Mazda CX-5 Service & Repair Manual: Automatic Transaxle Removal/Installation [Fw6 Ax EL]

CAUTION:

• Performing the following procedures without first removing the front ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, disconnect the front ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

• Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

Removal

1. Disconnect the negative battery cable..

2. Remove the air cleaner and air hose as a single unit..

3. Remove the battery tray and PCM component..

4. Disconnect the wiring harness clip from the transaxle.

5. Remove the splash shield..

6. Disconnect the control valve body connector.

CAUTION:

• Make sure that your hand does not touch the terminal as the connector terminal could be damaged.

• Water or foreign objects entering the connector can cause a poor connection or corrosion. Be sure not to drop water or foreign objects on the connector when disconnecting it.

7. Remove the bracket from the transaxle.

8. Disconnect the ground cable.

9. Disconnect the selector cable from the transaxle.

10. Remove the selector cable bracket.

11. Remove the joint cover..

12. Disconnect the intermediate shaft from the steering gear and linkage..

13. Remove the front tires..

14. Remove the front under cover No.2..

15. Remove the front under cover No.1..

16. Drain the ATF..

17. Disconnect the oil cooler from the transaxle with the hose connected. (Except Automatic Transaxle Replacement).

18. Disconnect the water hose from the oil cooler. (Automatic Transaxle Replacement).

19. Remove the starter..

20. Remove the blind cover.

21. Hold the crankshaft pulley to prevent drive plate from rotating.

22. Remove the torque converter nuts from the starter installation hole.

23. Disconnect the front ABS wheel-speed sensors from the steering knuckles..

24. Disconnect the clips securing the brake hose from the front shock absorbers..

25. Disconnect the tie-rod end ball joints from the steering knuckles..

26. Disconnect the front lower arms from the steering knuckles..

27. Disconnect the front stabilizer control links from the front stabilizer..

28. Disconnect the front drive shaft (LH) from the transaxle..

29. Remove the front drive shaft (RH) from the transfer..

30. Remove the propeller shaft..

31. Remove the bracket plate..

32. Remove the front crossmember component and No.1 engine mount rubber as a single unit..

33. Remove the exhaust manifold (WU-TWC)..

34. Remove the transfer..

35. Remove the bracket.

36. Remove the No.1 engine mounting bracket.

37. Install the SST

using the following procedures.

CAUTION:

• Refer to the SST instruction manual for the basic handing procedure.

a. Install one front foot No.2 to each of the left and right front shafts of the SST

.

b. Remove the windshield wiper arm and blade..

c. Remove the cowl grille..

d. Remove the cowl panel..

e. Protect the positions shown in the area using tape.

f. To enable to install the SST

, disconnect the clip shown in the figure and set the wiring harness aside.

g. Install the SST

using part number 99794 1025

or an M10—1.25

, length

25 mm {0.98 in}

bolt as shown in the figure.

Tightening torque

• 38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

Engine rear side

Tightening torque

• 38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

h. As shown in the figure, set the rear shafts of the SST

to the left and right shock absorber nuts

i. As shown in the figure, set the front shafts of the SST

to the left and right bolts.

j. When assembling the SST

(49 L017 5A0), disconnect the fuel hose from the clip shown in the figure to prevent interference between the fuel hose and SST

.

k. Install the SST (49 L017 5A0)

to the SST (49 C017 5A0)

as shown in the figure.

l. Install the SST

(49 L017 5A0) to the SST

(49 UN30 3050) with the hook of the SST

(49 L017 5A0) facing outward.

m. Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST

.

n. Apply tension to the chain to secure the engine.

38. Remove in the order shown in the figure.

WARNING:

• Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.

CAUTION:

• To prevent the torque converter and transaxle from separating, remove the transaxle without tilting it toward the torque converter.

1	Transaxle mounting bolts (upper side)
2	No.4 engine mount bracket (See No.4 engine mount bracket removal note.)
3	Transaxle mounting bolts (lower side) (See No.4 engine mount bracket removal note.)
4	Transaxle (See No.4 engine mount bracket removal note.) (See Transaxle mounting bolt removal note.)

No.4 engine mount bracket removal note

CAUTION:

• A slot has been adopted for the No.4 engine mount bracket installation hole. If the No.4 engine mount bracket is deviated from the original position when installing the No.4 engine mount, engine noise or vibration could increase. When removing the No.4 engine mount, place alignment marks on the No.4 engine mount bracket so that they can be assembled to the same positions as before removal.

1. Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal.

NOTE:

• Paint so that the outline of the nut is framed on the bracket side.

2. Remove the No.4 engine mount bracket.

Transaxle mounting bolt removal note

WARNING:

• Remove the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1. Adjust the SST

and lean the engine toward the transaxle.

2. Support the transaxle on a jack.

3. Remove the transaxle mounting bolts (lower side).

4. Remove the transaxle.

Installation

CAUTION:

• Verify that the torque converter stud bolts are inserted into the drive plate bolt holes, and install the transaxle installation bolts. Otherwise, the drive plate could be damaged.

1. Verify that the torque converter stud bolts are inserted into the drive plate bolt holes from the starter installation hole.

2. Install the transaxle mounting bolts.

Tightening torque

• 38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}

3. Tighten the stud bolts for the transaxle.

Tightening torque

• 15—25 N·m {1.6—2.5 kgf·m, 12—18 ft·lbf}

4. Install the No.4 engine mount bracket to No.4 engine mount rubber, and temporarily tighten the installation bolt.

5. Pull up the transaxle using the SSTs

, pass the transaxle stud bolts through the No.4 engine mount bracket, and temporarily tighten the No.4 engine mount installation nuts.

6. Install the No.1 engine mounting bracket.

Tightening torque

• 131—153 N·m {14—15 kgf·m, 97—112 ft·lbf}

7. Install the bracket.

Tightening torque

• 38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

8. Install the transfer..

9. Install the exhaust manifold (WU-TWC)..

10. Install the front crossmember component and No.1 engine mount rubber as a single unit..

11. Temporarily install the No.1 engine mount rubber and bracket plate.

12. Align the alignment marks on the No.4 engine mount bracket and nuts, and temporarily tighten the nuts shown in the figure.

13. Tighten the No.4 engine mount bracket installation nuts and bolt in the order shown in the figure.

No.	Tightening torque
1, 2, 3	92—116 N·m {9.4—11 kgf·m, 69—85 ft·lbf}
4	81—99 N·m {8.3—10 kgf·m, 60—73 ft·lbf}

14. Install the propeller shaft..

15. Remove the SST (49 C017 5A0)

.

16. Tighten the No.1 engine mount rubber and bracket plate installation bolts.

No.	Tightening torque
1	140—163 N·m {15—16 kgf·m, 104—120 ft·lbf}
2	55—69 N·m {5.7—7.0 kgf·m, 41—50 ft·lbf}
3	130—164 N·m {14—16 kgf·m, 96—120 ft·lbf}

17. Fix the crankshaft pulley to lock the torque converter against rotation.

CAUTION:

• After temporarily tightening the torque converter installation nut uniformly, tighten it to the specified torque.

18. Tighten the torque converter installation nut.

Tightening torque

• 41—54 N·m {4.2—5.5 kgf·m, 31—39 ft·lbf}

19. Install the blind cover.

20. Install the starter..

21. Install the front drive shaft (RH) to the transfer..

22. Install the front drive shaft (LH) to the transaxle..

23. Install the front stabilizer control links to the front stabilizer..

24. Install the front lower arms to the steering knuckles..

25. Install the tie-rod end ball joints to the steering knuckles..

26. Install the clips securing the brake hose to the front shock absorbers..

27. Install the front ABS wheel-speed sensors to the steering knuckles..

28. Connect the water hose to the oil cooler. (Automatic Transaxle Replacement).

29. Install the oil cooler to the transaxle with the hose connected. (Except Automatic Transaxle Replacement).

30. Install the

front under cover No.1..

31. Install the

front under cover No.2..

32. Install the front tires..

33. Install the intermediate shaft to the steering gear and linkage..

34. Install the joint cover..

35. Install the selector cable bracket.

36. Connect the selector cable to the transaxle.

37. Install the ground cable.

38. Install the bracket to the transaxle.

39. Connect the control valve body connector.

CAUTION:

• Make sure that your hand does not touch the terminal as the connector terminal could be damaged.

• Verify that there is no fluid or foreign matter adhering to the connector before connecting the connector.

• Insert the connector straight as the connector terminal could be damaged.

• Rotate the connector lever until a click is heard.

40. Install the

splash shield..

41. Connect the wiring harness to the transaxle.

42. Install the battery tray and PCM component..

43. Install the air cleaner and air hose as a single unit..

44. Connect the negative battery cable..

45. Add the ATF..

46. Perform the “Mechanical System Test”..