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Home › Mazda › 2003 › MPV ES › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle - Overhaul [Ja5EL] › Automatic Transaxle Disassembly › Disassembly Components › Disassembly Procedure

Disassembly Procedure

  1. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to keep any remaining fluid from spilling.
  2. Remove the transaxle range switch.
  3. Set the transaxle to a transmission stand using the SST  .
    Fig 1: Identifying Transmission Stand
    G02291466Courtesy of MAZDA MOTORS CORP.
    4. CAUTION:
    • Be careful not to scratch the mating surfaces of the control valve body cover and the transaxle case.
    • After removing the control valve body cover, remove the liquid gasket remaining on the mating surfaces.
  4. Remove the control valve body cover.
  5. Disconnect coupling connector between the solenoid valves and the terminal component.
    Fig 2: Disconnect Coupling Connector
    G02291467Courtesy of MAZDA MOTORS CORP.
  6. Remove the bolts which secure the control valve body to the transaxle case as shown in the figure.
    Fig 3: Removing Control Valve Body Bolts
    G02291468Courtesy of MAZDA MOTORS CORP.
    7. NOTE: When removing control valve body, be careful not to drop the manual valve.
    Fig 4: Removing Control Valve Body
    G02291469Courtesy of MAZDA MOTORS CORP.
  7. Remove the control valve body from the transaxle case.
    8. CAUTION: If the seal ring has dropped or is scratched, do not reuse it.
    Fig 5: Removing Seal Rings
    G02291470Courtesy of MAZDA MOTORS CORP.
  8. Remove the seal rings from the transaxle case.
  9. Remove the bracket from coupling connector, then remove the terminal component.
    10. CAUTION:
    • If the converter housing is hard to remove, lightly tap perimeter of the converter housing using a plastic hammer.

      Do not separate the converter housing and the transaxle case using a screwdriver.

      Be careful not to scratch mating surfaces of the converter housing and the transaxle case.

    • After removing the converter housing, remove the liquid gasket remaining on the mating surfaces.
    Fig 6: Removing Converter Housing
    G02291471Courtesy of MAZDA MOTORS CORP.
  10. Remove the bolts, then remove the converter housing.
  11. Remove the differential component.
    Fig 7: Removing Differential Component
    G02291472Courtesy of MAZDA MOTORS CORP.
  12. Remove the oil strainer.
    Fig 8: Removing Oil Strainer
    G02291473Courtesy of MAZDA MOTORS CORP.
  13. Remove the Transaxle Fluid Temperature (TFT) sensor and two magnets.
  14. Disconnect the intermediate sensor connector.
    Fig 9: Disconnecting Intermediate Sensor Connector
    G02291474Courtesy of MAZDA MOTORS CORP.
  15. Remove the intermediate sensor with the clip.
  16. Disconnect the Vehicle Speedometer Sensor (VSS) connector.
    Fig 10: Disconnecting Vehicle Speedometer Sensor Connector
    G02291475Courtesy of MAZDA MOTORS CORP.
  17. Remove the VSS with the clip and harness bracket.
    18. NOTE: Do not reuse the O-ring.
  18. Remove the O-ring from the input shaft.
  19. Remove the bolts, then remove the oil pump component.
    Fig 11: Removing Oil Pump
    G02291476Courtesy of MAZDA MOTORS CORP.
    20. CAUTION: If the oil pump gasket is bent or scratched, do not reuse it.
  20. Remove the oil pump gasket.
    21. NOTE: Do not reuse the seal rings.
  21. Pull out the input shaft.
  22. Remove the seal rings from the input shaft.
    Fig 12: Removing Seal Rings
    G02291477Courtesy of MAZDA MOTORS CORP.
  23. Remove the reduction gear component.
    Fig 13: Removing Reduction Gear
    G02291478Courtesy of MAZDA MOTORS CORP.
  24. Remove the sun gear on the reduction gear.
    Fig 14: Removing Sun Gear
    G02291479Courtesy of MAZDA MOTORS CORP.
    25. NOTE: Do not reuse the anchor end bolt.
    Fig 15: Removing Anchor End Bolt
    G02291480Courtesy of MAZDA MOTORS CORP.
  25. Remove the anchor end bolt which secures the reduction brake band.
  26. Remove the reduction brake band.
    Fig 16: Removing Reduction Brake Band
    G02291481Courtesy of MAZDA MOTORS CORP.
  27. Remove the direct clutch component.
    Fig 17: Removing Direct Clutch
    G02291482Courtesy of MAZDA MOTORS CORP.
  28. Remove the bearing race and bearing from one-way clutch inner race.
    Fig 18: Removing Bearing Race & Bearing
    G02291483Courtesy of MAZDA MOTORS CORP.
    29. CAUTION:
    • If the end cover is hard to remove, lightly tap perimeter of the end cover using a plastic hammer.

      Do not separate the end cover and the transaxle case using a screwdriver. Be careful not to scratch mating surfaces of the end cover and the transaxle case.

    • After removing the end cover, remove the liquid gasket remaining on the mating surfaces.
    Fig 19: Removing End Cover
    G02291484Courtesy of MAZDA MOTORS CORP.
  29. Remove the bolts, then remove the end cover.
    30. NOTE: Do not reuse the O-ring.
    Fig 20: Removing O-Rings From Bolts
    G02291485Courtesy of MAZDA MOTORS CORP.
  30. Remove the O-rings from two bolts.
    31. CAUTION: When removing the bolts, be careful not to drop the one-way clutch inner race.
  31. Remove the bolts which secure the one-way clutch inner race.
    32. NOTE: Do not reuse the O-rings.
  32. Remove the O-rings from two bolts.
  33. Remove the one-way clutch inner race.
    NOTE: Do not reuse the seal rings.
    Fig 21: Removing One-Way Clutch Inner Race
    G02291486Courtesy of MAZDA MOTORS CORP.
  34. Remove the seal rings from the one-way clutch inner race.
    Fig 22: Removing Seal Rings From One-Way Clutch Inner Race
    G02291487Courtesy of MAZDA MOTORS CORP.
  35. Remove the snap ring which secures the 2-4 brake accumulator onto the end cover.
  36. Remove the 2-4 brake accumulator cover and spring.
    Fig 23: Removing 2-4 Brake Accumulator Cover & Spring
    G02291488Courtesy of MAZDA MOTORS CORP.
    37. NOTE: Do not reuse the O-ring.
  37. Remove the O-ring from the 2-4 brake accumulator cover.
  38. Hold the 2-4 brake accumulator piston by hand. Then, blow out the piston using an air gun to blow air into oil circuit as shown in the figure.
    Fig 24: Removing 2-4 Brake Accumulator Piston
    G02291489Courtesy of MAZDA MOTORS CORP.
    39. NOTE: Do not reuse the O-ring.
  39. Remove the O-rings from the 2-4 brake accumulator piston.
  40. Pull out the oil pipes.
    Fig 25: Removing Oil Pipes
    G02291490Courtesy of MAZDA MOTORS CORP.
  41. Disconnect the connector from the turbine sensor.
  42. Remove the bolts, then remove the turbine sensor.
    Fig 26: Removing Turbine Sensor
    G02291491Courtesy of MAZDA MOTORS CORP.
  43. Remove the return spring and spring retainer.
    Fig 27: Removing Return Spring & Spring Retainer
    G02291492Courtesy of MAZDA MOTORS CORP.
  44. Remove the reverse clutch and high clutch component.
  45. Remove the needle bearing from the reverse clutch and high clutch component.
    Fig 28: Removing Needle Bearing From Reverse Clutch & High Clutch Component
    G02291493Courtesy of MAZDA MOTORS CORP.
  46. Remove the high clutch hub.
  47. Remove the race bearing from the high clutch hub.
    Fig 29: Removing Race Bearing From High Clutch Hub
    G02291494Courtesy of MAZDA MOTORS CORP.
  48. Remove the low clutch hub.
  49. Remove the race bearing and bearing race from the low clutch hub.
    Fig 30: Removing Race Bearing & Bearing Race From Low Clutch Hub
    G02291495Courtesy of MAZDA MOTORS CORP.
  50. Remove the front planetary carrier component.
  51. Remove the needle bearing and race bearing from the front planetary carrier component.
    Fig 31: Removing Needle Bearing & Race Bearing From Front Planetary Carrier
    G02291496Courtesy of MAZDA MOTORS CORP.
  52. Remove the rear sun gear.
  53. Remove the rear planetary carrier component.
  54. Remove the needle bearing and bearing race from the rear planetary carrier component.
    Fig 32: Removing Needle Bearing & Bearing Race From Rear Planetary Carrier
    G02291497Courtesy of MAZDA MOTORS CORP.
  55. Remove the rear internal gear.
  56. Remove the needle bearing from the rear internal gear.
    Fig 33: Removing Needle Bearing From Rear Internal Gear
    G02291498Courtesy of MAZDA MOTORS CORP.
  57. Remove the low clutch component.
  58. Remove the needle bearing.
    Fig 34: Removing Needle Bearing From Low Clutch Component
    G02291499Courtesy of MAZDA MOTORS CORP.
  59. Remove the 2-4 brake.
    1. Remove the snap ring.
    2. Remove 2-4 brake retaining plates, drive plates, and driven plates as a unit.
      Fig 35: Removing 2-4 Brake Snap Ring
      G02291500Courtesy of MAZDA MOTORS CORP.
  60. Remove the low and reverse brake.
    1. Install the SSTs  in the transaxle case as shown in the figure.
      Fig 36: Installing SST In Transaxle Case
      G02291501Courtesy of MAZDA MOTORS CORP.
      2. CAUTION: Depress the spring retainer only enough to remove the snap ring. Overpressing will damage the retainer component edges.
    2. Remove the snap ring.
    3. Remove the SSTs  .
    4. Remove the piston and retainer, return spring, and spring retainer.
    5. Remove the low and reverse brake dished plate, drive plates, driven plates, and retaining plate as a unit.
      Fig 37: Removing Low & Reverse Brake Dished Plate, Drive Plates, Driven Plates & Retaining Plates
      G02291502Courtesy of MAZDA MOTORS CORP.
    6. Remove the snap ring.
      Fig 38: Removing Low One-Way Clutch Snap Ring
      G02291503Courtesy of MAZDA MOTORS CORP.
      7. CAUTION: Be careful not to drop the low one-way clutch rollers.
    7. Remove the low one-way clutch.
  61. Remove the direct clutch accumulator.
    1. Remove the snap ring.
      Fig 39: Removing Direct Clutch Accumulator Snap Ring
      G02291504Courtesy of MAZDA MOTORS CORP.
      2. 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.
    2. Remove the direct clutch accumulator piston by applying compressed air through the hole of the direct clutch accumulator piston.
    3. Remove the springs.
      Fig 40: Removing Direct Clutch Accumulator Piston
      G02291505Courtesy of MAZDA MOTORS CORP.
  62. Remove the output gear.
    1. Remove the installation bolts of output gear.
    2. Set the SSTs  to the output gear, and remove the output gear using a press.
      Fig 41: Removing Output Gear
      G02291506Courtesy of MAZDA MOTORS CORP.
  63. Remove the brake band servo.
    1. Remove the snap ring.
      Fig 42: Removing Brake Band Servo Snap Ring
      G02291507Courtesy of MAZDA MOTORS CORP.
      2. 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
      CAUTION: Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will damage the seal.

      Do not apply compressed air for more than the aforementioned time when testing the system.

      Fig 43: Removing Reduction Accumulator Piston
      G02291508Courtesy of MAZDA MOTORS CORP.
    2. Remove the servo retainer and reduction accumulator piston component by applying compressed air as shown.
    3. Pushing the piston stem using a wood stick, remove the snap ring.
      Fig 44: Removing Band Servo Piston Snap Ring
      G02291509Courtesy of MAZDA MOTORS CORP.
    4. Remove the spacer, band servo piston, and spring.
      Fig 45: Removing Spacer, Band Servo Piston & Spring
      G02291510Courtesy of MAZDA MOTORS CORP.
  64. Remove the oil pipe from the converter housing.
    Fig 46: Removing Oil Pipe
    G02291511Courtesy of MAZDA MOTORS CORP.
  65. Remove the baffle plate.
  66. Set the SST  to the reduction gear bearing outer race, and remove it.
    Fig 47: Removing Reduction Gear Bearing Outer Race
    G02291512Courtesy of MAZDA MOTORS CORP.
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