Automatic Transaxle and Transfer Workshop Manual Aw6A-El Aw6Ax-El

1874-1U-06B(INDEX).
fm 1 ページ２００６年３月１３日　月曜日　午後９時３６分
Automatic CONTENTS
Transaxle and Title
Section
FEATURES SERVICE
Transfer GENERAL INFORMATION 00 00

Workshop DRIVELINE/AXLE 03 03
Manual TRANSMISSION/TRANSAXLE 05 05
AW6A–EL © 2006 Mazda Motor Corporation

AW6AX–EL PRINTED IN U.S.A., FEBRUARY 2006
Form No. 1874–1U–06B
Part No. 9999–95–0AW6–07
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
FEATURES(cover).fm 1 ページ２００６年３月１３日　月曜日　午後９時４０分
FEATURES
FEATURES_1874-1U-06B(03-00).fm 1 ページ２００６年３月１３日　月曜日　午後９時３８分
DRIVELINE/AXLE 03
SECTION
03-00
Toc of SCT . . . . . . . . . . . . . . . . . . 03-00
OUTLINE TRANSFER . . . . . . . . . . . . . . . 03-16
Toc of SCT
03-00 OUTLINE
DRIVELINE/AXLE FEATURES . . . . . . . . 03-00–1 DRIVELINE/AXLE SPECIFICATIONS. . . 03-00–1
End of Toc
DRIVELINE/AXLE FEATURES
NG: DRIVELINE/AXLE
id030000100100
Improved reliability • Separate oil pump and oil cooler have been adopted to the transfer
End Of Sie
DRIVELINE/AXLE SPECIFICATIONS
id030000100200
Item Specification
Grade API service GL-5
Type
Viscosity SAE 80W-90
Transfer oil
Oil capacity
(L {US qt, Imp qt}) 1.2 {1.3,1.1}
(approx. quantity)
End Of Sie
03-00–1
TRANSFER
03-16 TRANSFER
TRANSFER STRUCTURAL VIEW . . . . . 03-16–1 TRANSFER POWER FLOW . . . . . . . . . . . 03-16–2
TRANSFER CROSS-SECTIONAL TRANSFER OIL COOLER
VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–1 CONSTRUCTION . . . . . . . . . . . . . . . . . 03-16–2
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
03-16–1
TRANSFER
TRANSFER POWER FLOW
id031600100300
acxuun00000600
End Of Sie
TRANSFER OIL COOLER CONSTRUCTION
id031600100400
WATER IN VIEW A
WATER OUT
VIEW FROM A
acxuun00000601
End Of Sie
03-16–2
FEATURES_1874-1U-06B(05-00).fm 1 ページ２００６年３月１３日　月曜日　午後９時３９分
TRANSMISSION/TRANSAXLE 05
SECTION
Toc of SCT . . . . . . . . . . . . . . . . . . 05-00

OUTLINE AUTOMATIC TRANSAXLE . . . 05-17
05-00
Toc of SCT
05-00 OUTLINE
TRANSMISSION/TRANSAXLE AUTOMATIC TRANSAXLE
FEATURES . . . . . . . . . . . . . . . . . . . . . . 05-00–1 SPECIFICATIONS . . . . . . . . . . . . . . . . 05-00–1
End of Toc
TRANSMISSION/TRANSAXLE FEATURES
NG: TRANSMISSION/TRANSAXLE
id050000100200
ATX [AW6A-EL, AW6AX-EL]

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

id050000100300
Item Specifications
Transaxle type AW6A-EL, AW6AX-EL
1GR 4.148
2GR 2.370
3GR 1.555
Gear ratio 4GR 1.154
5GR 0.859
6GR 0.685
Reverse 3.393
Final gear ratio 3.749
Type JWS3309
ATF Capacity (approx. quantity)
7.0 {7.4, 6.2}
(L {US qt, Imp qt})
Torque converter stall torque ratio 2.15
C1 clutch 7/7
Hydraulic system C2 clutch 4/4
(Number of drive/driven plates) C3 clutch 4/4
B2 brake 7/6
Band servo Servo diameter (piston outer dia./retainer 61.3/66.0
(mm {in}) outer dia.) {2.41/2.60}
Ring gear 81
Front planetary gear
Sun gear 45
(Number of teeth)
Pinion gear 17
Ring gear 72
Middle sun gear 33
Rear planetary gear
Rear sun gear 27
(Number of teeth)
Long pinion gear 18
Short pinion gear 17
Counter drive gear (Number of teeth) 52
Driven gear 49
Counter gear (Number of teeth)
Drive gear 15
Ring gear (Number of teeth) 53
• The example of automatic transaxle specifications. (specifications of the CX-7)
End Of Sie
05-00–1
AUTOMATIC TRANSAXLE
05-17 AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE OUTLINE . . 05-17–1 3GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17–9
AUTOMATIC TRANSAXLE 4GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17–10
CROSS-SECTIONAL VIEW . . . . . . . . . 05-17–2 5GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17–11
POWERFLOW STRUCTURE . . . . . . . . . 05-17–4 6GR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17–12
Description of Components . . . . . . . . . 05-17–4 R position . . . . . . . . . . . . . . . . . . . . . . . 05-17–13
POWERFLOW OPERATION . . . . . . . . . . 05-17–5 CENTRIFUGAL HYDRAULIC PRESSURE
1GR (D range) . . . . . . . . . . . . . . . . . . . 05-17–6 CANCEL CLUTCH OUTLINE . . . . . . . . 05-17–15
1GR (M range) . . . . . . . . . . . . . . . . . . . 05-17–7 TORQUE CONVERTER OUTLINE. . . . . . 05-17–17 05-17
2GR . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17–8
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 6-
speed 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
05-17–1
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE CROSS-SECTIONAL VIEW
id051700101900
AW6A-EL
ONE-WAY
C2 CLUTCH B2 BRAKE CLUTCH C1 CLUTCH B1 BRAKE C3 CLUTCH
TORQUE
CONVERTER
COUNTER
DRIVE GEAR
COUNTER GEAR
(DRIVEN)
COUNTER GEAR
(DRIVE)
DIFFERENTIAL
acxuun00000612
05-17–2
AUTOMATIC TRANSAXLE
AW6AX-EL
ONE-WAY
C2 CLUTCH B2 BRAKE 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
05-17–3
AUTOMATIC TRANSAXLE
POWERFLOW STRUCTURE
id051700102200
Description of Components
C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH C3 CLUTCH

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 RING GEAR

: LOCK
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
05-17–4
AUTOMATIC TRANSAXLE
ONE-WAY CLUTCH B1 BRAKE

C3 CLUTCH
C1 CLUTCH
B2 BRAKE REAR PLANETARY
RING GEAR FRONT
C2 CLUTCH PLANETARY
COUNTER CARRIER
FRONT
REAR PLANETARY DRIVE GEAR PLANETARY
LONG PINION
PINION GEAR
GEAR FRONT 05-17
PLANETARY
RING GEAR
REAR REAR PLANETARY

PLANETARY MIDDLE SUN GEAR
CARRIER 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 Operation
C1 clutch • Connects front planetary carrier to rear planetary rear sun gear
C2 clutch • Connects intermediate shaft to rear planetary carrier
C3 clutch • Connects front planetary carrier to rear planetary middle sun gear
B1 brake • Locks rear planetary middle sun gear
B2 brake • Locks rear planetary carrier
One-way clutch • Locks counterclockwise rotation of rear planetary carrier
05-17–5
AUTOMATIC TRANSAXLE
1GR (D range)
C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

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 Input, Locked, Output
Input: Ring gear
Front Locked: Sun gear
Output: Carrier
Input: Rear sun gear
Rear Locked: Carrier
Output: Ring gear
1. Input shaft (rotates clockwise) [same revolutions as the torque converter’s 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 one-
way clutch.]
8. Rear planetary long pinion gear (rotates clockwise on its axis)
[the rear planetary middle sun gear rotates counterclockwise (idling)]
05-17–6
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
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.
05-17–7
AUTOMATIC TRANSAXLE
2GR

CLUTCH
B1 BRAKE C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000622

Input: Ring gear
Output: Carrier
Input: Rear Sun gear
Rear Locked: Middle Sun gear
Output: Ring gear
1. Input shaft (rotates clockwise) [same revolutions as the torque converter’s 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)
05-17–8
AUTOMATIC TRANSAXLE
Engine brake
• When the engine brake is operating, driving force is transmitted from the tires.
3GR

CLUTCH
B1 BRAKE C3 CLUTCH
05-17
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000623

[Operating components: C1 clutch, C3 clutch]
Input: Ring gear
Output: Carrier
Input: Rear Sun gear, Middle Sun gear
Rear Locked: -
Output: Ring gear
1. Input shaft (rotates clockwise) [same revolution as the torque converter’s 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]
05-17–9
AUTOMATIC TRANSAXLE
Engine brake
4GR

CLUTCH
B1 BRAKE C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000624

Input: Ring gear
Output: Carrier
Input: Rear Sun gear, Carrier
Rear Locked: -
Output: Ring gear
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]
05-17–10
AUTOMATIC TRANSAXLE
10. Rear planetary long pinion gear (rotates counterclockwise on its axis, orbits clockwise)
[because the rear planetary long pinion gear’s 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]
Engine brake 05-17

5GR

CLUTCH
B1 BRAKE C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000625

Input: Ring gear
Output: Carrier
Input: Carrier, Middle Sun gear
Rear Locked: -
Output: Ring gear
1. Input shaft (rotates clockwise) [same revolutions as torque converter’s turbine runner]
05-17–11
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]
[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 gear’s 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

CLUTCH
B1 BRAKE C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000626
05-17–12
AUTOMATIC TRANSAXLE
[Operating components: B1 brake, C2 clutch]
Front -
Input: Carrier
Rear Locked: Middle Sun gear
Output: Ring gear
2. Intermediate shaft (rotates clockwise) [same revolution as the torque converter’s turbine runner]
3. B1 brake [locks the rear planetary middle sun gear] 05-17
4. C2 clutch [connects the intermediate shaft and the rear planetary carrier]
5. Rear planetary carrier (rotates clockwise) [same revolution as the intermediate shaft]
[because the rear planetary middle sun gear is locked, it is always in a speed increasing condition]
[because the rear planetary long pinion gear’s rotation is added to the rear planetary carrier revolution, the rear
planetary ring gear revolution is faster than those of the rear planetary carrier]
Engine brake
R position

CLUTCH
B1 BRAKE C3 CLUTCH
RING GEAR
(DIFFERENTIAL)
COUNTER GEAR
acxuun00000627
05-17–13
AUTOMATIC TRANSAXLE
Input: Ring gear
Output: Carrier
Input: Middle Sun gear
Rear 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
05-17–14
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
A B
A
B
B
A : PISTON HYDRAULIC PRESSURE CHAMBER

B : CENTRIFUGAL HYDRAULIC PRESSURE CANCEL CHAMBER
acxuun00000628
05-17–15
AUTOMATIC TRANSAXLE
WITH CENTRIFUGAL HYDRAULIC WITHOUT CENTRIFUGAL HYDRAULIC

PRESSURE CANCEL CLUTCH PRESSURE CANCEL CLUTCH
PISTON HYDRAULIC PISTON HYDRAULIC

PRESSURE CHAMBER PRESSURE CHAMBER
CENTRIFUGAL HYDRAULIC
PRESSURE CANCEL CHAMBER
PISTON HYDRAULIC CENTRIFUGAL HYDRAULIC CENTRIFUGAL HYDRAULIC

PRESSURE PRESSURE PRESSURE CANCEL
acxuun00000629
End Of Sie
NG: TORQUE CONVERTER
05-17–16
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.
CONVERTER
TCC PISTON COVER
05-17
TURBINE PUMP
RUNNER IMPELLER
STATER
OIL PUMP
INPUT SHAFT
acxuun00000605
End Of Sie
05-17–17
SERVICE(cover).fm 1 ページ２００６年３月１３日　月曜日　午後９時４０分
SERVICE
SERVICE_1874-1U-06B(00-00).fm 1 ページ２００６年３月１３日　月曜日　午後９時４０分
GENERAL INFORMATION 00SECTION

00-00
Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–2 Inspection During Removal,
Range of Topics . . . . . . . . . . . . . . . . . . 00-00–2 Disassembly . . . . . . . . . . . . . . . . . . . . 00-00–6
Service Procedure . . . . . . . . . . . . . . . . 00-00–2 Arrangement of Parts . . . . . . . . . . . . . . 00-00–7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–4 Cleaning of Parts . . . . . . . . . . . . . . . . . 00-00–7
Advisory Messages. . . . . . . . . . . . . . . . 00-00–4 Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–7
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–8
Conversion to SI Units (Système Rubber Parts and Tubing . . . . . . . . . . . 00-00–8
International d'Unités) . . . . . . . . . . . . 00-00–5 Hose Clamps . . . . . . . . . . . . . . . . . . . . 00-00–8
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-00–5 Torque Formulas . . . . . . . . . . . . . . . . . 00-00–8
Upper and Lower Limits . . . . . . . . . . . . 00-00–5 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–9
FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6 ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00-00–9
Preparation of Tools and Measuring Connectors . . . . . . . . . . . . . . . . . . . . . . 00-00–9
Equipment . . . . . . . . . . . . . . . . . . . . . 00-00–6 SAE STANDARDS. . . . . . . . . . . . . . . . . . 00-00–10
Special Service Tools . . . . . . . . . . . . . . 00-00–6 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00-00–11
Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–6
End of Toc
WM: GENERAL INFORMATION
00-00–1
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 SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
49 1232 670A
49 H002 671 SHOWS TIGHTENING

TORQUE
49 H032 322 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.
00-00–2
GENERAL INFORMATION
SHOWS SERVICE
Procedure ITEM (S)
INDICATES RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES THAT NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal) 00-00
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
GREASE
FOR SERVICE 12 SST R
INSTALL THE PARTS BY SHOWS APPLICATION

PERFORMING STEPS 8 43—56 {4.3—5.8, 32—41}
POINTS OF GREASE, ETC.
10
1— 3 IN REVERSE ORDER 44—60 {4.4—6.2, 32—44} 7 R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS EXPENDABLE PARTS
SST
3
5
6 SHOWS DETAILS
SST
GREASE
4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115}
SHOWS TIGHTENING
1 R TORQUE UNITS
SHOWS REFERRAL
NOTES FOR SERVICE N·m {kgf·m, ft·lbf}
1 Split pin 7 Split pin

2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
acxuuw00000435
00-00–3
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
New appropriate
OIL Apply oil engine oil or gear
oil
New appropriate
BRAKE Apply brake fluid
FLUID brake fluid
New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid
Appropriate
Apply grease
GREASE
grease
Appropriate
SEALANT Apply sealant
sealant
Apply petroleum Appropriate

P jelly petroleum jelly
O-ring, gasket,
R Replace part
etc.
Use SST or
SST equivalent
Appropriate tools
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
00-00–4
GENERAL INFORMATION
UNITS
id000000100400
Electrical current A (ampere)

Electric power W (watt)
Electric resistance ohm 00-00
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm2 (kilogram force per square

centimeter)
psi (pounds per square inch)
Number of
rpm (revolutions per minute)
revolutions
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)
Conversion to SI Units (Système International d'Unités)

• 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
00-00–5
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
00-00–6
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
00-00–7
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 SST
recalculated due to the extra length that the SST
3
or equivalent adds to the torque wrench.

2
1
Recalculate the torque by using the following

0
formulas. Choose the formula that applies to you.

1
2
3
Torque Unit Formula

N·m N·m × [L/(L+A)]
kgf·m kgf·m × [L/(L+A)]
kgf·cm kgf·cm × [L/(L+A)] A L
ft·lbf ft·lbf × [L/(L+A)]
acxuuw00000019
in·lbf in·lbf × [L/(L+A)]
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
00-00–8
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
id000000800400
Connectors
Disconnecting connectors
• When disconnecting a connector, grasp the
connectors, not the wires. 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
00-00–9
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 GOOD NO GOOD
the wiring harness side.
acxuuw00000457
• Inspect the terminals of waterproof connectors

from the connector side since they cannot be GOOD NO GOOD
accessed from the wiring harness side.
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 SAE Standard
Remark Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MAP Manifold Absolute Pressure
APP Accelerator Pedal Position MAF sensor Mass Air Flow Sensor
ACL Air Cleaner MFL Multiport Fuel Injection
A/C Air Conditioning OBD On-board Diagnostic System
BARO Barometric Pressure OL Open Loop
B+ Battery Positive Voltage OC Oxidation Catalytic Converter
CMP sensor Camshaft Position Sensor O2S Oxygen sensor
CAC Charge Air Cooler PNP Park/Neutral Position
CLS Closed Loop System PSP Power Steering Pressure
CTP Closed Throttle Position PCM Powertrain Control Module #3
CPP Clutch Pedal Position Pulsed
PAIR Pulsed Secondary Air Injection
CIS Continuous Fuel Injection System injection
CKP sensor Crankshaft Position Sensor Injection
DLC Data Link Connector AIR Secondary Air Injection with air
DTM Diagnostic Test Mode #1 pump
DTC Diagnostic Test Code(s) SAPV Secondary Air Pulse Valve
DI Distributor Ignition Sequential Multiport Fuel
SFI
DLI Distributorless Ignition Injection
EI Electronic Ignition #2 3GR Third Gear
ECT Engine Coolant Temperature TWC Three Way Catalytic Converter
EM Engine Modification TB Throttle Body
EVAP Evaporative Emission TP sensor Throttle Position Sensor
00-00–10
GENERAL INFORMATION
SAE Standard SAE Standard
Remark Remark
Abbreviation Name Abbreviation Name
EGR Exhaust Gas Recirculation TCC Torque Converter Clutch
FC Fan Control Transmission (Transaxle) Control
TCM
FF Flexible Fuel Module 00-00
4GR Fourth Gear TR Transmission (Transaxle) Range
GEN Generator TC Turbocharger
GND Ground VSS Vehicle Speed Sensor
With VR Voltage Regulator
HO2S Heated Oxygen Sensor
heater VAF sensor Volume Air Flow Sensor
IAC Idle Air Control Warm Up Three Way Catalytic
WU-TWC #4
IAT Intake Air Temperature Converter
KS Knock Sensor WOP Wide Open Throttle
MIL Malfunction Indicator Lamp
#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
id000000801000
ATF Automatic Transaxle Fluid

LH Left Hand
RH Right Hand
SST Special Service Tool
TFT Transaxle Fluid Temperature
2WD 2 Wheel Drive
End Of Sie
00-00–11
SERVICE_1874-1U-06B(03-16).fm 1 ページ２００６年３月１３日　月曜日　午後９時４１分
DRIVELINE/AXLE 03
SECTION
03-16
Toc of SCT
TRANSFER . . . . . . . . . . . . . . . . 03-16 SERVICE TOOLS . . . . . . . . . . . 03-60
TECHNICAL DATA . . . . . . . . . . 03-50
Toc of SCT
03-16 TRANSFER
TRANSFER CLEANING. . . . . . . . . . . . . . 03-16–1 TRANSFER ASSEMBLY . . . . . . . . . . . . . 03-16–13
Cleaning Precautions . . . . . . . . . . . . . . 03-16–1 Before Service Precautions . . . . . . . . . 03-16–13
TRANSFER DISASSEMBLY . . . . . . . . . . 03-16–1 Drive Gear Case Component
Before Service Precautions. . . . . . . . . . 03-16–1 Assembly. . . . . . . . . . . . . . . . . . . . . . 03-16–14
Transfer Component Disassembly . . . . 03-16–2 Drive Gear Case Component Assembly
Transfer Component Disassembling Procedure . . . . . . . . . . . . . . . . . . . . . 03-16–15
Procedure . . . . . . . . . . . . . . . . . . . . . . 03-16–3 Front Carrier Component Assembly . . . 03-16–21
Drive Gear Case Component Front Carrier Component Assembly
Disassembly . . . . . . . . . . . . . . . . . . . . 03-16–4 Procedure . . . . . . . . . . . . . . . . . . . . . 03-16–22
Drive Gear Case Component Transfer Component Assembly . . . . . . 03-16–28
Disassembly Procedure . . . . . . . . . . . 03-16–5 Transfer Component Assembly
Front Carrier Component Procedure . . . . . . . . . . . . . . . . . . . . . 03-16–29
Disassembly . . . . . . . . . . . . . . . . . . . . 03-16–9
Front Carrier Component Disassembling
Procedure . . . . . . . . . . . . . . . . . . . . . 03-16–10
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.
03-16–1
TRANSFER
Transfer Component Disassembly
R 5
1
bawuua00000167
.
1 Drain plug 4 Drive gear case component

2 Oil level plug 5 Front carrier component
3 Oil cooler
03-16–2
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. 49 M005 561
4. Remove the drive gear case component.
49 0107 680A
bawuua00000169
03-16–3
TRANSFER
Drive Gear Case Component Disassembly
RH
5
3 4
8
9 SST
7 SST
11 SST
1 R
R 12 R
10 SST
15
SST
R 14
SST
R 13
LH R 16
bawuua00000170
.
1 Oil seal (RH outer) 9 Bearing (RH)

2 Drive gear shaft 10 Bearing (LH)
3 Bearing cap 11 Drive gear
4 Adjustment shim 12 Oil seal (RH inner)
5 Spacer 13 Oil seal (LH outer)
6 Drive gear component 14 Oil seal (LH inner)
7 Bearing outer race (LH) 15 Baffle plate
8 Bearing outer race (RH) 16 Drive gear case
03-16–4
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
03-16–5
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
03-16–6
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
03-16–7
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
03-16–8
TRANSFER
Front Carrier Component Disassembly
R
15 SST
16
R 17 SST
5
6 03-16
20
25
R 24
SST 21 1 18 R
22
23
SST R
19 4 LEFT—HAND SCREW
R
3
2
10
9 11
SST 12
SST 14
A 13
SST
12
7 SST 11
8
SST 9
bawuua00000189
.
1 Oil pipe 14 Ring gear shaft

2 Oil strainer 15 Locknut
3 Side cover 16 Washer
4 Ring gear lockbolt 17 Companion flange
5 Oil pump 18 Oil seal
6 Oil pump shaft 19 Drive pinion gear
7 Bearing cap 20 Bearing (rear)
8 Ring gear component 21 Distance piece
9 Adjustment shim 22 Bearing (front)
10 Spacer 23 Spacer
11 Bearing outer race (side) 24 Bearing outer race (front)
12 Bearing (side) 25 Bearing outer race (rear)
13 Ring gear
03-16–9
TRANSFER
Front Carrier Component Disassembling Procedure
1. Install the front carrier component to the SST.
2. Remove the oil strainer. 49 M005 561
3. Remove the oil pipe.
4. Remove the side cover.
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. MARK
7. Remove the bearing caps.
bawuua00000192
8. Using a suitable wrench, secure the ring gear

shaft, and remove the ring gear lockbolt.
bawuua00000193
03-16–10
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
03-16–11
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
03-16–12
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} 49 T032 302
Plate thickness: 1 mm {0.04 in} or more
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.
03-16–13
TRANSFER
Drive Gear Case Component Assembly
RH
37—51 N·m
{3.8—5.2 kgf·m, 27.3—37.6 ft·lbf}
8
10 9
4
3 SST
5
6.9—9.8 N·m
{70—99 kgf·cm, 61—86 in·lbf}
11 R
1 6 R SST
SST
2 SST
15
SST R 12
SST R 13
LH R 16
14
bawuua00000204
.
1 Drive gear 9 Adjustment shim

2 Bearing (LH) 10 Bearing cap
3 Bearing (RH) 11 Oil seal (RH outer)
4 Bearing outer race (RH) 12 Oil seal (LH inner)
5 Bearing outer race (LH) 13 Oil seal (LH outer)
6 Oil seal (RH inner) 14 Drive gear shaft
7 Drive gear component 15 Baffle plate
8 Spacer 16 Drive gear case
03-16–14
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 N·m {70— 99 kgf·cm, 61— 86 in·lbf}
bawuua00000206
3. Using a press, assemble the bearing (RH).

Substitution SST
• 49 H028 202
Outer diameter: 58— 61 mm {2.29— 2.40 in}
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
Inner diameter: 56 mm {2.20 in} or more 49 H028 202
5. Temporarily assemble the bearing outer race
(RH) and spacer to the drive gear.
bawuua00000208
03-16–15
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. 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 Thickness (mm {in}) Identification mark Thickness (mm {in})
350 3.50 {0.1378} 420 4.20 {0.1654}
355 3.55 {0.1398} 425 4.25 {0.1673}
360 3.60 {0.1417} 430 4.30 {0.1693}
365 3.65 {0.1437} 435 4.35 {0.1713}
370 3.70 {0.1457} 440 4.40 {0.1732}
375 3.75 {0.1476} 445 4.45 {0. 1752}
380 3.80 {0.1496} 450 4.50 {0.1772}
385 3.85 {0.1516} 455 4.55 {0.1791}
390 3.90 {0.1535} 460 4.60 {0. 1811}
395 3.95 {0.1555} - -
400 4.00 {0.1575} - -
405 4.05 {0.1594} - -
410 4.10 {0.1614} - -
415 4.15 {0.1634} - -
11. Using the plastic hammer, install the bearing

outer race (LH).
bawuua00000211
03-16–16
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 N·m {3.8— 5.2 kgf·m, 27.3— 37.6 ALIGNMENT MARK
ft·lbf}
bawuua00000215
16. Assemble the SST to the drive gear shaft, and

hand-tighten the nut.
SST tightening torque

2.1 N·m {21 kgf·cm, 19 in·lbf}
49 L011 201
bawuua00000216
03-16–17
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 N·m {6.2— 21.4 kgf·cm, 5.4— 18.5
in·lbf}
• If the drive gear rotational torque is not within

the specification, adjust it by selecting the
proper spacer.
bawuua00000217
18. Remove the drive gear shaft.
19. Using a SSTs, install the oil seals.
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
Plate thickness: 2 mm {0.08 in} or more 49 S019 006
15.7—17.3
{0.62—0.68}
mm {in}
bawuua00000218
03-16–18
TRANSFER
LH outer
49 G030 797
49 L019 301
03-16
OIL SEAL
5.0—6.0
{0.20—0.23}
mm {in}
bawuua00000219
RH inner
Substitution SST
• 49 B025 001 49 G030 797
Plate thickness: 2 mm {0.08 in} or more 49 B025 001
18.7—20.3
{0.74—0.79}
mm {in}
bawuua00000220
03-16–19
TRANSFER
RH outer
Substitution SST
• 49 T034 201A 49 T034 201A
Inner diameter: 55 mm {2.17 in} or more
Length: 5 mm {0.20 in} or more
-0.8—0.8
{-0.03—0.03}
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 C-
ring.
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
03-16–20
TRANSFER
Front Carrier Component Assembly
127—284
{13.0—28.9, 93.7—209.4}
11 SST OIL
R
10
GREASE
R 9 03-16
21
20
6
SST 1
R 2 SST
SST
SST 5 25
8 R
4
3
SST R
LEFT—HAND SCREW
SST 7 22 150—200 {15.3—20.3, 110.7—147.4}
A
R
23 6.9—9.8 N·m
{70—100 kgf·cm, 61—86 in·lbf}
24
17
16 15
14 R
SST
12
A
SST 13
R 14
SST
19 15
18
63—93 {6.5—9.4, 46.4—68.5} 16
N·m {kgf·m, ft·lbf}
bawuua00000224
.
1 Bearing outer race (rear) 14 Bearing (side)

2 Bearing outer race (front) 15 Bearing outer race (side)
3 Spacer 16 Adjustment shim
4 Bearing (front) 17 Spacer
5 Distance piece 18 Ring gear component
6 Bearing (rear) 19 Bearing cap
7 Drive pinion gear 20 Oil pump shaft
8 Oil seal 21 Oil pump
9 Companion flange 22 Ring gear lockbolt
10 Washer 23 Side cover
11 Locknut 24 Oil strainer
12 Ring gear shaft 25 Oil pipe
13 Ring gear
03-16–21
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 (A)
• 49 G033 105 (A)
Outer diameter: 25 mm {0.99 in} or more
• 49 G033 105 (B) 49 G033 105
Plate thickness: 1 mm {0.04 in} or more (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 (A)
49 G033 105
• 49 G033 105 (A)
• 49 G033 105 (B)
4. Temporarily assemble the bearing outer races
(B)
(side).
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
03-16–22
TRANSFER
6. Measure the width of the front carrier ring gear
installation area with the spacer installed. This is B
dimension B.
7. The maximum and minimum total thickness C of SPACER
the adjustment shims on both sides can be
expressed by the following formula:
C = B - A - (0.01— 0.03 mm {0.00039— 0.00118 03-16

in})
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
350 3.50 {0.1378} 410 4.10 {0.1614}
355 3.55 {0.1398} 415 4.15 {0.1634}
360 3.60 {0.1417} 420 4.20 {0.1654}
365 3.65 {0.1437} 425 4.25 {0.1673}
370 3.70 {0.1457} 430 4.30 {0.1693}
375 3.75 {0.1476} 435 4.35 {0.1713}
380 3.80 {0.1496} 440 4.40 {0.1732}
385 3.85 {0.1516} 445 4.45 {0.1752}
390 3.90 {0.1535} 450 4.50 {0.1772}
395 3.95 {0.1555} 455 4.55 {0.1791}
400 4.00 {0.1574} 460 4.60 {0.1811}
405 4.05 {0.1594} - -
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 49 M005 561
carrier ring gear side and spacer on opposite
side.
12. Assemble the ring gear component to the front
carrier.
bawuua00000230
13. Using the plastic hammer, assemble the selected

adjustment shim in between the spacer and
bearing race as shown in the figure.
bawuua00000231
03-16–23
TRANSFER
14. Align the alignment marks of the bearing caps,
assemble the bearing caps, and tighten the bolts MARK
temporarily.
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 N·m {6.2— 21.4 kgf·cm, 5.4— 18.5 in·lbf}
• 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 003
• 49 F027 005 49 F027 003
Outer diameter: 61— 61.8 mm {2.41— 2.43
in}
• 49 F027 007
in}
Plate thickness: 1 mm {0.04 in} or more 49 F027 005
49 F027 007
bawuua00000233
18. Using the SSTs, adjust the drive pinion height as

49 8531 565
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 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
03-16–24
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. 03-16
(8) Measure the average value between the 49 0727 570
values of both sides measured in Step 7. This
value is the spacer thickness which
determines the pinion height.
bawuua00000236
Pinion height error factor within allowance

limit
± 0.032 mm {± 0.00126 in}
Spacer
08 3.08 {0.1213} 29 3.29 {0.1295}
09 3.095 {0.1219} 30 3.305 {0.1301}
11 3.11 {0.1224} 32 3.32 {0.1307}
12 3.125 {0.1230} 33 3.335 {0.1313}
14 3.14 {0.1236} 35 3.35 {0.1319}
15 3.155 {0.1242} 36 3.365 {0.1325}
17 3.17 {0.1248} 38 3.38 {0.1331}
18 3.185 {0.1254} 39 3.395 {0.1335}
20 3.20 {0.1260} 41 3.41 {0.1343}
21 3.215 {0.1266} 42 3.425 {0.1348}
23 3.23 {0.1272} 44 3.44 {0.1354}
24 3.245 {0.1278} 45 3.455 {0.1360}
26 3.26 {0.1283} 47 3.47 {0.1366}
27 3.275 {0.1289} - -
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.
Substitution SST 49 F401 331 SPACER
• 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.
03-16–25
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 49 S120 710
when the specified preload value is obtained.
Tightening torque
127— 284 N·m {13.0— 28.9 kgf·m, 93.7—
209.4 ft·lbf}
Drive pinion preload value

0.88— 1.37 N·m {9.0— 14.0 kgf·cm, 7.9— 12.1
in·lbf}
bawuua00000546
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
• 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.
bawuua00000538
31. Using the SST, tighten the new locknut to the

tightening torque noted when the preload was
adjusted. 49 S120 710
32. Reverify the preload.
Drive pinion preload value

0.88— 1.37 N·m {9.0— 14.0 kgf·cm, 7.9— 12.1
in·lbf}
33. Assemble the ring gear component following the

procedure in Step 11 to 14.
34. Set the dial gauge with the measuring probe
bawuua00000546
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.
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

bawuua00000539
above, adjust it by sliding the ring gear in the shaft
direction.
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.
03-16–26
TRANSFER
37. Tighten the bearing cap bolts.
Tightening torque
63— 93 N·m {6.5— 9.4 kgf·m, 46.4— 68.5 ft·lbf}
38. Perform the drive pinion and ring gear tooth

contact inspection.
(1) Apply tooth marking compound evenly to both 03-16
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,
bawuua00000540
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
TOE CONTACT FLANK CONTACT
in the figure, replace the drive pinion spacer
with a thinner one to maintain the drive pinion
further away.
bawuua00000242
(5) If heal and face contact is indicated as shown

TOE CONTACT FLANK CONTACT
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
bawuua00000243
ring gear shaft.
Tightening torque
150— 200 N·m {15.3— 20.3 kgf·m, 110.7—
147.4 ft·lbf}
40. Align the cast hexagon of the oil pump shaft and
assemble the oil pump and oil pump shaft.
bawuua00000244
03-16–27
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 N·m {70— 100 kgf·cm, 61— 86 OIL HOLE
in·lbf}
bawuua00000245
46. Remove the front carrier component from the
SST.
Transfer Component Assembly
23.5—29.4
{2.4—2.9, 17.4—21.6}
GREASE
3
GREASE
R 1
SEALANT
2
39.2—58.8
{4.0—5.9, 29.0—43.3}
5 R
19—27
{2.0—2.7, 14.1—19.9}
19—27
{2.0—2.7, 14.1—19.9}
R
39.2—58.8
4 {4.0—5.9, 29.0—43.3}
N·m {kgf·m, ft·lbf}

bawuua00000246
.
1 Front carrier component 4 Drain plug

2 Drive gear case component 5 Oil level plug
3 Oil cooler
03-16–28
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.
03-16
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 N·m {2.0— 2.7 kgf·m, 14.1— 19.9 ft·lbf}
3. Install the oil cooler.

4. Tighten the oil cooler installation bolt with a O-ring.
Tightening torque
23.5— 29.4 N·m {2.4— 2.9 kgf·m, 17.4— 21.6 ft·lbf}
5. Tighten the drain plug with a new washer.
Tightening torque
39.2— 58.8 N·m {4.0— 5.9 kgf·m, 29.0— 43.3 ft·lbf}
End Of Sie
03-16–29
SERVICE_1874-1U-06B(03-50).fm 1 ページ２００６年３月１３日　月曜日　午後９時４３分
TECHNICAL DATA
03-50 TECHNICAL DATA
DRIVELINE/AXLE TECHNICAL DATA . . 03-50–1
End of Toc
DRIVELINE/AXLE TECHNICAL DATA
WM: DRIVELINE/AXLE
id035000800100
03-50
Item Specification
Standard drive gear bearing preload 0.6—2.1 N·m {6.2—21.4 kgf·cm, 5.4—18.5 in·lbf}
Standard ring gear bearing preload 0.6—2.1 N·m {6.2—21.4 kgf·cm, 5.4—18.5 in·lbf}
Pinion height error factor within allowance limit ± 0.032 mm {± 0.00126 in}
Drive pinion preload value 0.88—1.37 N·m {9.0—14.0 kgf·cm, 7.9—12.1 in·lbf}
Standard drive pinion backlash 0.09—0.11 mm {0.0035—0.0043 in}
End Of Sie
03-50–1
SERVICE TOOLS
03-60 SERVICE TOOLS
SERVICE TOOLS . . . . . . . . . . . . . . . . . . 03-60–1
End of Toc
SERVICE TOOLS
AT: DRIVELINE/AXLE
id036000500100
03-60
49 0107 680A 49 M005 561 49 W032 201
Engine stand Differential Body

carrier hanger
49 B025 001 49 T032 316 49 T032 317
(Dust Seal Shaft Weight

Installer) Body
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 Coupling flange Gear case

pulley boss holder remover
puller
49 H027 002 49 T034 201A 49 T032 302
Bearing Dust boot Bearing installer

remover 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 Drive pinion Installer

72 model
03-60–1
SERVICE TOOLS
49 H025 003A 49 0727 570 49 0305 555
Bearing installer Pinion height Block Gauge

gauge body (20mm)
49 8531 555 49 F401 331 49 F401 337A
Block Gauge Body Attachment C

(11mm)
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 Oil seal installer

bearing puller
End Of Sie
03-60–2
SERVICE_1874-1U-06B(05-17).fm 1 ページ２００６年３月１３日　月曜日　午後９時４４分
TRANSMISSION/TRANSAXLE 05SECTION
Toc of SCT
AUTOMATIC TRANSAXLE . . . . 05-17 SERVICE TOOLS . . . . . . . . . . . 05-60 05-17
TECHNICAL DATA . . . . . . . . . . 05-50
Toc of SCT
05-17 AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE REAR PLANETARY GEAR COMPONENT
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-17–2 AND ONE-WAY CLUTCH COMPONENT
Precaution . . . . . . . . . . . . . . . . . . . . . . . 05-17–2 DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05-17–56
Disassembly . . . . . . . . . . . . . . . . . . . . . 05-17–3 Components . . . . . . . . . . . . . . . . . . . . . 05-17–56
Disassembly procedure. . . . . . . . . . . . . 05-17–9 Disassembly Procedure . . . . . . . . . . . . 05-17–56
OIL PUMP REAR PLANETARY GEAR
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–26 INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–57
Components . . . . . . . . . . . . . . . . . . . . . 05-17–26 REAR PLANETARY GEAR COMPONENT
Disassembly Procedure . . . . . . . . . . . . 05-17–27 AND ONE-WAY CLUTCH COMPONENT
Assembly Procedure . . . . . . . . . . . . . . . 05-17–28 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-17–58
B1 BRAKE PISTON Components . . . . . . . . . . . . . . . . . . . . . 05-17–58
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–29 Assembly Procedure . . . . . . . . . . . . . . 05-17–59
Components . . . . . . . . . . . . . . . . . . . . . 05-17–29 C2 CLUTCH COMPONENT
Disassembly Procedure . . . . . . . . . . . . 05-17–30 DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05-17–60
Assembly Procedure . . . . . . . . . . . . . . . 05-17–30 Components . . . . . . . . . . . . . . . . . . . . . 05-17–60
C3 CLUTCH COMPONENT Disassembly Procedure . . . . . . . . . . . . 05-17–61
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-17–31 C2 CLUTCH INSPECTION . . . . . . . . . . . 05-17–63
Components . . . . . . . . . . . . . . . . . . . . . 05-17–31 C2 CLUTCH COMPONENT
Disassembly Procedure . . . . . . . . . . . . 05-17–32 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-17–64
C3 CLUTCH INSPECTION. . . . . . . . . . . . 05-17–33 Components . . . . . . . . . . . . . . . . . . . . . 05-17–64
C3 CLUTCH COMPONENT Assembly Procedure . . . . . . . . . . . . . . 05-17–65
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 05-17–34 TRANSAXLE CASE AND B2 BRAKE
Components . . . . . . . . . . . . . . . . . . . . . 05-17–34 DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–68
Assembly Procedure . . . . . . . . . . . . . . . 05-17–35 Low and Reverse Brake Piston
FRONT PLANETARY GEAR Disassembly Note . . . . . . . . . . . . . . . 05-17–69
COMPONENT INPUT SHAFT Low and Reverse Brake Piston
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–37 Assembly Note . . . . . . . . . . . . . . . . . . 05-17–70
Components . . . . . . . . . . . . . . . . . . . . . 05-17–37 Low and Reverse Brake Return Spring
Disassembly Procedure . . . . . . . . . . . . 05-17–38 Assembly Note . . . . . . . . . . . . . . . . . . 05-17–70
Assembly Procedure . . . . . . . . . . . . . . . 05-17–39 TRANSAXLE CASE AND B2 BRAKE
C1 CLUTCH COMPONENT INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–71
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-17–42 CONTROL VALVE BODY
Components . . . . . . . . . . . . . . . . . . . . . 05-17–42 DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–72
Disassembly Procedure . . . . . . . . . . . . 05-17–43 Components . . . . . . . . . . . . . . . . . . . . . 05-17–72
C1 CLUTCH INSPECTION. . . . . . . . . . . . 05-17–44 Disassembly Procedure . . . . . . . . . . . . 05-17–73
C1 CLUTCH COMPONENT Assembly Procedure . . . . . . . . . . . . . . 05-17–74
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 05-17–45 AUTOMATIC TRANSAXLE
Components . . . . . . . . . . . . . . . . . . . . . 05-17–45 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-17–75
Assembly Procedure . . . . . . . . . . . . . . . 05-17–46 Assembly . . . . . . . . . . . . . . . . . . . . . . . 05-17–75
COUNTER DRIVE GEAR Components . . . . . . . . . . . . . . . . . . . . . 05-17–77
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–49 Assembly Procedure . . . . . . . . . . . . . . 05-17–83
Components . . . . . . . . . . . . . . . . . . . . . 05-17–49 AUTOMATIC TRANSAXLE
Disassembly Procedure . . . . . . . . . . . . 05-17–50 INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–104
Assembly Procedure . . . . . . . . . . . . . . . 05-17–52 B2 Brake Inspection . . . . . . . . . . . . . . . 05-17–104
ONE-WAY CLUTCH COMPONENT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–55
End of Toc
05-17–1
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.
05-17–2
AUTOMATIC TRANSAXLE
Disassembly
Components
5
15 R
7
20 R
05-17
R 21 R 6 R 22
13 R
18 R 14
16 R
12
19 R
R 4 R 11
10
8 R
3
17
*1
2
bawuua00000279
.
1 Oil pipe and O-ring 7 TCM

2 Torque converter 8 Control valve body cover
3 Drain plug 9 Lock plate
4 Gasket 10 Suction cover
5 Filler plug 11 Gasket
6 O-ring 12 Control valve body component
05-17–3
AUTOMATIC TRANSAXLE
13 Coupler component lock plate 18 Oil seal (converter housing side)
14 Coupler component 19 O-ring (converter housing side) (2WD)
15 O-ring 20 Oil seal (transaxle case side)
16 Gasket 21 O-ring (transaxle case side)
17 Input/turbine speed sensor 22 Oil seal (manual shaft)
*1
: The figure shows Mazda6 specification.
05-17–4
AUTOMATIC TRANSAXLE
1 3
22
R 2
10
5
23
05-17
15
6
14
4 13
12
37
35
38
29
7 36
34
24 R
33
R 39
32
31
30 21
20
28 19
27 25 17
16
26
11
18
9
8
bawuua00000280
1 Breather pipe 4 Gasket

2 O-ring 5 Gasket
3 Transaxle case gasket 6 Oil Pump component
05-17–5
AUTOMATIC TRANSAXLE
7 Oil strainer 24 Lock washer
8 C3 clutch component 25 Counter drive gear
9 Front planetary gear component and input shaft 26 Vehicle speed sensor (VSS)
10 Brake band anchor bolt 27 Spacer
11 B1 brake band 28 Snap Ring
12 Snap ring 29 Rear planetary gear component and one-way clutch
13 Brake piston cover component
14 B1 brake piston 30 Bearing race
15 Piston return spring 31 Thrust bearing
16 Thrust bearing 32 Bearing race
17 Bearing race 33 Snap ring
18 C1 clutch component 34 Retaining plate
19 Thrust bearing 35 Drive plate
20 Bearing race 36 Driven plate
21 Sun gear input drum 37 Retaining plate
22 Counter gear component 38 C2 clutch component
23 Differential component 39 Thrust bearing
05-17–6
AUTOMATIC TRANSAXLE
1
2
05-17
bawuua00000281
1 Tube clamp 3 Magnet

2 Oil reservoir lock plate 4 Oil pipe
05-17–7
AUTOMATIC TRANSAXLE
4
1 R
5
12 10
8
7
6
20
11
2
19
3
R 17
18
14
17 R
13
15
16
bawuua00000282
05-17–8
AUTOMATIC TRANSAXLE
1 Stud bolt 11 Parking rod
2 Detent spring cover 12 Parking pin
3 Detent spring 13 Pipe clamp
4 Parking pawl shaft 14 Transaxle case No.1 plate
5 Pawl return spring 15 Wiring harness clip
6 Spring guide sleeve 16 Oil cooler outlet tube
7 Torsion spring 17 O-ring
8 Parking pawl bracket 18 Seal ring
9 Parking pawl 19 Transaxle case plate No.2 05-17
10 Manual valve lever 20 Transaxle case plate No.3
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
05-17–9
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.

49 L010 1A0
Caution
• When installing the SST to the transaxle,
use bolts (M12×1.25) with a thread length
of 90 mm {3.54 in}.
49 0107 680A
bawuua00000288
05-17–10
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
05-17–11
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 CLAMP
connector.
12. Disconnect the coupler component from the 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
05-17–12
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
05-17–13
AUTOMATIC TRANSAXLE
19. Remove the control valve body installation bolts.
Caution
2
• Do not drop the control valve body
component.
3
6
5
4 1
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 O-RING
sensor.
GASKET
bawuua00000303
05-17–14
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
05-17–15
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
05-17–16
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
05-17–17
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. PRINT
Note
• Before replacing with a new B1 brake band,
soak it at least 2 h in ATF.
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
05-17–18
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
05-17–19
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
05-17–20
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
05-17–21
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
05-17–22
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
bawuua00000340
transaxle case side when removing the rear
planetary gear component.
63. Remove the thrust bearing and the bearing races.
bawuua00000341

ring.
bawuua00000342
05-17–23
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.

PRINT
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.
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
05-17–24
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
05-17–25
AUTOMATIC TRANSAXLE
OIL PUMP DISASSEMBLY/ASSEMBLY
id051700500100
Components
GREASE
4 R
SST
1 R ATF
3 ATF
GREASE
:NON SUPPLY PART

bawuua00000001
.
1 O-ring 3 Seal ring

2 Thrust washer 4 Oil seal
05-17–26
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
05-17–27
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
Outer diameter: 67 mm {2.64 in} or more 49 U027 003
Inner diameter: 54— 61 mm {2.13— 2.40 in}
2. Apply grease to the oil seal lip.
-0.2—0.2 mm
3. Apply ATF to the new seal rings and sliding {-0.00788—0.00788 in}
surface of the oil pump component.
Caution
• Do not expand the seal rings too much.
bawuua00000006
• 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.

5 mm {0.197 in}
Then install the seal rings to the oil pump
component.
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
bawuua00000007
the thrust washer so that it does not drop
when installed.
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
05-17–28
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 R ATF
ATF R 2
bawuua00000351
.
1 O-ring 2 O-ring
05-17–29
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
05-17–30
AUTOMATIC TRANSAXLE
C3 CLUTCH COMPONENT DISASSEMBLY
id051700500300
Components
5 SST
6
8 7
05-17
12
R 11 R 10
2 SELECTIVE
3
bawuua00000354
.
1 Snap ring 7 Piston return spring

2 Retaining plate 8 Spring retainer
3 Drive plate 9 C3 clutch piston
4 Driven plate 10 O-ring
5 Snap ring 11 O-ring
6 C3 clutch balancer 12 C3 clutch drum
05-17–31
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
05-17–32
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 05-17
in the figure. bawuua00000359
7. Remove the O-rings from the C3 clutch drum.

End Of Sie
bawuua00000360
C3 CLUTCH INSPECTION
id051700500400
• If the lining is flaking or has changed color, or PRINT
Note
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
05-17–33
AUTOMATIC TRANSAXLE
C3 CLUTCH COMPONENT ASSEMBLY
id051700500500
Components
8 SST
7 ATF
5 6
4 ATF
ATF ATF
1
R 2 R 3
12
11 SELECTIVE
10
bawuua00000361
.
1 C3 clutch drum 7 C3 clutch balancer

2 O-ring 8 Snap ring
3 O-ring 9 Driven plate
4 C3 clutch piston 10 Drive plate
5 Spring retainer 11 Retaining plate
6 Piston return spring 12 Snap ring
05-17–34
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
05-17–35
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
retaining plate, drive and driven plates.
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 bawuua00000369

appropriate retaining plate.
05-17–36
AUTOMATIC TRANSAXLE
Retaining plate size
Identification mark Thickness (mm {in})
1 2.8 {0.110}
A 2.85 {0.112}
2 2.9 {0.114}
B 2.95 {0.116}
3 3.0 {0.118}
C 3.05 {0.120}
4 3.1 {0.122}
05-17
5 3.2 {0.126}
6 3.3 {0.130}
7 3.4 {0.134}
8 3.5 {0.138}
End Of Sie
FRONT PLANETARY GEAR COMPONENT INPUT SHAFT DISASSEMBLY/ASSEMBLY

id051700500600
Components
3
2
8 R ATF
ATF
9
7 R
6 ATF
5 ATF
4
bawuua00000497
.
1 Thrust washer 6 Bearing race

2 Front planetary gear component 7 Seal ring
3 Thrust washer 8 Seal ring
4 Front planetary sun gear 9 Input shaft
5 Thrust bearing
05-17–37
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
05-17–38
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
05-17–39
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.
11. Apply ATF to the new seal rings and sliding
surface of the input shaft.
Caution
• Do not expand the oil seal rings too
much.
bawuua00000508
05-17–40
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 05-17
is installed.
• Do not coat grease to the oil holes of the
bawuua00000509
thrust washer.

14. Install the thrust washer to the front planetary
gear component.
End Of Sie
bawuua00000510
05-17–41
AUTOMATIC TRANSAXLE
id051700500700
Components
SELECTIVE 2
11
10 R
9
8
7
6
5 SST
bawuua00000370
.
1 Snap ring 7 Piston return spring

2 Retaining plate 8 Spring retainer
3 Drive plate 9 C1 clutch piston
4 Driven plate 10 O-ring
5 Snap ring 11 C1 clutch drum
6 C1 clutch balancer
05-17–42
AUTOMATIC TRANSAXLE
ring from the C1 clutch drum.
05-17
bawuua00000371

plates from the C1 clutch drum.
Note
plates.
bawuua00000372

49 G025 001
Caution
Caution
balancer.
bawuua00000373

retainer from the C1 clutch drum.
bawuua00000374
05-17–43
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
shown in the figure. bawuua00000375
7. Remove the O-rings from the C1 clutch drum.

End Of Sie
bawuua00000376
id051700500800
Note
bawuua00000511



End Of Sie
bawuua00000512
05-17–44
AUTOMATIC TRANSAXLE
id051700500900
Components
SELECTIVE 10 05-17
11
1
2 R
ATF
3 ATF
5
6 ATF
7 SST
bawuua00000377
.
1 C1 clutch drum 7 Snap ring

2 O-ring 8 Driven plate
3 C1 clutch piston 9 Drive plate
4 Spring retainer 10 Retaining plate
5 Piston return spring 11 Snap ring
6 C1 clutch balancer
05-17–45
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.
bawuua00000381
05-17–46
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
• Inspect the number and order of the RETAINING PLATE
retaining plate, drive and driven plates.
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}

05-17–47
AUTOMATIC TRANSAXLE
1 2.8 {0.110}
2 2.9 {0.114}
3 3.0 {0.118}
4 3.1 {0.122}
A 3.15 {0.124}
5 3.2 {0.126}
B 3.25 {0.128}
6 3.3 {0.130}
C 3.35 {0.132}
7 3.4 {0.134}
8 3.5 {0.138}
End Of Sie
05-17–48
AUTOMATIC TRANSAXLE
COUNTER DRIVE GEAR DISASSEMBLY/ASSEMBLY
id051700501000
Components
9 R
SST
11
8 SST
10 R 05-17
13 SST
12
4 SST
5
SST
7 R
bawuua00000386
.
1 Rear planetary ring gear 8 Counter drive gear

2 Snap ring 9 Bearing race
3 Rear planetary ring gear flange 10 Bearing race
4 Nut 11 Snap ring
5 Washer 12 Center support
6 Snap ring 13 Tapered roller bearing
7 Tapered roller bearing
05-17–49
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
05-17–50
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
05-17–51
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 STEEL PLATE
• 49 L033 101
49 L033 101
bawuua00000397
2. Using a flathead screwdriver, install the hole snap

ring to the counter drive gear.
bawuua00000395
05-17–52
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
bawuua00000400
direction.
6. Install the washer and nut.

7. Using the SST, tighten the nut.
NUT
WASHER
bawuua00000401
05-17–53
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

N·m {kgf·cm, in·lbf}
Bearing Starting torque Rotating torque
New 0.40 — 0.50 {4.08 — 5.09, 3.55 — 4.41} 0.40 — 0.48 {4.08 — 4.89, 3.55 — 4.24}
Reused 0.20 — 0.25 {2.04 — 2.54, 1.77 — 2.20} 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
05-17–54
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

id051700501100
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.
LOCK FREE
End Of Sie
bawuua00000513
05-17–55
AUTOMATIC TRANSAXLE
REAR PLANETARY GEAR COMPONENT AND ONE-WAY CLUTCH COMPONENT DISASSEMBLY
id051700501200
Components
3
9
2
4
5
6
7
8
bawuua00000514
.
1 One-way clutch component 6 Bearing race

2 Thrust washer 7 Planetary sun gear
4 Bearing race 9 Rear planetary gear component
5 Thrust bearing
1. Remove the one-way clutch component from the
rear planetary gear component.
bawuua00000515
05-17–56
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.
05-17–57
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
1
GREASE
7 ATF
6 ATF
5 ATF
4 ATF
bawuua00000521
.
1 Rear planetary gear component 5 Bearing race

2 Thrust washer 6 Thrust bearing
4 Bearing race 8 Planetary sun gear
05-17–58
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

bawuua00000523
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.
End Of Sie
bawuua00000524
05-17–59
AUTOMATIC TRANSAXLE
id051700501500
Components
3 SELECTIVE
7
6 SST
12 R
11 R 13
10
bawuua00000045
.
1 Thrust bearing 4 Drive plate

2 Snap ring 5 Driven plate
3 Retaining plate 6 Snap ring
05-17–60
AUTOMATIC TRANSAXLE
7 C2 clutch balancer 11 O-ring
8 Piston return spring 12 O-ring
9 Spring retainer 13 Intermediate shaft
10 C2 clutch piston
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

49 G025 001
Caution
• Do not contract the return spring too
much.
Caution
bawuua00000049
balancer.
05-17–61
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
as shown in the figure. bawuua00000051
8. Remove the O-rings from the intermediate shaft.

End Of Sie
bawuua00000052
05-17–62
AUTOMATIC TRANSAXLE
id051700501600
05-17
Note
bawuua00000525



End Of Sie
bawuua00000526
05-17–63
AUTOMATIC TRANSAXLE
id051700501700
Components
10
12
11 SELECTIVE
7 ATF
8 SST
13
2 R
3 R 1
ATF
ATF
4 ATF
bawuua00000086
.
1 Intermediate shaft 4 C2 clutch piston

2 O-ring 5 Spring retainer
3 O-ring 6 Piston return spring
05-17–64
AUTOMATIC TRANSAXLE
7 C2 clutch balancer 11 Retaining plate
8 Snap ring 12 Snap ring
9 Driven plate 13 Thrust bearing
10 Drive plate
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}
Inner diameter Thickness
Upper 51.90 {2.043} 1.60 {0.0630}
Lower 50.40 {1.984} 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
05-17–65
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
RETAINING PLATE
Caution
• Inspect the number and order of the
DRIVE PLATE
retaining plate, drive and driven plates. 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
05-17–66
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
• If not within the specification, select an

bawuua00000095

1 2.5 {0.0984}
2 2.6 {0.102}
3 2.7 {0.106}
4 2.8 {0.110}
A 2.85 {0.112}
5 2.9 {0.114}
B 2.95 {0.116}
6 3.0 {0.118}
C 3.05 {0.120}
7 3.1 {0.122}
8 3.2 {0.126}
End Of Sie
05-17–67
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
2
1 SST
5 R
4 R
ATF
ATF
bawuua00000404
1 Snap ring 3 Low and reverse brake piston

2 Low and reverse brake return spring (See 05-17-69 Low and Reverse Brake Piston
(See 05-17-70 Low and Reverse Brake Return Disassembly Note.)
Spring Assembly Note.) (See 05-17-70 Low and Reverse Brake Piston
Assembly Note.)
4 O-ring
5 O-ring
05-17–68
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
05-17–69
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

49 G019 0A9
position where the snap ring groove is visible.
bawuua00000410
05-17–70
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
bawuua00000527
color, replace the intermediate shaft with a

new one.
PRINT
Note
bawuua00000528

B2 brake return spring free length


End Of Sie
AT: CONTROL VALVE BODY
bawuua00000529
05-17–71
AUTOMATIC TRANSAXLE
CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY
id051700502000
Components
1 ATF
3
bawuua00000530
.
1 Manual valve 4 Shift solenoid A

2 E-ring 5 Shift solenoid B
3 Manual valve connecting rod
05-17–72
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
05-17–73
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 N·m {81.6 — 122.3 kgf·cm, 70.9
— 106.1 in·lbf}
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
05-17–74
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE ASSEMBLY
id051700502200
Assembly
Bearing and race locations
C2 CLUTCH COMPONENT
PLANETARY SUN GEAR
REAR PLANETARY
GEAR COMPONENT 05-17
6
ONE-WAY CLUTCH
COMPONENT 11
10
9
8
7
SUN GEAR INPUT DRUM
4 C1 CLUTCH COMPONENT
3
INPUT SHAFT
FRONT PLANETARY SUN GEAR
FRONT PLANETARY GEAR COMPONENT
C3 CLUTCH COMPONENT
OIL PUMP COMPONENT

bawuua00000412
05-17–75
AUTOMATIC TRANSAXLE
1 2 3 4 5 6 7 8 9 10 11
64.0 101.0 85.0 79.8 104.2
Outer — — — — — —
{2.52} {3.98} {3.35} {3.14} {4.10}
Thrust washer (mm {in})
51.0 75.3 72.7 68.3 69.0
Inner — — — — — —
{2.01} {2.96} {2.86} {2.69} {2.72}
43.7
Outer — — — — — — — — — —
{1.72}
Bearing race (front) (mm {in})
25.6
Inner — — — — — — — — — —
{1.01}
61.3 52.6 45.6 48.7 43.8 75.0
Outer — — — — —
{2.41} {2.07} {1.80} {1.92} {1.72} {2.95}
Bearing (mm {in})
43.7 39.2 33.2 35.0 24.25 50.5
Inner — — — — —
{1.72} {1.54} {1.31} {1.38} {0.9547} {1.99}
68.8 48.5 47.0 45.6 41.7
Outer — — — — — —
{2.71} {1.91} {1.85} {1.80} {1.64}
Bearing race (rear) (mm {in})
46.9 38.1 35.2 33.2 24.2
Inner — — — — — —
{1.85} {1.50} {1.39} {1.31} {0.953}
05-17–76
AUTOMATIC TRANSAXLE
Components
05-17
17
20 R
16
12
9 11
13
14
15
1
10
19
2
18
R 4
3 ATF
4 R
6
5
bawuua00000413
.
05-17–77
AUTOMATIC TRANSAXLE
1 Transaxle case plate No.3 11 Manual valve lever
2 Transaxle case plate No.2 12 Parking pawl
3 Seal ring 13 Parking pawl bracket
4 O-ring 14 Torsion spring
5 Oil cooler outlet tube 15 Spring guide sleeve
6 Wiring harness clip 16 Pawl return spring
7 Transaxle case No.1 plate 17 Parking pawl shaft
8 Pipe clamp 18 Detent spring
9 Parking pin 19 Detent spring cover
10 Parking rod 20 Stud bolt
05-17–78
AUTOMATIC TRANSAXLE
4
3
05-17
bawuua00000414
1 Oil pipe 3 Oil reservoir lock plate

2 Magnet 4 Tube clamp
05-17–79
AUTOMATIC TRANSAXLE
ATF
39 37
18 ATF
R 38
30
35 ATF
17 ATF
25
34
26
36 ATF 27
SST
28
ATF
3
ATF 5
2 ATF
11
33 ATF
4 ATF
6
16 R ATF
7
R 1
8 ATF
9 ATF
10 ATF
19
ATF
ATF
ATF 20
ATF
12 21
ATF
13 15 ATF 23
24
14
29
22
31
32 ATF
bawuua00000415
1 Thrust bearing 3 Retaining plate

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

2 O-ring (transaxle case side) 9 Coupler component
3 Oil seal (transaxle case side) 10 Coupler component lock plate
4 O-ring (converter housing side) (2WD) 11 Control valve body component
5 Oil seal (converter housing side) 12 Gasket
6 Input/turbine speed sensor 13 Suction cover
7 Gasket 14 Lock plate
05-17–82
AUTOMATIC TRANSAXLE
15 Control valve body cover 19 Gasket
16 TCM 20 Drain plug
17 O-ring 21 Torque converter
18 Filler plug 22 Oil pipe and O-ring
*1
: 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 G030 797
• 49 F026 102
Outer diameter: 27 mm {1.07 in} or more -0.3—0.4 mm
Inner diameter: 15— 18 mm {0.60— 0.70 in} {-0.0118—0.0157 in}
2. Apply ATF to the new seal rings and sliding
surface of the transaxle case. 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 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}
bawuua00000419
05-17–83
AUTOMATIC TRANSAXLE
5. Install the transaxle case plate No.2.
Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}
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—
Driven— Drive— Driven— Drive— Driven—
Retaining
bawuua00000423
RETAINING PLATE
Caution
retaining plates, drive and driven plates. DRIVE PLATE DRIVEN PLATE
RETAINING PLATE
bawuua00000424
05-17–84
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
05-17–85
AUTOMATIC TRANSAXLE
17. While holding the one-way clutch component,
inspect that the planetary gear turns to right LOCK FREE
(clockwise) but does not turn to left
(counterclockwise).
Caution
• Do not damage the VSS.
bawuua00000430
18. Install the VSS and spacer to the counter drive

gear.
Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}
SPACER
19. Apply ATF to the spline on the counter drive gear

and spline on the ring gear.
Caution
bawuua00000431
harness.
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 B B
82.7 — 93.6 N·m {8.5 — 9.5 kgf·cm, 61.0 —
69.0 ft·lbf}
Bolt length (measured from below the head)

A: 28 mm {1.102 in}
B: 35 mm {1.378 in}
A
B
B B
bawuua00000432
05-17–86
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 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
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
05-17–87
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
05-17–88
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 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
05-17
bawuua00000442
36. Install the spring guide sleeve and the torsion

spring.
Tightening torque
7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
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
bawuua00000443
installed.
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
05-17–89
AUTOMATIC TRANSAXLE
39. Install the detent spring cover and detent spring
to the transaxle case.
Tightening torque
7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
bawuua00000445
Note
• When installing, ensure that the center of the
detent spring’s 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.
05-17–90
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 C3 CLUTCH COMPONENT
engages with the sun gear drum as shown in
the figure.
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 N·m {13.6 — 20.3 kgf·m, 98.3
— 147.4 ft·lbf}
bawuua00000453
05-17–91
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. B
A
A
Tightening torque
19.6 — 29.4 N·m {2.0 — 2.9 kgf·m, 14.5 —
21.6 ft·lbf}
A
Bolt length (measured from below the head)
A: 22 mm {0.866 in} B A
B: 35 mm {1.378 in} A
bawuua00000457
05-17–92
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 MARK
intersects with the case.
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.
05-17–93
AUTOMATIC TRANSAXLE
Piston rod size
Identification mark Length (mm {in})
— 102.80 {4.0473}
1 103.05 {4.0571}
2 103.30 {4.0669}
3 103.55 {4.0768}
4 103.80 {4.0866}
5 104.05 {4.0965}
6 104.30 {4.1063}
7 104.55 {4.1161}
8 104.80 {4.1260}
9 105.05 {4.1358}
10 105.30 {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
05-17–94
AUTOMATIC TRANSAXLE
61. Install the oil reservoir lock plate and the tube
clamp to the converter housing.
Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}
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
05-17–95
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
D
E
A
B
B
B B
A
B C A
B C
B
B
B A
B A
B B
bawuua00000470
Bolt number Bolt size Length (measured from below the head) (mm {in})
A M8 × 1.25 30 {1.18}
B M8 × 1.25 35 {1.38}
C M8 × 1.25 39 {1.54}
D M10 × 1.25 25 {0.984}
E M10 × 1.25 40 {1.57}
72. Tighten the bolts.
Tightening torque
A, B, C: 23.5 — 35.3 N·m {2.4 — 3.5 kgf·m, 17.4 — 26.0 ft·lbf}
D, E: 29.4 — 41.2 N·m {3.0 — 4.2 kgf·m, 21.7 — 30.3 ft·lbf}
Caution
• Do not damage the input/turbine speed sensor.
05-17–96
AUTOMATIC TRANSAXLE
73. Install the input/turbine speed sensor to the
transaxle case.
Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}
05-17
bawuua00000471
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.
bawuua00000472
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
bawuua00000473
79. Connect the manual valve link and install the

SEPARATE PLATE
bawuua00000474
05-17–97
AUTOMATIC TRANSAXLE
80. Temporarily install the control valve body
component with the bolts.
Bolt length (measured from below the head) A

A: 31 mm {1.220 in}
B: 17 mm {0.669 in}
C: 21 mm {0.827 in} B
B
B
Note
• Aligning the bolt holes, temporarily tighten
the bolts by hand. C C
bawuua00000475
81. Temporarily install the suction cover and a new

gasket with the bolts.
bawuua00000476
82. Tighten the bolts in the order shown in the figure.
Tightening torque
5
8 — 12 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
4
1
2
3 6
7
8
bawuua00000477
05-17–98
AUTOMATIC TRANSAXLE
83. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.
05-17
VSS CONNECTOR INPUT/TURBINE SPEED SENSOR

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
bawuua00000479
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 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
86. Connect the solenoid connectors, VSS connector

and the input/turbine speed sensor connector.
bawuua00000480
05-17–99
AUTOMATIC TRANSAXLE
87. Connect the coupler component to the clamps.
CLAMP
Note
• Completely remove sealant and oil with CLAMP
white gasoline or similar.
bawuua00000481
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.
bawuua00000482
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.
bawuua00000483
05-17–100
AUTOMATIC TRANSAXLE
91. Install the new control valve body cover with new
seal bolts.
Tightening torque
9.8 — 15.7 N·m {100 — 160 kgf·cm, 87 —
138 in·lbf}
05-17
bawuua00000484
92. Inspect the condition of connector pin of the

coupler component (foreign material, bent/broken
pins) and O-ring.
bawuua00000485
93. Align the transaxle case and the coupler

component connector.
bawuua00000486
94. Be sure to match the position of the TCM

marking.
Caution
• Do not turn more than 60° from the
marking.
bawuua00000487
05-17–101
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 N·m {2.0 — 2.9 kgf·m, 14.5 —
21.6 ft·lbf}
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
47—51 mm
{1.85—2.00 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
Outer diameter: 54.5— 61 mm {2.15— 2.40 49 H028 202
in} 3—4 mm
Inner diameter: 52 mm {2.05 in} or more {0.118—0.157 in}
bawuua00000490
05-17–102
AUTOMATIC TRANSAXLE
Converter Housing Side
Substitution SST AW6A-EL
• 49 F027 009
Outer diameter: 76.8 mm {3.02 in}
49 F027 009
• 49 L033 101
Outer diameter: 73— 76.3 mm {2.88— 3.00 2.3—3.3 mm
{0.091—0.130 in}
in}
Inner diameter: 69 mm {2.72 in} or more
Length: 20 mm {0.79 in} or more
Plate thickness: 2 mm {0.08 in} or more 05-17
AW6AX-EL
49 L033 101
7.4—8.4 mm
{0.292—0.330 in}
bawuua00000491
100.Install a new gasket and the drain plug.
Tightening torque
23.5 — 54.9 N·m {2.4 — 5.5 kgf·m, 17.4 —
40.4 ft·lbf}
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.
bawuua00000493
05-17–103
AUTOMATIC TRANSAXLE
102.To ensure that the torque converter is installed
A
accurately, measure distance A between the end
TORQUE CONVERTER
of the torque converter and the end of the
converter housing.
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

bawuua00000494
Workshop Manual.)
104.Add the ATF.
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
bawuua00000012
RETAINING PLATE
Caution
retaining plates, drive and driven plates. DRIVE PLATE DRIVEN PLATE
RETAINING PLATE
bawuua00000013

into the groove.
Caution
the position shown in the figure.
bawuua00000014
05-17–104
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

47 4.7 {0.185}
48 4.8 {0.189}
49 4.9 {0.193}
50 5.0 {0.197}
51 5.1 {0.201}
52 5.2 {0.205}
53 5.3 {0.209}

ring.
bawuua00000014
7. Remove the retaining plates, drive and driven

plates.
Note
plates.
End Of Sie
bawuua00000012
05-17–105
SERVICE_1874-1U-06B(05-50).fm 1 ページ２００６年３月１３日　月曜日　午後９時５３分
TECHNICAL DATA
05-50 TECHNICAL DATA
TRANSMISSION/TRANSAXLE
TECHNICAL DATA . . . . . . . . . . . . . . . . 05-50–1
End of Toc
TRANSMISSION/TRANSAXLE TECHNICAL DATA
WM: TRANSMISSION/TRANSAXLE
id055000800100
Item Specification
C3 clutch return spring free length Standard: 12.91 mm {0.5083 in} 05-50
C3 clutch piston stroke 0.6 — 0.8 mm {0.024 — 0.031 in}
C1 clutch return spring free length Standard: 17.01 mm {0.6697 in}
Front side: 33.26 — 33.286 mm {1.3095 — 1.3104 in}
Rear planetary gear bushing inner diameter
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 planetary sun gear bushing inner diameter
Rear side: 24.2 — 24.226 mm {0.9528 — 0.9537 in}
C2 clutch return spring free length Standard: 14.02 mm {0.5520 in}
Transaxle case bushing inner diameter Standard: 21.932 — 21.953 mm {0.86347 — 0.86429 in}
B2 brake return spring free length Standard: 19.01 mm {0.7485 in}
Input shaft end play 0.349 — 1.081 mm {0.01374 — 0.04255 in}
B1 brake piston stroke 5.50 — 6.00 mm {0.217 — 0.236 in}
Distance A (between the end of the torque converter Mazda6: 18 mm {0.709 in}
and the end of the converter housing) CX-7: 31.4 mm {1.24 in}
B2 brake clearance 1.20 — 1.40 mm {0.047 — 0.055 in}
Counter drive gear starting and rotating torque

N·m {kgf·cm, in·lbf}
Bearing Starting torque Rotating torque
New 0.40 — 0.50 {4.08 — 5.09, 3.55 — 4.41} 0.40 — 0.48 {4.08 — 4.89, 3.55 — 4.24}
Reused 0.20 — 0.25 {2.04 — 2.54, 1.77 — 2.20} 0.20 — 0.24 {2.04 — 2.44, 1.77 — 2.11}
End Of Sie
05-50–1
SERVICE_1874-1U-06B(05-60).fm 1 ページ２００６年３月１３日　月曜日　午後９時５３分
SERVICE TOOLS
05-60 SERVICE TOOLS
TRANSMISSION/TRANSAXLE SST. . . . 05-60–1
End of Toc
TRANSMISSION/TRANSAXLE SST
AT: TRANSMISSION/TRANSAXLE
id056000500100
49 0107 680A 49 L010 1A0 49 U027 003
Engine stand Engine hanger Oil seal installer 05-60

set
49 G025 001 49 G019 040 49 G019 026
Sensor rotor Wrench Plate

installer
49 B032 317 49 F027 009 49 L033 101
Bearing & oil Attachment for Oil seal installer

seal remover 68 & 77
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 Block L

lifter set
End Of Sie
05-60–1

Automatic Transaxle and Transfer Workshop Manual Aw6A-El Aw6Ax-El

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1874-1U-06B(INDEX).

Transfer GENERAL INFORMATION 00 00

AW6A–EL © 2006 Mazda Motor Corporation

This manual explains the service points for

Mazda Motor Corporation

DRIVE PINION GEAR

OIL PUMP DRIVE GEAR SHAFT

DRIVE GEAR CASE

DRIVE GEAR SHAFT

OIL LEVEL PLUG

DRIVE PINION GEAR

Toc of SCT . . . . . . . . . . . . . . . . . . 05-00

ATX [AW6A-EL, AW6AX-EL]

AUTOMATIC TRANSAXLE SPECIFICATIONS

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH C3 CLUTCH

REAR PLANETARY GEAR FRONT PLANETARY GEAR

RING GEAR RING GEAR

ONE-WAY CLUTCH B1 BRAKE

REAR REAR PLANETARY

REAR PLANETARY REAR SUN GEAR FRONT PLANETARY SUN GEAR

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

Power transmission pathway

[Operating components: C1 clutch, One-way clutch]

[Operating components: C1 clutch, B2 brake]

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

Power transmission pathway

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

Power transmission pathway

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

Power transmission pathway

Engine brake 05-17

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

Power transmission pathway

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

C2 CLUTCH B2 BRAKE ONE-WAY COUNTER DRIVE GEAR C1 CLUTCH

C2 CLUTCH C1 CLUTCH C3 CLUTCH

A : PISTON HYDRAULIC PRESSURE CHAMBER

WITH CENTRIFUGAL HYDRAULIC WITHOUT CENTRIFUGAL HYDRAULIC

PISTON HYDRAULIC PISTON HYDRAULIC

PISTON HYDRAULIC CENTRIFUGAL HYDRAULIC CENTRIFUGAL HYDRAULIC

GENERAL INFORMATION 00SECTION

Toc of SCT INFORMATION . . . . 00-00

49 H002 671 SHOWS TIGHTENING

INSTALL THE PARTS BY SHOWS APPLICATION

1 Split pin 7 Split pin

Apply petroleum Appropriate

Upper and lower limits

Electrical current A (ampere)

Positive pressure kgf/cm2 (kilogram force per square

Conversion to SI Units (Système International d'Unités)

Upper and Lower Limits

210— 260 kPa {2.1— 2.7 kgf/cm2, 30— 38 psi}

Special Service Tools

Inspection During Removal, Disassembly

Rubber Parts and Tubing

or equivalent adds to the torque wrench.

Recalculate the torque by using the following

formulas. Choose the formula that applies to you.

Torque Unit Formula