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Home › Mazda › 2006 › Tribute s, FWD › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle - Overhaul › Transaxle - Assembly

Transaxle - Assembly

    All applications 

  1. Prepare the transaxle for assembly by proceeding with the following steps:
    • Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent.
    • Dry all parts with moisture-free regulated compressed air (do not use shop towels).
    • Lubricate all internal parts (including friction plates) with clean automatic transaxle fluid.
    • Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
      • Drive sprocket thrust washers.
      • Driven sprocket thrust bearing shims.
      • Differential case thrust bearing shims.
      • Low/reverse clutch pressure plates.
    • During assembly, use petroleum jelly to hold the parts in place (do not use grease).
    • Lightly coat bolt and nut threads with automatic transaxle fluid for correct installation torque specifications.
      Fig 1: Installing Intermediate And Overdrive Band Assembly Into Transaxle Case
      G04321481Courtesy of MAZDA MOTORS CORP.
  2. Install intermediate and overdrive band assembly into the transaxle case.
    Fig 2: Installing Pump Assembly Into Case
    G04321482Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle. Lubricate the seal rings with clean automatic transaxle fluid.
  3. Install pump assembly into the case.
    Fig 3: Tightening Pump Bolts In Sequence With Torque Specifications
    G04321483Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Tighten the bolts in the indicated sequence.
  4. Install the pump assembly bolts.
    Fig 4: Installing Low/Reverse Clutch Piston Using Special Tool
    G04321484Courtesy of MAZDA MOTORS CORP.
  5. Using the special tools, install the low/reverse clutch piston.
    • Lubricate seals and piston bore with clean automatic transaxle fluid.
      Fig 5: Installing Low/Reverse Clutch Return Spring Assembly
      G04321485Courtesy of MAZDA MOTORS CORP.
  6. Install the low/reverse clutch return spring assembly.
    Fig 6: Installing Retaining Ring
    G04321486Courtesy of MAZDA MOTORS CORP.
  7. Install the low/reverse clutch return spring retaining ring.
    Fig 7: Installing Low/Reverse Clutch Wave Spring
    G04321487Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The low/reverse clutch wave spring is fitted in this position for measurement purposes only.
  8. Install the low/reverse clutch wave spring.
    Fig 8: Installing Low/Reverse Clutch Plates
    G04321488Courtesy of MAZDA MOTORS CORP.
  9. Install the low/reverse clutch plates.
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the thin eight wave low/reverse clutch cushion spring.
    4. Install the low/reverse clutch pressure plate.
      Fig 9: Installing Special Tool
      G04321489Courtesy of MAZDA MOTORS CORP.
  10. Install the special tool.
    Fig 10: Measuring Clearance Between Low/Reverse Clutch Pressure Plate And Transaxle Endplay
    G04321490Courtesy of MAZDA MOTORS CORP.
  11. Measure the clearance between the low/reverse clutch pressure plate and the transaxle endplay gauge.
    • Take a second measurement on the opposite side.
    • Average the two measurements to get the clearance.
    • If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
    • Pressure plate sizes:
      • 2.57-2.46 mm (0.101-0.097 in).
      • 2.36-2.26 mm (0.092-0.089 in).
      • 2.16-2.06 mm (0.085-0.081 in).
        Fig 11: Removing Low/Reverse Clutch Pressure Plate
        G04321491Courtesy of MAZDA MOTORS CORP.
        NOTE:
        • One tooth of the low/reverse clutch pressure plate is notched for identification.
  12. Remove the special tool, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring, and the low/reverse clutch internal spline clutch plates (friction).
    1. Low one-way clutch thrust plate.
    2. Low/reverse clutch pressure plate.
    3. Low/reverse clutch external spline clutch plates (steel).
    4. Low/reverse clutch wave spring.
    5. Low/reverse clutch internal spline clutch plates (friction).
      Fig 12: Installing Pump Support Thrust Bearing
      G04321492Courtesy of MAZDA MOTORS CORP.
  13. Install the No. 1 pump support thrust bearing assembly.
    Fig 13: Installing Forward/Coast/Direct Clutch Cylinder Assembly
    G04321493Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Remove the seal sizer from forward/coast/direct clutch cylinder.
  14. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
    Fig 14: Installing Turbine Shaft
    G04321494Courtesy of MAZDA MOTORS CORP.
  15. Install the turbine shaft.
    Fig 15: Installing No. 4 Turbine Shaft Thrust Bearing
    G04321495Courtesy of MAZDA MOTORS CORP.
  16. Install the No. 4 turbine shaft thrust bearing.
    17. Fig 16: Installing Sun Gear
    G04321496Courtesy of MAZDA MOTORS CORP.
  17. Install the forward one-way clutch and low/intermediate sun gear assembly.
    Fig 17: Installing Sun Gear Thrust Bearing
    G04321497Courtesy of MAZDA MOTORS CORP.
  18. Install the No. 5 low/intermediate sun gear thrust bearing.
    Fig 18: Installing Low/Intermediate Carrier Assembly
    G04321498Courtesy of MAZDA MOTORS CORP.
  19. Install the low/intermediate carrier assembly.
    Fig 19: Installing No. 6 Low/Intermediate Carrier Thrust Bearing
    G04321499Courtesy of MAZDA MOTORS CORP.
  20. Install the No. 6 low/intermediate carrier thrust bearing.
    Fig 20: Installing Low/Intermediate Ring Gear Assembly
    G04321500Courtesy of MAZDA MOTORS CORP.
  21. Install the low/intermediate ring gear assembly.
    Fig 21: Installing No. 7 Reverse/Overdrive Sun Gear Thrust Bearing
    G04321501Courtesy of MAZDA MOTORS CORP.
  22. Install the No. 7 reverse/overdrive sun gear thrust bearing.
    Fig 22: Installing Reverse/Overdrive Sun Gear And Shell Assembly
    G04321502Courtesy of MAZDA MOTORS CORP.
  23. Install the reverse/overdrive sun gear and shell assembly.
    Fig 23: Installing Reverse/Overdrive Carrier Assembly
    G04321503Courtesy of MAZDA MOTORS CORP.
  24. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
    Fig 24: Installing Ten-Wave Low/Reverse Clutch Wave Spring
    G04321504Courtesy of MAZDA MOTORS CORP.
  25. Install the thick, ten-wave low/reverse clutch wave spring.
    Fig 25: Installing Low/Reverse Clutch Plates
    G04321505Courtesy of MAZDA MOTORS CORP.
  26. Install the low/reverse clutch plates (model dependent).
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the low/reverse clutch pressure plate previously selected.
      Fig 26: Installing Eight-Wave Low/Reverse Clutch Wave Spring
      G04321506Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Early production vehicles may not have a wave spring.
  27. If equipped, install the thin, eight-wave low/reverse clutch wave spring.
    Fig 27: Installing Low One-Way Clutch Assembly
    G04321507Courtesy of MAZDA MOTORS CORP.
  28. Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.
    Fig 28: Installing Low One-Way Clutch Thrust Plate
    G04321508Courtesy of MAZDA MOTORS CORP.
  29. Install the low one-way clutch thrust plate.
    Fig 29: Installing Low One-Way Clutch Retaining Ring
    G04321509Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Make sure to position the low one-way clutch retaining ring as shown.
  30. Install the low one-way clutch retaining ring.
    Fig 30: Installing Manual Valve Detent Lever Actuating Rod Assembly
    G04321510Courtesy of MAZDA MOTORS CORP.
  31. Install the manual valve detent lever actuating rod assembly.
    • Install the parking cam actuator lever.
      Fig 31: Installing Manual Valve Detent Lever
      G04321511Courtesy of MAZDA MOTORS CORP.
  32. Install the manual valve detent lever.
    Fig 32: Installing Special Tools With Torque Specifications
    G04321512Courtesy of MAZDA MOTORS CORP.
  33. Install the special tools.
    Fig 33: Installing Special Tool With Short Spacers
    G04321513Courtesy of MAZDA MOTORS CORP.
  34. Install the special tool with short spacers.
    Fig 34: Measuring Distance From Top Of Special Tool To No. 12 Driven Sprocket Bearing Surface Area
    G04321514Courtesy of MAZDA MOTORS CORP.
  35. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area.
    • Record this dimension.
    • This dimension is designated with A.
      Fig 35: Measuring Distance From Top Of Special Tool To Bearing Surface
      G04321515Courtesy of MAZDA MOTORS CORP.
  36. Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
    • Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
    • The average of these two dimensions is dimension B.
    • Remove the special tools.
  37. Subtract dimension B from dimension A to get dimension C.
  38. Use the third dimension to select the correct No. 11 driven sprocket shim.
    • Select a shim from the driven sprocket shim chart.
    DRIVEN SPROCKET ALIGNMENT SHIM NO.11

    Shim Size mm inch
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim AB: 2.20-2.10 0.086-0.082
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim BB: 2.02-1.92 0.079-0.075
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim CB: 1.85-1.75 0.072-0.068
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim DB: 1.67-1.57 0.065-0.061
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim EB: 1.50-1.40 0.059-0.052
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim FB: 1.32-1.22 0.051-0.048
    Distance measured during gauging procedure and appropriate thrust bearing shim AB: 14.34-14.1 0.564-0.557
    Distance measured during gauging procedure and appropriate thrust bearing shim BB: 14.16-14.00 0.557-0.551
    Distance measured during gauging procedure and appropriate thrust bearing shim CB: 13.99-13.83 0.551-0.544
    Distance measured during gauging procedure and appropriate thrust bearing shim DB: 13.82-13.66 0.544-0.537
    Distance measured during gauging procedure and appropriate thrust bearing shim EB: 13.65-13.49 0.537-0.531
    Distance measured during gauging procedure and appropriate thrust bearing shim FB: 13.48-13.32 0.531-0.524
    Fig 36: Installing Driven Sprocket Shim And Driven Sprocket Bearing
    G04321516Courtesy of MAZDA MOTORS CORP.
  39. Install and lubricate the following:
    1. Lubricate the needles and seals in the No. 18 driven sprocket bearing.
    2. Install the selected No. 11 driven sprocket shim.
    3. Install the No. 12 driven sprocket bearing.
      Fig 37: Installing Reverse/Overdrive Ring Gear Thrust Bearing
      G04321517Courtesy of MAZDA MOTORS CORP.
  40. Install the No. 9 reverse/overdrive ring gear thrust bearing.
    Fig 38: Installing Reverse/Overdrive Ring Gear Assembly
    G04321518Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
  41. Install the reverse/overdrive ring gear assembly.
    Fig 39: Installing Special Tools With Torque Specifications
    G04321519Courtesy of MAZDA MOTORS CORP.
  42. Install the special tools.
    Fig 40: Installing Special Tool With Short Spacers
    G04321520Courtesy of MAZDA MOTORS CORP.
  43. Install the special tool with short spacers.
    Fig 41: Measuring Distance From Top Of Special Tool To Face Of Reverse/Overdrive Ring Gear Assembly
    G04321521Courtesy of MAZDA MOTORS CORP.
  44. Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area.
    • Repeat this measurement 180 degrees from the first measurement.
    • The average of these two dimensions is dimension A.
    • Remove the special tools.
  45. Subtract 25.4 mm (1.00 in) thickness of special tool and the thickness of short spacers.
    • This is dimension B.
  46. Subtract dimension A from dimension B.
    • This is dimension C.
  47. Select No. 10 thrust washer from the drive sprocket thrust washer chart.
    • Use the third dimension to select the No. 10 drive sprocket thrust washer.
    DRIVE SPROCKET ALIGNMENT NO. 10 THRUST WASHER

    No.10 Thrust Washer mm inch
    Drive sprocket to converter housing thrust washer AA: 1.51-1.41 0.059-0.052
    Drive sprocket to converter housing thrust washer BA: 1.77-1.67 0.069-0.065
    Drive sprocket to converter housing thrust washer CA: 2.03-1.93 0.079-0.075
    Drive sprocket to converter housing thrust washer DA: 2.29-2.19 0.090-0.086
    Distance measured during gauging procedure and appropriate thrust washer AA: 1.12-0.86 0.044-0.033
    Distance measured during gauging procedure and appropriate thrust washer BA: 0.85-0.60 0.033-0.023
    Distance measured during gauging procedure and appropriate thrust washer CA: 0.59-0.34 0.023-0.013
    Distance measured during gauging procedure and appropriate thrust washer DA: 0.33-0.08 0.012-0.003
    Fig 42: Installing Drive Sprocket Thrust Washer On Torque Converter Housing
    G04321522Courtesy of MAZDA MOTORS CORP.
  48. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
    Fig 43: Removing Reverse/Overdrive Ring Gear Assembly
    G04321523Courtesy of MAZDA MOTORS CORP.
  49. Remove the reverse/overdrive ring gear assembly.
    Fig 44: Installing Filter And Seal Assembly
    G04321524Courtesy of MAZDA MOTORS CORP.
  50. Install the filter and seal assembly.
    Fig 45: Installing Special Tool In Filter Eyelet And Transaxle Hole
    G04321525Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • See the following illustration for correct tool usage.
  51. Install the special tool in the filter eyelet and transaxle hole.
    Fig 46: Installing Special Tool (1 Of 2)
    G04321526Courtesy of MAZDA MOTORS CORP.
    Fig 47: Installing Special Tool (2 Of 2)
    G04321527Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Lubricate the filter recirculating regulator exhaust seal before installation.
  52. Using the special tool, install the filter recirculating regulator exhaust seal.
    Fig 48: Installing Chain Pan In Transaxle Case
    G04321528Courtesy of MAZDA MOTORS CORP.
  53. Install the chain pan in the transaxle case.
    Fig 49: Installing Drive Chain Assembly
    G04321529Courtesy of MAZDA MOTORS CORP.
  54. Assemble and install the drive chain assembly.
    1. Drive chain (copper colored link facing upward).
    2. Driven sprocket assembly.
    3. Reverse/overdrive ring gear assembly.
    • Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
      Fig 50: Installing Chain Pan Cover
      G04321530Courtesy of MAZDA MOTORS CORP.
  55. Install the chain pan cover by snapping it into place.
    Fig 51: Installing Driven Sprocket Thrust Bearing
    G04321531Courtesy of MAZDA MOTORS CORP.
  56. Install the No. 13 driven sprocket thrust bearing.
    Fig 52: Installing Final Drive Carrier And Differential Assembly
    G04321532Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The all wheel drive differential is shown. The front wheel drive differential may or may not have splines.
  57. Install the final drive carrier and differential assembly.
    Fig 53: Installing Special Tool With Torque Specifications
    G04321533Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Plastic washers should be placed between bolt heads and special tool.
  58. Install the special tools.
    1. Install the special tool.
    2. Install the special tool and bolts.
      Fig 54: Measuring Distance From Top Of Special Tool To Shim Surface Area
      G04321534Courtesy of MAZDA MOTORS CORP.
  59. Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
    • The special tools will need to be relocated to carry out the second measurement.
    • Repeat this measurement 180 degrees from the first measurement.
    • The average of these two dimensions is dimension B.
  60. Use combined thickness of the special tool with long spacers 177.8 mm (7.0 in) as dimension A.
  61. Subtract dimension B from dimension A. This is dimension C.
  62. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart.
    DIFFERENTIAL END PLAY NO. 14 SHIM

    If dimension "C" is: Use No. 14 Differential Shim:
    130.76 to 130.46 mm (5.148 to 5.136 in.) 1.08 to 0.98 mm (0.042 to 0.038 in.)
    130.45 to 130.16 mm (5.136 to 5.124 in.) 1.38 to 1.28 mm (0.054 to 0.050 in.)
    130.15 to 129.87 mm (5.124 to 5.113 in.) 1.67 to 1.57 mm (0.065 to 0.061 in.)
    129.86 to 129.57 mm (5.113 to 5.101 in.) 1.97 to 1.87 mm (0.077 to 0.073 in.)
    129.56 to 129.27 mm (5.101 to 5.089 in.) 2.27 to 2.17 mm (0.089 to 0.085 in.)
    Fig 55: Installing Differential Bearing Shim And Differential Bearing
    G04321535Courtesy of MAZDA MOTORS CORP.
  63. Install the differential bearing assembly
    1. Install the No. 14 differential bearing shim (selective fit).
    2. Install the No. 15 differential bearing.
      Fig 56: Installing Torque Converter Housing Onto Transaxle Case
      G04321536Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • Check for correct alignment of the lube tube on the converter housing.
  64. Install the torque converter housing onto the transaxle case.
    • Position and install the split flange gasket.
      Fig 57: Installing Torque Converter Housing-To-Transaxle Case Tightening Bolts In Sequence With Torque Specifications
      G04321537Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Tighten the bolts in the indicated sequence.
  65. Install the torque converter housing-to-transaxle case bolts.
    Fig 58: Installing Intermediate And Overdrive Servo Applying Rod And Piston Assembly
    G04321538Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Note the number of grooves on the intermediate and overdrive servo apply rod.
  66. Lubricate the assembly with clean transaxle fluid.
    1. Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
    2. Install the intermediate and overdrive servo apply rod and piston assembly.
    3. Install the overdrive servo apply rod spring.
      Fig 59: Installing Special Tool
      G04321539Courtesy of MAZDA MOTORS CORP.
  67. Install the special tool.
    Fig 60: Installing Special Tool With Torque Specifications
    G04321540Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Struts on the special tool fit into the servo cover retaining ring groove.
  68. Assemble the special tool.
    1. Install struts.
    2. Install bar.
    3. Install bolts.
    4. Install the center bolt.
      Fig 61: Measuring Distance To Bar Of Special Tool
      G04321541Courtesy of MAZDA MOTORS CORP.
  69. Using the special tool, measure the distance to the bar of special tool.
    • Record this as dimension A.
    70. Fig 62: Identifying Center Bolt Of Special Tool
    G04321542Courtesy of MAZDA MOTORS CORP.
  70. Back off the center bolt of special tool until the piston movement stops.

    71. Vehicles with narrow groove case 

    Fig 63: Measuring Dimension To Bar Of Special Tool With Torque Specifications
    G04321543Courtesy of MAZDA MOTORS CORP.
  71. Using the special tool, measure the dimension to the bar of special tool. Record as dimension B.
    • Subtract dimension A from B to find the travel.
    • If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.
    INTERMEDIATE/OVERDRIVE SERVO APPLY ROD

    Part Number Number of Rings Rod Length
    F3RP-7H188-CB 0 108.1 mm (4.25 in)
    F3RP-7H188-BB 1 107.1 mm (4.21 in)
    F3RP-7H188-AB 2 105.7 mm (4.16 in)

    72. Vehicles with wide groove case 

  72. Using the special tool, measure the dimension to the bar of special tool. Record as dimension B.
    • Subtract dimension A from B to find the travel.
    • If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.
      Fig 64: Measuring Dimension To Bar Of Special Tool With Torque Specifications
      G04321544Courtesy of MAZDA MOTORS CORP.
    INTERMEDIATE/OVERDRIVE SERVO APPLY ROD

    Part Number Number of Rings Rod Length
    F3RP-7H188-CB 0 108.1 mm (4.25 in)
    F3RP-7H188-BB 1 107.1 mm (4.21 in)
    F3RP-7H188-AB 2 105.7 mm (4.16 in)

    73. All applications 

  73. Wipe the servo piston and the servo cover cap with a lint-free cloth.
    CAUTION:
    • Do not clean the rubber sealing surfaces of the servo piston and servo cover cap with cleaning solvent, or damage to the sealing surface may result.
  74. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston attached to the servo rod.
  75. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston.
  76. Inspect the servo retainer spring for cracks, breaks or deformation.
    Fig 65: Installing Special Tool
    G04321545Courtesy of MAZDA MOTORS CORP.
  77. Install the special tool.
    Fig 66: Tightening Special Tool Bolt
    G04321546Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • If the case is stamped "WG", install a wide-groove snap ring, or damage to the servo will result.
    CAUTION:
    • Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring.
    NOTE:
    • If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
  78. Tighten the special tool bolt.
    • Install the servo cover retaining ring, using retaining ring pliers.
      Fig 67: Loosening Special Tool Bolt
      G04321547Courtesy of MAZDA MOTORS CORP.
  79. Loosen the special tool bolt.
    • When spring tension is released, remove the special tool.
      Fig 68: Inspecting Hydraulic Circuits Using Special Tool
      G04321548Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not check the coast clutch since the piston may be forced out of the forward clutch piston.
    NOTE:
    • If any leaks occur, make sure the special tool is correctly seated.
  80. Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 19 kPa (2.76 psi) of moisture-free regulated compressed air.
    1. Reverse clutch test port.
    2. Forward clutch test port.
    3. Direct clutch test port.
    4. Low/reverse clutch test port.
    5. Servo release test port.
    6. Servo apply test port.
    7. Transmission air test plate.
      • If air leakage is detected, disassemble the transaxle and locate source of leakage.
        Fig 69: Installing Thermostatic Fluid Level Control Valve Bracket Bolt With Torque Specifications
        G04321549Courtesy of MAZDA MOTORS CORP.
  81. Install the thermostatic fluid level control valve.
    1. Position the thermostatic fluid level control valve.
    2. Install the bracket.
    3. Install the thermostatic fluid level control valve bracket bolt.
      Fig 70: Installing Solenoid Body Electrical Connector
      G04321550Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.
  82. Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.
    Fig 71: Connecting Manual Valve
    G04321551Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Handle main control valve body with care to prevent manual valve damage.
  83. Connect the manual valve.
    1. Lift the main control away from the case.
    2. Connect the Z-link to the manual valve.
      Fig 72: Installing Main Control Valve Body Tightening Mounting Bolts In Sequence With Torque Specifications
      G04321552Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others.
  84. Install the main control valve body mounting bolts.
    Fig 73: Installing Manual Control Lever With Torque Specifications
    G04321553Courtesy of MAZDA MOTORS CORP.
  85. Install the manual control lever.
    Fig 74: Positioning Manual Valve
    G04321554Courtesy of MAZDA MOTORS CORP.
  86. Rotate the manual valve detent lever assembly to the NEUTRAL position.
    1. Low 1.
    2. Low 2.
    3. Drive.
    4. Neutral.
    5. Reverse.
    6. Park.
      Fig 75: Positioning Transaxle Range (TR) Sensor
      G04321555Courtesy of MAZDA MOTORS CORP.
  87. Position the transaxle range (TR) sensor.
    Fig 76: Aligning TR Sensor Tightening Bolts With Torque Specifications
    G04321556Courtesy of MAZDA MOTORS CORP.
  88. Using the special tool, align the TR sensor and tighten the bolts.
    NOTE:
    • The main control cover gasket is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary.
  89. Install the main control cover gasket.
    Fig 77: Tightening Bolts In Sequence With Torque Specifications
    G04321557Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Tighten the bolts in the indicated sequence.
  90. Install the main control cover.
    Fig 78: Installing Vent Tube
    G04321558Courtesy of MAZDA MOTORS CORP.
  91. Install the vent tube.
    Fig 79: Installing Transaxle Filler Tube Grommet
    G04321559Courtesy of MAZDA MOTORS CORP.
  92. Install a new transaxle filler tube grommet.
    Fig 80: Installing Transaxle Filler Tube Assembly With Torque Specifications
    G04321560Courtesy of MAZDA MOTORS CORP.
  93. Install the transaxle filler tube assembly.
    1. Install the tube.
    2. Install the transaxle filler tube bolt.
      • Install the fluid level indicator.
        Fig 81: Installing TSS Sensor And Bolt With Torque Specifications
        G04321561Courtesy of MAZDA MOTORS CORP.
  94. Install the turbine shaft speed (TSS) sensor.
    1. Use petroleum jelly on the O-ring seal and position the TSS sensor.
      • Install a new O-ring seal.
    2. Install the TSS sensor bolt.
      Fig 82: Installing LH Differential Seal Using Special Tool
      G04321562Courtesy of MAZDA MOTORS CORP.
  95. Using the special tool, install the LH differential seal.
    Fig 83: Installing RH Differential Seal Using Special Tool
    G04321563Courtesy of MAZDA MOTORS CORP.
  96. Using the special tool, install the RH differential seal.
    Fig 84: Installing Torque Converter Fluid Seal Using Special Tool
    G04321564Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.
  97. Using the special tool, install the torque converter fluid seal.
    • Coat the torque converter seal garter spring with petroleum jelly.
      Fig 85: Installing Drain Plug With Torque Specifications
      G04321565Courtesy of MAZDA MOTORS CORP.
  98. Install the drain plug.
    Fig 86: Installing Pump Drive Shaft
    G04321566Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Check for correct rotation of the pump drive shaft.
  99. Install the pump drive shaft.
    Fig 87: Installing Torque Converter Using Special Tool
    G04321567Courtesy of MAZDA MOTORS CORP.
  100. Using the special tool, install the torque converter.
    Fig 88: Checking Clearance Between Straight Edge And Pilot Hub
    G04321568Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The torque converter hub must be fully seated into the transaxle pump drive gear.
  101. Check the installation depth of the torque converter.
    • Lay a straightedge on the transaxle converter housing.
    • Check the clearance between the straight edge and the pilot hub.
      Fig 89: Removing Transaxle From Special Tool
      G04321569Courtesy of MAZDA MOTORS CORP.
  102. Remove the transaxle from the special tool.
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