
Tightening torque
8 12 Nm {82 122 kgfcm, 72 105
inlbf}
86. Connect the solenoid connectors, VSS connector
and the input/turbine speed sensor connector.
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05-1799
SERVICE_1874-1U-06B(05-17).fm
100
AUTOMATIC TRANSAXLE
87. Connect the coupler component to the clamps.
CLAMP
Note
Completely remove sealant and oil with
white gasoline or similar.
CLAMP
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88. Clean sealant and oil off the contact surface of

the transaxle case with the control valve body
cover and the bolt holes.
Note
Completely remove oil with white gasoline or
similar.
89. Clean oil off the contact surface of the new control
valve body cover with the transaxle case.
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90. Apply sealant to the new control valve body cover

Caution
Be careful that the coupler component
will not become caught between the
control valve body cover and transaxle
case.
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05-17100
SERVICE_1874-1U-06B(05-17).fm
101
AUTOMATIC TRANSAXLE
91. Install the new control valve body cover with new
seal bolts.
Tightening torque
9.8 15.7 Nm {100 160 kgfcm, 87
138 inlbf}
05-17
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92. Inspect the condition of connector pin of the

coupler component (foreign material, bent/broken
pins) and O-ring.
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93. Align the transaxle case and the coupler

component connector.
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94. Be sure to match the position of the TCM

marking.
Caution
Do not turn more than 60 from the
marking.
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05-17101
SERVICE_1874-1U-06B(05-17).fm
102
AUTOMATIC TRANSAXLE
95. Verify the correct positioning of the TCM and
coupler component.
96. Install the TCM to the transaxle case.
Tightening torque
19.6 29.4 Nm {2.0 2.9 kgfm, 14.5
21.6 ftlbf}
Caution
Do not repair the threads using a tap or
other tools.
Do not overtighten the stud bolts. (The
stud bolts should remain protruded from
the end of the transaxle case more than
47 mm {1.85 in}.)
If any of the stud bolts is overtightened,
the transaxle case may be damaged
(holes in the case may result).
If the transaxle case is damaged, the
transaxle must be replaced.
bawuua00000488
97. Install the double nutted stud bolts to the

transaxle case.
98. Remove the double nutted from the stud bolt.
Caution
4751 mm
{1.852.00 in}
bawuua00000489
99. Using the SST and a hammer, tap a new oil seal so that the specified oil seal position is obtained.
Transaxle Case Side
Substitution SST
49 H028 202
49 H028 202
Outer diameter: 54.5 61 mm {2.15 2.40
in}
34 mm
{0.1180.157 in}
bawuua00000490
05-17102
SERVICE_1874-1U-06B(05-17).fm
103
AUTOMATIC TRANSAXLE
Converter Housing Side
Substitution SST
49 F027 009
Outer diameter: 76.8 mm {3.02 in}
49 L033 101
in}
Length: 20 mm {0.79 in} or more
AW6A-EL
49 F027 009
2.33.3 mm
{0.0910.130 in}
05-17
AW6AX-EL
49 L033 101
7.48.4 mm
{0.2920.330 in}
bawuua00000491
100.Install a new gasket and the drain plug.

Tightening torque
23.5 54.9 Nm {2.4 5.5 kgfm, 17.4
40.4 ftlbf}
Caution
Do not drop the torque converter.
Be careful that fingers do not get caught.
bawuua00000492
101.Using a flathead screwdriver, position the drive

gear on the oil pump component in the center.
Then install the torque converter component to
the transaxle.
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05-17103
SERVICE_1874-1U-06B(05-17).fm
104
AUTOMATIC TRANSAXLE
102.To ensure that the torque converter is installed
accurately, measure distance A between the end
of the torque converter and the end of the
converter housing.
A
TORQUE CONVERTER
Distance A (between the end of the torque

converter and the end of the converter
housing)
Mazda6: 18 mm {0.709 in}
CX-7: 31.4 mm {1.24 in}
103.Install the O-rings and oil pipes. (Refer to the
Workshop Manual.)
104.Add the ATF.
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End Of Sie
AUTOMATIC TRANSAXLE INSPECTION
id051700502300
B2 Brake Inspection
1. Apply ATF to the driven plates, drive plates and retaining plates.
Note
Replace with new drive plates after soaking them at least 2 h in ATF.
2. Install driven plates, drive plates and the retaining
plate in the following order to the transaxle case
Retaining
Caution
retaining plates, drive and driven plates.
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RETAINING PLATE
DRIVE PLATE
DRIVEN PLATE
RETAINING PLATE
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into the groove.
Caution
the position shown in the figure.
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05-17104
SERVICE_1874-1U-06B(05-17).fm
105
AUTOMATIC TRANSAXLE
4. Set a dial indicator as shown in the figure.
5. While applying compressed air into the oil
passage as shown in the figure, measure the B2
brake clearance and inspect the piston moves
smoothly.
Air pressure
200 kPa {2.0 kgf/cm2, 29 psi}
B2 brake clearance
1.20 1.40 mm {0.047 0.055 in}
05-17
If not within the specification, select another

retaining plate.
bawuua00000015

Identification mark
47
48
49
50
51
52
53
Thickness (mm {in})

4.7 {0.185}
4.8 {0.189}
4.9 {0.193}
5.0 {0.197}
5.1 {0.201}
5.2 {0.205}
5.3 {0.209}

ring.
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7. Remove the retaining plates, drive and driven

plates.
Note
plates.
End Of Sie
bawuua00000012
05-17105
SERVICE_1874-1U-06B(05-50).fm
TECHNICAL DATA
05-50
TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . 05-501
End of Toc
TRANSMISSION/TRANSAXLE TECHNICAL DATA
WM: TRANSMISSION/TRANSAXLE
Item
Rear planetary gear bushing inner diameter
Rear planetary sun gear bushing inner diameter
Transaxle case bushing inner diameter
B2 brake return spring free length
Input shaft end play
B1 brake piston stroke
Distance A (between the end of the torque converter
and the end of the converter housing)
B2 brake clearance
id055000800100
Specification
0.6 0.8 mm {0.024 0.031 in}
1.2 1.4 mm {0.047 0.055 in}
Front side: 33.26 33.286 mm {1.3095 1.3104 in}
Rear side: 33.26 33.286 mm {1.3095 1.3104 in}
Front side: 24.2 24.226 mm {0.9528 0.9537 in}
Rear side: 24.2 24.226 mm {0.9528 0.9537 in}
0.45 0.65 mm {0.0178 0.0255 in}
Standard: 21.932 21.953 mm {0.86347 0.86429 in}
0.349 1.081 mm {0.01374 0.04255 in}
5.50 6.00 mm {0.217 0.236 in}
Mazda6: 18 mm {0.709 in}
CX-7: 31.4 mm {1.24 in}
1.20 1.40 mm {0.047 0.055 in}
Counter drive gear starting and rotating torque

Nm {kgfcm, inlbf}
Bearing
New
Reused
Starting torque
0.40 0.50 {4.08 5.09, 3.55 4.41}
0.20 0.25 {2.04 2.54, 1.77 2.20}
Rotating torque
0.40 0.48 {4.08 4.89, 3.55 4.24}
0.20 0.24 {2.04 2.44, 1.77 2.11}
End Of Sie
05-501
05-50
SERVICE_1874-1U-06B(05-60).fm
SERVICE TOOLS
05-60
SERVICE TOOLS
TRANSMISSION/TRANSAXLE SST. . . . 05-601
End of Toc
TRANSMISSION/TRANSAXLE SST
AT: TRANSMISSION/TRANSAXLE
id056000500100
49 0107 680A
49 L010 1A0
49 U027 003
Engine stand
Engine hanger
set
Oil seal installer
49 G025 001
49 G019 040
49 G019 026
Sensor rotor
installer
Wrench
Plate
49 B032 317
49 F027 009
49 L033 101
Bearing & oil

seal remover
Attachment for
68 & 77
Oil seal installer
49 W027 001
49 G019 0A9
49 G030 797
Body
Compressor
Handle
49 F026 102
49 T019 0A1
49 H028 202
Bearing installer
Servo piston
lifter set
Block L
05-60
End Of Sie
05-601

CX-7 Transmission Manual

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CX-7 Transmission Manual

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1874-1U-06B(INDEX).

2006 Mazda Motor Corporation

DRIVELINE/AXLE FEATURES . . . . . . . . 03-001

DRIVELINE/AXLE SPECIFICATIONS. . . 03-001

(L {US qt, Imp qt})

TRANSFER STRUCTURAL VIEW . . . . . 03-161

TRANSFER POWER FLOW . . . . . . . . . . . 03-162

TRANSFER STRUCTURAL VIEW

DRIVE PINION GEAR

DRIVE GEAR SHAFT

DRIVE GEAR CASE

DRIVE GEAR SHAFT

DRIVE PINION GEAR

AUTOMATIC TRANSAXLE . . . 05-17

ATX [AW6A-EL, AW6AX-EL]

Centrifugal hydraulic pressure cancel clutch has been adopted.

AUTOMATIC TRANSAXLE SPECIFICATIONS

Final gear ratio

Torque converter stall torque ratio

7.0 {7.4, 6.2}

The example of automatic transaxle specifications. (specifications of the CX-7)

AUTOMATIC TRANSAXLE OUTLINE . .

COUNTER DRIVE GEAR

REAR PLANETARY GEAR

FRONT PLANETARY GEAR

FRONT PLANETARY SUN GEAR

List of operating components

COUNTER DRIVE GEAR

Power transmission pathway

Input, Locked, Output

COUNTER DRIVE GEAR

[Operating components: C1 clutch, B2 brake]

COUNTER DRIVE GEAR

Power transmission pathway

Input, Locked, Output

COUNTER DRIVE GEAR

Power transmission pathway

Input, Locked, Output

COUNTER DRIVE GEAR

Power transmission pathway

Input, Locked, Output

COUNTER DRIVE GEAR

Power transmission pathway

Input, Locked, Output

COUNTER DRIVE GEAR

Input, Locked, Output

COUNTER DRIVE GEAR

Input, Locked, Output

WITHOUT CENTRIFUGAL HYDRAULIC

HOW TO USE THIS MANUAL . . . . . . . . . 00-002

Inspection During Removal,

SHOWS PROCEDURE ORDER

Fluid Pressure Inspection

LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION

SHOWS PROCEDURE ORDER

4356 {4.35.8, 3241}

SHOWS EXPENDABLE PARTS

118156 {12.016.0, 87115}

Lower Trailing Link Ball Joint, Upper Trailing Link

UPPER TRAILING LINK