Assembly procedure

Measure the bushing of the front sun gear.
Front sun gear bushing inner diameter

Standard: 18.000-18.018 mm {0.70866-0.70936 in}

Maximum: 18.038 mm {0.71016 in}
If not as specified, replace the front sun gear.

Fig 1: Measuring Bushing Of Front Sun Gear
Courtesy of MAZDA MOTORS CORP.
Measure the bushing of the end cover.
End cover bushing inner diameter

Standard: 23.600-23.621 mm {0.92913-0.92995 in}

Maximum: 23.641 mm {0.93075 in}
If not as specified, replace the end cover.

Fig 2: Measuring Bushing Of End Cover
Courtesy of MAZDA MOTORS CORP.
Measure the bushing of the secondary sun gear.
Secondary sun gear bushing inner diameter

Standard: 26.000-26.021 mm {1.02362-1.02445 in}

Maximum: 26.041 mm {1.02524 in}
If not as specified, replace the secondary sun gear.

Fig 3: Measuring Bushing Of Secondary Sun Gear
Courtesy of MAZDA MOTORS CORP.
Assemble the SST .

Fig 4: Identifying SST
Courtesy of MAZDA MOTORS CORP.
Lift the transaxle case and mount it on the SST .
NOTE:
- If the transaxle case has been newly replaced perform step (9).
Install the oil pipe.

Fig 5: Transaxle Case On SST
Courtesy of MAZDA MOTORS CORP.
Install the bearing race, then tighten torx screws.
Tightening torque

10.8-13.7 N.m {110-140 kgf.cm, 95.5-121 in.lbf}

Fig 6: View Of Bearing Race
Courtesy of MAZDA MOTORS CORP.
Install the bearing race to the transaxle case.

Fig 7: Installing Bearing Race To Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the locknut.
1. Set the primary gear.
  
  Fig 8: View Of Primary Gear
  Courtesy of MAZDA MOTORS CORP.
2. Set the distance piece and bearing.
  
  Fig 9: View Of Distance Piece And Bearing
  Courtesy of MAZDA MOTORS CORP.
3. Loosely tighten the locknut.
  
  Fig 10: View Of Locknut
  Courtesy of MAZDA MOTORS CORP.
4. Set the SSTs in the order shown.
  
  Fig 11: Identifying SSTs
  Courtesy of MAZDA MOTORS CORP.
  
  Fig 12: Identifying SSTs
  Courtesy of MAZDA MOTORS CORP.
5. Tighten the locknut from the end cover side to adjust the preload within the specification.
  Primary gear preload
  
  0.50-0.90 N.m {5.10-9.17 kgf.cm, 4.42-7.96 in.lbf}
  
  Fig 13: Tightening Locknut
  Courtesy of MAZDA MOTORS CORP.
6. Stake the locknut.
7. Remove the SST
Fig 14: Staking Lock Nut
Courtesy of MAZDA MOTORS CORP.
Install the front internal gear and one-way clutch.
Apply petroleum jelly to the bearing, and secure it to the front planetary gear component.

Fig 15: View Of Front Internal Gear And One-Way Clutch
Courtesy of MAZDA MOTORS CORP.
Install the front planetary gear component.
Apply petroleum jelly to the bearing, and secure it to the front sun gear.

Fig 16: View Of Front Planetary Gear Component
Courtesy of MAZDA MOTORS CORP.
Install the front sun gear.

Fig 17: View Of Front Sun Gear
Courtesy of MAZDA MOTORS CORP.
Install the rear planetary gear.
NOTE:
- Rotate the engine stand so that the oil pan faces downward. Pull the front internal gear and one-way clutch component a little until the groove for the snap ring appears, then install the snap ring.
Fig 18: View Of Rear Planetary Gear
Courtesy of MAZDA MOTORS CORP.

Fig 19: Identifying Front Internal Gear And One Way Clutch
Courtesy of MAZDA MOTORS CORP.
Install the snap ring.
Rotate the engine stand so that the end cover faces upward, and verify that the snap ring is installed accurately.

Fig 20: View Of Snap Ring
Courtesy of MAZDA MOTORS CORP.
Install the band servo component.
1. Install the servo return spring and servo piston.
2. Apply ATF to the O-ring, and install it to the transaxle case.
3. Install the servo retainer.
  Tightening torque
  
  11-14 N.m {113-142 kgf.cm, 98-123 in.lbf}
Apply petroleum jelly to the bearing, and secure it to the clutch component.

Fig 21: View Of Servo Retainer
Courtesy of MAZDA MOTORS CORP.
Install the clutch component.

Fig 22: View Of Clutch Component
Courtesy of MAZDA MOTORS CORP.
Install the 2-4 brake band.

Fig 23: View Of Brake Band
Courtesy of MAZDA MOTORS CORP.

Select the band strut.

Find an appropriate bolt (under head length: 60-70 mm {2.36-2.75 in}) , and tighten the 2-4 brake band with the bolt.
Tightening torque

4.9 N.m {50 kgf.cm, 43 in.lbf}
Measure the dimension A shown in the figure.
Remove the bolt.

Fig 24: View Of Bolt Dimension A
Courtesy of MAZDA MOTORS CORP.
Measure the dimension B shown in the figure.
Calculate according to the formula below.
B - A = C (The middle of the under head length)

C - 4 = D (The lower limit of under head length)

C - 4.7 = E (The upper limit of under head length)

Select a band strut whose length should be between D and E.

Fig 25: Measuring Band Strut Length

Courtesy of MAZDA MOTORS CORP.

Band strut length for 2-4 brake band servo stroke (mm {in})

BAND STRUT LENGTH SPECIFICATIONS

36.0 {1.417}	36.5 {1.437}	37.0 {1.457}
37.25 {1.467}	37.5 {1.476}	37.75 {1.486}
38.0 {1.496}	38.25 {1.506}	38.5 {1.516}
39.0 {1.535}	-	-

Install the selected band strut.
Tightening torque

37-52 N.m {3.8-5.3 kgf.m, 28-38 ft.lbf}

Fig 26: View Of Selected Band Strut

Courtesy of MAZDA MOTORS CORP.

Use the following procedure to adjust the total end play.

Install the thickest bearing race (2.6 mm {0.102 in}) to the end cover.
Install the end cover to the clutch component.
Measure the clearance A between transaxle case and end cover.
Calculate according to the formulas below. Select an appropriate bearing race whose bearing thickness matches the calculated limits.
A - 2.6 mm {0.102} (Bearing thickness) = B

B - 0.25 = C (The lower limit of bearing thickness)

B - 0.50 = D (The upper limit of bearing thickness)

Fig 27: Measuring Clearance Between Transaxle Case And End Cover
Courtesy of MAZDA MOTORS CORP.

Select a bearing race whose thickness is between D mm {in} and C mm {in}.

Bearing race sizes

BEARING RACE SIZES

mm {in}
1.8 {0.071}	2.0 {0.079}	2.2 {0.087}
2.4 {0.094}	2.6 {0.102}	-

CAUTION:

The bearing race and end cover may be damaged if the end cover is not installed correctly to the transaxle case. Align the projection of the bearing race within the area of the arrows shown in the figure, and then install the end cover to the transaxle case.

Fig 28: Identifying Bearing Race

Courtesy of MAZDA MOTORS CORP.

Remove the end cover, apply petroleum jelly to the selected bearing race, then install it to the end cover.

Apply ATF to new seal ring, and install it to the end cover.
Seal ring inner diameter

A: 47.1 mm {1.854 in}

B: 55.8 mm {2.197 in}

Fig 29: Measuring Seal Ring Inner Diameter
Courtesy of MAZDA MOTORS CORP.
Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the end cover.
Apply ATF to the O-ring and install it to the transaxle case.

Fig 30: Applying Silicone Sealant To Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the end cover to the transaxle case.
Tightening torque

19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
Install the reduction brake to the transaxle case. (See REDUCTION BRAKE DISASSEMBLY/ASSEMBLY .)
NOTE:
- If the transaxle case has been newly replaced perform Step (32).
Fig 31: View Of End Cover, O-rings And Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the needle bearing using the SST as shown in the figure.

Fig 32: View Of Needle Bearing
Courtesy of MAZDA MOTORS CORP.
Install the spacer and one-way clutch No.2 to the transaxle case.
Apply ATF to new seal ring, and install it to the transaxle case.
Apply petroleum jelly to the needle bearing, and secure it to the transaxle case.

Fig 33: View Of Spacer, One-Way Clutch No.2 And Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the direct clutch component to the transaxle case.

Fig 34: View Of Direct Clutch Component, Needle Bearing And Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the secondary sun gear.

Fig 35: View Of Secondary Sun Gear
Courtesy of MAZDA MOTORS CORP.
Install the output gear component.
Install the bearing race to the output gear component.
Apply petroleum jelly to the needle bearing, and secure it to the output gear component.

Fig 36: View Of Output Gear Component
Courtesy of MAZDA MOTORS CORP.

Use the following procedure to adjust the total end play.

Measure clearance A between the installation surface and the hole depth of the converter housing.
Install the bearing to the output gear component.
Measure clearance B between the converter housing installation surface and the bearing.
Calculate the total end play according to the following formula:
step (1) value - step (3) value = total end play.

select the snap ring.

Fig 37: Measuring Clearance Between Converter Housing Installation Surface And Bearing

Courtesy of MAZDA MOTORS CORP.

Adjust shim size for output gear component total end play

ADJUST SHIM SIZE FOR OUTPUT GEAR COMPONENT TOTAL END PLAY

total end play {in}	Adjust shims sizes mm {in}
1.431-1.481 {0.057-0.058}	1.20 {0.047}
1.381-1.431 {0.055-0.056}	1.15 {0.045}
1.331-1.381 {0.053-0.054}	1.10 {0.043}
1.281-1.331 {0.051-0.052}	1.05 {0.041}
1.231-1.281 {0.049-0.050}	1.00 {0.039}
1.181-1.231 {0.047-0.048}	0.95 {0.037}
1.131-1.181 {0.045-0.046}	0.90 {0.035}
1.081-1.131 {0.043-0.044}	0.85 {0.033}
1.031-1.081 {0.041-0.042}	0.80 {0.031}
0.981-1.031 {0.039-0.040}	0.75 {0.029}
0.931-0.981 {0.037-0.038}	0.70 {0.028}
0.881-0.931 {0.035-0.036}	0.65 {0.026}
0.831-0.881 {0.033-0.034}	0.60 {0.024}
0.781-0.831 {0.031-0.032}	0.55 {0.022}
0.731-0.781 {0.029-0.030}	0.50 {0.020}

Install the selected adjustment shim to the converter housing.

Install the bearing using the SST as shown in the figure.
Press-in force

8.8 kN {897 kgf, 1978 lbf}

Fig 38: Installing Selected Adjustment Shim To Converter Housing
Courtesy of MAZDA MOTORS CORP.
Install the pawl return spring to the transaxle case.

Fig 39: View Of Pawl Return Spring And Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the packing pawl and parking pawl shaft to the transaxle case.

Fig 40: View Of Packing Pawl, Parking Pawl Shaft And Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the pawl return spring to the parking pawl and parking pawl shaft.

Fig 41: View Of Pawl Return Spring, Parking Pawl And Parking Pawl Shaft
Courtesy of MAZDA MOTORS CORP.
Install the support plate to the transaxle case.

Fig 42: View Of Support Actuator Plate And Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the actuator plate to the transaxle case.
Tightening torque

11-14 N.m {113-142 kgf.cm, 98-123 in.lbf}

Fig 43: View Of Actuator Plate To Transaxle Case Bolts
Courtesy of MAZDA MOTORS CORP.
Install the differential.
Install the forward clutch hub.

Fig 44: View Of Forward Clutch Hub
Courtesy of MAZDA MOTORS CORP.
Install the forward clutch component.

Fig 45: View Of Forward Clutch Component
Courtesy of MAZDA MOTORS CORP.
Apply a light coat of silicone sealant to the contact surfaces of the converter housing and the transaxle case.

Fig 46: Applying Silicone Sealant To Contact Surfaces Of Converter Housing
Courtesy of MAZDA MOTORS CORP.
Install the converter housing.
Tightening torque

19-25 N.m {1.9-2.6 kgf.m, 14-18 ft-lbf}

Fig 47: View Of Converter Housing
Courtesy of MAZDA MOTORS CORP.
Install the SST into the differential side gears.
Apply ATF to the new O-ring and install it to the oil pump.

Fig 48: Installing SST Into Differential Side Gears
Courtesy of MAZDA MOTORS CORP.
Install the oil pump.
Tightening torque

19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}

Fig 49: Installing Oil Pump
Courtesy of MAZDA MOTORS CORP.
Install the parking rod lever component.
Tightening torque

19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}

Fig 50: View Of Parking Rod Lever Component
Courtesy of MAZDA MOTORS CORP.
Apply ATF to the new O-ring and install it to the manual shaft.
Install the manual shaft.
1. Install the manual shaft to the manual plate and detent bracket component.
  
  Fig 51: View Of Manual Shaft
  Courtesy of MAZDA MOTORS CORP.
2. Install the knock pin.
Fig 52: View Of Knock Pin
Courtesy of MAZDA MOTORS CORP.
Install the accumulator component.

Fig 53: View Of Accumulator Component
Courtesy of MAZDA MOTORS CORP.
Install the coupler component.
CAUTION:
- Make sure that the head of the manual valve and the parking rod are assembled properly. If they are not, the ranges cannot be changed.
Fig 54: View Of Coupler Component
Courtesy of MAZDA MOTORS CORP.

Fig 55: View Of Primary Control Valve Body
Courtesy of MAZDA MOTORS CORP.
Install the primary control valve body.
Tightening torque

7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}

Bolt length (measured from below the head)

B: 40 mm {1.575 in}

No mark: 70 mm {2.756 in}

Fig 56: View Of Primary Control Valve Body
Courtesy of MAZDA MOTORS CORP.
Apply ATF to the new O-ring and install it to the oil strainer.
Install the oil strainer.

Match the harness colors, then connect the solenoid connector and TFT sensor.

SOLENOID VALVE DESCRIPTION

Solenoid valve	Color of connector (harness side)
Pressure control solenoid A	Black
Shift solenoid A	White
Shift solenoid B	Blue
Shift solenoid C	Green
Shift solenoid D	White
Shift solenoid E	Black

Fig 57: View Of Oil Strainer

Courtesy of MAZDA MOTORS CORP.

Install the ground.
Tightening torque

7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}

Fig 58: View Of Solenoids And Connectors
Courtesy of MAZDA MOTORS CORP.
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:
- Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.
- If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle case and oil pan, and clean with cleaning fluids.
Apply a light coat of silicone sealant to the contact surfaces of oil pan and transaxle case.
Install the oil pan.
Tightening torque

6-8 N.m {62-81 kgf.cm, 54-70 in.lbf}

Fig 59: View Of Oil Pan
Courtesy of MAZDA MOTORS CORP.
Apply ATF to the new O-ring and install it to the transaxle case.
Install the tubular pins.
Install the coupler component.

Fig 60: View Of Tubular Pins
Courtesy of MAZDA MOTORS CORP.
Install the secondary control valve body and ground.
Tightening torque

7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}

Bolt length (measured from below the head)

B: 40 mm {1.575 in}

C: 50 mm {1.969 in}

Fig 61: View Of Secondary Control Valve Body Bolts And Ground
Courtesy of MAZDA MOTORS CORP.

Match the harness colors, then connect the solenoid connector.

SOLENOID VALVE DESCRIPTION

Solenoid valve	Color of connector (harness side)
Pressure control solenoid B	White
Shift solenoid F	Black

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:

Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.
If any old sealant gets into the transaxle during installation of the oil cover, trouble may occur in the transaxle case and oil pan, and clean with cleaning fluids.

Apply a light coat of silicone sealant to the contact surfaces of oil cover and transaxle case.
Install the oil cover.
Tightening torque

7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}

Fig 62: View Of Oil Cover
Courtesy of MAZDA MOTORS CORP.
Install the oil pipe and connector bolt.
Tightening torque

24-35 N.m {2.4-3.6 kgf.cm, 18-26 in.lbf}
Install the connector pipe.
Tightening torque

24-35 N.m {2.4-3.6 kgf.cm, 18-26 in.lbf}
Apply ATF to the new O-ring and install it to the intermediate sensor.
Install the intermediate sensor.
Tightening torque

8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
Apply ATF to the new O-ring and install it to the vehicle speed sensor.
Install the vehicle speed sensor.
Tightening torque

8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
Apply ATF to the new O-ring and install it to the input/turbine speed sensor.
Install the oil pressure switch.
Tightening torque

17.1-22.1 N.m {1.75-2.25 kgf.m, 12.7-16.2 ft.lbf}
Install the input/turbine speed sensor.
Tightening torque

8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
Install the transaxle range switch.
1. Rotate the manual shaft to the N position.
  
  Fig 63: Rotating Manual Shaft
  Courtesy of MAZDA MOTORS CORP.
2. Turn the protrusion a resistance between the terminals B and C become 750 ohms.
  
  Fig 64: Identifying Protrusion
  Courtesy of MAZDA MOTORS CORP.
  
  Fig 65: Identifying TR Switch Terminal
  Courtesy of MAZDA MOTORS CORP.
3. Install the TR switch while aligning the protrusion and groove as shown.
4. hand-tighten the TR switch mounting bolts.
  
  Fig 66: Aligning Protrusion And Groove
  Courtesy of MAZDA MOTORS CORP.
5. Inspect the resistance between the terminals B and C.
  - If not as specified, readjust the TR switch.
  Resistance
  
  750 ohms
6. Tighten the TR switch mounting bolts
  
  Fig 67: Identifying TR Switch Terminal
  Courtesy of MAZDA MOTORS CORP.
  
  Tightening torque
  
  8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
  CAUTION:
  - Do not use an impact wrench. Hold the manual shaft lever when removing the manual shaft nut, or the transaxle may be damaged.
7. Install the manual shaft lever and the washer.
  
  Fig 68: View Of Manual Shaft Lever And Washer
  Courtesy of MAZDA MOTORS CORP.
8. Set the adjustable wrench as shown to hold the manual shaft lever, and tighten the manual shaft nut.
  Tightening torque
  
  32-46 N.m {3.2-4.7 kgf.m, 24-33 ft.lbf}
Fig 69: Holding Manual Shaft Lever
Courtesy of MAZDA MOTORS CORP.
Remove the transaxle from the SST.
Apply ATF to the new O-ring and install it to the oil filler tube.
Install the oil dipstick and oil filler tube to the transaxle.
Tightening torque

7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}
Drain any ATF remaining in the torque converter.
Pour in solvent (approx. 0.5 L {0.53 US qt, 0.44 Imp qt}).
Shake the torque converter to clean the inside.
Pour out the solvent.
Pour the ATF.
Install the torque converter by aligning its gap to the oil pump inner rotor gap as shown in the figure.

Fig 70: View Of Torque Converter
Courtesy of MAZDA MOTORS CORP.
To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing.
Between the end of the torque converter and the end of the converter housing

Distance A: 21.4 mm {0.84 in}

Fig 71: Measuring Distance Between End Of Torque Converter And End Of Converter Housing
Courtesy of MAZDA MOTORS CORP.