Mazda 6 2014 -Manual Transaxle Workshop Manual

WARNING

Servicing a vehicle can be dangerous. If you have not received

service-related training, the risks of injury, property damage, and

failure of servicing increase. The recommended servicing procedures

for the vehicle in this workshop manual were developed with

Mazda-trained technicians in mind. This manual may be useful to

non-Mazda trained technicians, but a technician with our

service-related training and experience will be at less risk when

performing service operations. However, all users of this manual are

expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks

not normally encountered in a general technician's experience.

They should be followed to reduce the risk of injury and the risk

that improper service or repair may damage the vehicle or render it

unsafe. It is also important to understand that the "Warnings" and

"Cautions" are not exhaustive. It is impossible to warn of all

the hazardous consequences that might result from failure to follow

the procedures.

The procedures recommended and described in this manual are

effective methods of performing service and repair. Some require tools

specifically designed for a specific purpose. Persons using procedures

and tools which are not recommended by Mazda Motor Corporation

must satisfy themselves thoroughly that neither personal safety nor

safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are

the latest available at the time of printing, and

Mazda Motor Corporation

reserves the right to change the vehicle designs and alter the contents

of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or

with parts which match the quality of genuine Mazda replacement

parts. Persons using replacement parts of lesser quality than that of

genuine Mazda replacement parts must satisfy themselves thoroughly

that neither personal safety nor safety of the vehicle will be

jeopardized.

Mazda Motor Corporation is not responsible for any problems which

may arise from the use of this manual. The cause of such problems

includes but is not limited to insufficient service-related training, use of

improper tools, use of replacement parts of lesser quality than that of

genuine Mazda replacement parts, or not being aware of any revision

of this manual.

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Title Section

GENERAL INFORMATION 00

TRANSMISSION/TRANSAXLE

05

CONTENTS

Manual

Transaxle

Workshop

Manual

C66M-R

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.

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

PRINTED IN U.S.A., JANUARY 2012

Form No. 1A09–1U–12A

Part No. 9999–95–C66M–12

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00

GENERAL INFORMATION

00-00–1

SECTION

00-00

Toc of SCT

GENERAL INFORMATION. . . .00-00

Toc of SCT

00-00 GENERAL INFORMATION

HOW TO USE THIS MANUAL . . . . . . . . . 00-00–2

Range of Topics . . . . . . . . . . . . . . . . . .00-00–2

Service Procedure . . . . . . . . . . . . . . . .00-00–2

Symbols . . . . . . . . . . . . . . . . . . . . . . . .00-00–4

Advisory Messages. . . . . . . . . . . . . . . . 00-00–4

UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-00–5

Conversion From SI Units

(Système International d'Unités). . . . .00-00–5

Number Of Digits For

Converted Values . . . . . . . . . . . . . . . . 00-00–5

Converted Value Rounding

Off And Rounding Up/down . . . . . . . .00-00–5

ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–5

FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6

Preparation of Tools and

Measuring Equipment . . . . . . . . . . . . 00-00–6

Special Service Tools. . . . . . . . . . . . . . 00-00–6

Disassembly. . . . . . . . . . . . . . . . . . . . . 00-00–6

Inspection During

Removal, Disassembly. . . . . . . . . . . . 00-00–6

Arrangement of Parts. . . . . . . . . . . . . . 00-00–7

Cleaning of Parts . . . . . . . . . . . . . . . . . 00-00–7

Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–7

Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–8

Rubber Parts and Tubing . . . . . . . . . . . 00-00–8

Torque Formulas . . . . . . . . . . . . . . . . . 00-00–8

Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–8

End of Toc

WM: GENERAL INFORMATION

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GENERAL INFORMATION

00-00–2

HOW TO USE THIS MANUAL

id000000000100

Range of Topics

• This manual contains procedures for performing all required service operations. The procedures are divided

into the following basic operations:

— Removal/Installation

— Disassembly/Assembly

— Replacement

— Inspection

— Adjustment

• Simple operations which can be performed easily just by looking at the actual unit (i.e., removal/installation of

parts, 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

location and contents of the procedures are

explained in detail and shown in the illustrations.

49 H002 671

49 H032 322

49 1232 670A

SHOWS PROCEDURE ORDER

FOR SERVICE

Fluid Pressure Inspection

1. Assemble the SSTs as shown in the figure.

Tightening torque

SHOWS TIGHTENING

TORQUE

SPECIFICATIONS

Caution

Connect the gauge set from under

the vehicle to prevent contact with

the drive belt and the cooling fan.

39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

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GENERAL INFORMATION

00-00–3

00-00

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.

GREASE

SHOWS NON-REUSEABLE PARTS

SHOWS DETAILS

KNUCKLE

UPPER TRAILING LINK

LOWER TRAILING LINK

SST

R

9

2

1

4

5

3

6

1

2

8

7

12

10

11

N·m {kgf·m, ft·lbf}

118—156 {12.0—16.0, 87—115}

94—116 {9.5—11.9, 69—86}

43—56 {4.3—5.8, 32—41}

49 T028 304

49 T028 305

49 T028 303

Procedure

LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION

1. Jack up the rear of the vehicle and support it with safety stands.

2. Remove the undercover. (See 01-10-4 Undercover Removal)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Inspect the rear wheel alignment and adjust it if necessary.

1

Split pin

2

Nut

3

Lower trailing link ball joint

4

(See 02-14-5 Lower Trailing Link Ball Joint Removal Note)

Bolt

5

Lower trailing link

6

Dust boot (lower trailing link)

7

Split pin

8 Nut

9 Upper trailing link ball joint

(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)

10

Nut

11

Upper trailing link

12

Dust boot (upper trailing link)

Lower Trailing Link Ball Joint, Upper Trailing Link

Ball Joint Removal Note

Remove the ball joint using the SSTs.

—

44—60 {4.4—6.2, 32—44}

"Removal/Installation"

Portion

"Inspection After

Installation" Portion

INSTALL THE PARTS BY

PERFORMING STEPS

1—3 IN REVERSE ORDER

SHOWS PROCEDURE ORDER

FOR SER

VICE

SHO

WS TIGHTENING

TORQUE

SPECIFICATIONS

SHOWS SERVICE

ITEM (S)

INDICATES ANY RELEVANT

REFERENCES WHICH

NEED

T

O BE FOLLOWED DURING

INSTALLATION

SHOWS SPECIAL

SERVICE TOOL (SST)

FOR SERVICE OPERATION

SHOWS APPLICATION

POINTS OF GREASE, ETC.

SHOWS TIGHTENING

TORQUE UNITS

SHOWS SPECIAL

SERVICE TOOL (SST)

NO.

SHOWS REFERRAL

NOTES FOR

SER

VICE

SHOWS THERE

ARE REFERRAL

NOTES FOR SERVICE

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GENERAL INFORMATION

00-00–4

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.

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

Symbol Meaning Kind

Apply oil New appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle/

transmission fluid

New appropriate automatic

transaxle/

transmission fluid

Apply grease Appropriate grease

Apply sealant

Appropriate

sealant

Apply petroleum jelly

Appropriate

petroleum jelly

Replace part O-ring, gasket, etc.

Use SST or

equivalent

Appropriate tools

OIL

BRAKE

FLUID

ATF

GREASE

SEALANT

P

R

SST

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GENERAL INFORMATION

00-00–5

00-00

UNITS

id000000100400

Conversion From 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.

Number Of Digits For Converted Values

• The number digits for converted values is the same as the number of significant figures

*1

of the SI unit.

• For the torque value, the number of significant figures is, in principle, is 2 digits, in consideration of market

practicalities. However, if the number of decimal places at the upper and lower limits of the converted value

differs, the one with least number of decimal places is used. In addition, if the integer part is 3 digits or more,

the integer part becomes the significant number of figures.

*1 : The number of significant figures is the number of digits from the left-most non-zero digit to the right-most digit

including 0. (Example: 0.12 is 2 digits, 41.0 is 3 digits)

Converted Value Rounding Off And Rounding Up/down

• If there is no tolerance in the SI unit value, after conversion, rounding off is to within the number of significant

digits.

• If there is tolerance in the SI unit value and the figure after conversion indicates the upper limit, the number of

digits is rounded down to within the number of significant figures. If it indicates the lower limit, they are rounded

up to within the number of significant figures.

• Even if the SI unit value is the same, the converted value may differ based on whether that value is the upper or

lower limit.

End Of Sie

ABBREVIATIONS

id000000010100

End Of Sie

GAIHAN: -

Electric current A (ampere)

Electric power W (watt)

Electric resistance ohm

Electric voltage V (volt)

Length

mm (millimeter)

in (inch)

Negative pressure

kPa (kilo pascal)

mmHg (millimeters of mercury)

inHg (inches of mercury)

Positive pressure

kPa (kilo pascal)

kgf/cm

2

(kilogram force per square centimeter)

psi (pounds per square inch)

Number of revolutions rpm (revolutions per minute)

Tor qu e

N·m (Newton meter)

kgf·m (kilogram force meter)

kgf·cm (kilogram force centimeter)

ft·lbf (foot pound force)

in·lbf (inch pound force)

Volume

L (liter)

US qt (U.S. quart)

Imp qt (Imperial quart)

ml (milliliter)

cc (cubic centimeter)

cu in (cubic inch)

fl oz (fluid ounce)

Weight

g (gram)

oz (ounce)

MTX Manual Transaxle

SST Special Service Tool

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GENERAL INFORMATION

00-00–6

FUNDAMENTAL PROCEDURES

id000000750100

Preparation of Tools and Measuring Equipment

• Be sure that all necessary tools and measuring

equipment are available before starting any work.

Special Service Tools

• Use special service tools or equivalent when they

are required.

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.

Inspection During Removal, Disassembly

• When removed, each part should be carefully

inspected for malfunction, deformation, damage

and other problems.

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49 SE01 310

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GENERAL INFORMATION

00-00–7

00-00

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.

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.

Reassembly

• Standard values, such as torques and certain

adjustments, must be strictly observed in the

reassembly of all parts.

• If removed, the following parts should be replaced

with new ones:

— Oil seals

— Gaskets

— O-rings

— Lockwashers

— Cotter pins

— Nylon nuts

• 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.

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GENERAL INFORMATION

00-00–8

Adjustment

• Use suitable gauges and testers when making

adjustments.

Rubber Parts and Tubing

• Prevent gasoline or oil from getting on rubber

parts or tubing.

Torque Formulas

• When using a torque wrench-SST or equivalent

combination, the written torque must be

recalculated due to the extra length that the SST

or equivalent adds to the torque wrench.

Recalculate the torque by using the following

formulas. Choose the formula that applies to you.

A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.

Vise

• When using a vise, put protective plates in the

jaws of the vise to prevent damage to parts.

End Of Sie

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Torque Unit Formula

N·m N·m × [L/(L+A)]

kgf·m kgf·m × [L/(L+A)]

kgf·cm kgf·cm × [L/(L+A)]

ft·lbf ft·lbf × [L/(L+A)]

in·lbf in·lbf × [L/(L+A)]

0

1

2

3

SST

A

L

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PROTECTIVE PLATES

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05-15–1

05

TRANSMISSION/TRANSAXLE

SECTION

05-15

Toc of SCT

MANUAL TRANSAXLE . . . . . .05-15

TECHNICAL DATA . . . . . . . . . .05-50

SERVICE TOOLS. . . . . . . . . . . 05-60

Toc of SCT

05-15 MANUAL TRANSAXLE

PRECAUTION. . . . . . . . . . . . . . . . . . . . . .05-15–2

Service Caution. . . . . . . . . . . . . . . . . . .05-15–2

TRANSAXLE DISASSEMBLY . . . . . . . . . 05-15–3

Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–3

Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–5

TRANSAXLE CASE AND CLUTCH

HOUSING DISASSEMBLY. . . . . . . . . . .05-15–6

Oil Path Removal Note . . . . . . . . . . . . .05-15–7

Oil Seal Removal Note . . . . . . . . . . . . .05-15–7

Bearing Outer Race

(Differential) Removal Note. . . . . . . . .05-15–7

SHIFT CONTROL MODULE

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-15–8

Pin Removal Note . . . . . . . . . . . . . . . . .05-15–9

Clip Removal Note . . . . . . . . . . . . . . . .05-15–10

SHIFT CONTROL

MODULE ASSEMBLY . . . . . . . . . . . . . .05-15–11

Oil Seal Assembly Note . . . . . . . . . . . .05-15–12

Clip Assembly Note. . . . . . . . . . . . . . . .05-15–12

Pin Assembly Note . . . . . . . . . . . . . . . . 05-15–12

REVERSE IDLER GEAR COMPONENT

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-15–14

REVERSE IDLER GEAR COMPONENT

INSPECTION . . . . . . . . . . . . . . . . . . . . .05-15–15

Reverse idler gear inspection . . . . . . . .05-15–15

Synchronizer ring inspection. . . . . . . . .05-15–15

Clutch hub component inspection. . . . .05-15–15

REVERSE IDLER GEAR

COMPONENT ASSEMBLY . . . . . . . . . . 05-15–16

Clutch Hub Sleeve Assembly Note . . . .05-15–17

Shim Assembly Note. . . . . . . . . . . . . . .05-15–17

PRIMARY SHAFT COMPONENT

PREINSPECTION. . . . . . . . . . . . . . . . . . 05-15–18

3rd Gear Thrust

Clearance Inspection . . . . . . . . . . . . .05-15–18

4th Gear Thrust

Clearance Inspection . . . . . . . . . . . . .05-15–18

5th Gear Thrust

Clearance Inspection . . . . . . . . . . . . .05-15–18

6th Gear Thrust

Clearance Inspection . . . . . . . . . . . . .05-15–19

PRIMARY SHAFT

COMPONENT DISASSEMBLY . . . . . . .05-15–20

Ball Bearing (Transaxle Case Side)

Removal Note . . . . . . . . . . . . . . . . . . . 05-15–21

Clutch Hub (3GR/4GR)

Removal Note . . . . . . . . . . . . . . . . . . . 05-15–21

Clutch Hub (5GR/6GR)

Removal Note. . . . . . . . . . . . . . . . . . . 05-15–21

Ball Bearing (Clutch Housing Side)

Removal Note. . . . . . . . . . . . . . . . . . . 05-15–22

PRIMARY SHAFT

COMPONENT INSPECTION. . . . . . . . . 05-15–22

Gear Inspection . . . . . . . . . . . . . . . . . . 05-15–22

Primary Shaft Inspection . . . . . . . . . . . 05-15–22

Synchronizer Ring Inspection. . . . . . . . 05-15–23

Clutch Hub Component Inspection. . . . 05-15–23

PRIMARY SHAFT

COMPONENT ASSEMBLY . . . . . . . . . . 05-15–24

Ball Bearing (Clutch Housing Side)

Assembly Note. . . . . . . . . . . . . . . . . . 05-15–25

Clutch Hub (5GR/6GR)

Assembly Note. . . . . . . . . . . . . . . . . . 05-15–25

Clutch Hub Sleeve Assembly Note. . . . 05-15–25

Synchronizer Key Assembly Note . . . . 05-15–26

Synchronizer Ring Assembly Note. . . . 05-15–26

Clutch Hub (3GR/4GR)

Assembly Note

. . . . . . . . . . . . . . . . . . 05-15–27

Ba

ll Be

aring (Transaxle Case Side)

Assembly Note. . . . . . . . . . . . . . . . . . 05-15–27

SECONDARY SHAFT COMPONENT

PREINSPECTION . . . . . . . . . . . . . . . . . 05-15–27

Secondary 1st Gear Thrust

Clearance Inspection . . . . . . . . . . . . . 05-15–27

Secondary 2nd Gear Thrust

Clearance Inspection . . . . . . . . . . . . . 05-15–27

SECONDARY SHAFT COMPONENT DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–28

Tapered Roller Bearing

(Transaxle Case Side), Secondary

4th Gear Removal Note . . . . . . . . . . . 05-15–29

Secondary 3rd Gear, Secondary

6th Gear Removal Note . . . . . . . . . . . 05-15–29

Secondary 5th Gear Removal Note. . . 05-15–29

Tapered Roller Bearing

(Clutch Housing Side)

Removal Note. . . . . . . . . . . . . . . . . . . 05-15–30

SECONDARY SHAFT

COMPONENT INSPECTION. . . . . . . . . 05-15–30

Gear Inspection . . . . . . . . . . . . . . . . . . 05-15–30

Gear sleeve inspection. . . . . . . . . . . . . 05-15–30

Secondary Shaft Inspection. . . . . . . . . 05-15–31

Synchronizer Ring Inspection. . . . . . . . 05-15–31

Clutch Hub Component Inspection. . . . 05-15–32

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MANUAL TRANSAXLE

05-15–2

SECONDARY SHAFT

COMPONENT ASSEMBLY . . . . . . . . . .05-15–32

Middle Cone Ring Assembly Note . . . .05-15–33

Synchronizer Ring

(Secondary 1st Gear)

Assembly Note . . . . . . . . . . . . . . . . . . 05-15–34

Clutch Hub Assembly Note. . . . . . . . . .05-15–34

Gear Sleeve Assembly Note. . . . . . . . . 05-15–35

Secondary Shaft Assembly Note . . . . .05-15–35

Clutch Hub Sleeve Assembly Note . . . .05-15–36

Synchronizer Key Assembly Note. . . . .05-15–37

Synchronizer Ring

(Secondary 2nd Gear)

Assembly Note . . . . . . . . . . . . . . . . . . 05-15–37

Secondary 2nd Gear

Assembly Note . . . . . . . . . . . . . . . . . . 05-15–37

Friction Damper (Secondary 2nd Gear)

Assembly Note . . . . . . . . . . . . . . . . . . 05-15–38

Secondary 5th Gear Assembly Note. . .05-15–38

Secondary 6th Gear and Secondary

3rd Gear Assembly Note. . . . . . . . . . .05-15–39

Secondary 4th Gear Assembly Note. . .05-15–39

Tapered Roller Bearing

Assembly Note . . . . . . . . . . . . . . . . . . 05-15–39

DIFFERENTIAL BACKLASH

ADJUSTMENT . . . . . . . . . . . . . . . . . . . .05-15–40

Thrust Washer

Selection Calculation . . . . . . . . . . . . . 05-15–42

DIFFERENTIAL DISASSEMBLY. . . . . . . 05-15–43

Tapered Roller Bearing

Removal Note. . . . . . . . . . . . . . . . . . . 05-15–44

Ring Gear Removal Note . . . . . . . . . . . 05-15–44

Pin Removal Note . . . . . . . . . . . . . . . . 05-15–45

DIFFERENTIAL ASSEMBLY. . . . . . . . . . 05-15–45

Pin Assembly Note. . . . . . . . . . . . . . . . 05-15–46

Ring Gear Assembly Note . . . . . . . . . . 05-15–46

Tapered Roller Bearing

Installation Note . . . . . . . . . . . . . . . . . 05-15–47

BEARING PRELOAD ADJUSTMENT. . . 05-15–47

Primary Shaft Preload Adjustment. . . . 05-15–47

Secondary Shaft

Preload Adjustment . . . . . . . . . . . . . . 05-15–51

Differential Preload Adjustment . . . . . . 05-15–55

TRANSAXLE CASE AND

CLUTCH HOUSING ASSEMBLY . . . . . 05-15–59

Bearing Outer Race

(Differential) Assembly Note. . . . . . . . 05-15–59

Oil Seal Assembly Note . . . . . . . . . . . . 05-15–60

TRANSAXLE ASSEMBLY. . . . . . . . . . . . 05-15–60

Step 1. . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–60

Step 2. . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–66

End of Toc

OHM: C66 MANUAL TRANSA XLE

PRECAUTION

id051500168000

Warning

• Always wear protective eye wear when using compressed air. Otherwise, dirt particles blown off

by compressed air could get into the eyes.

Service Caution

Disassembly

1. Clean the outside of the transaxle using steam and/or degreaser before disassembly.

2. To prevent dust penetration into the transaxle, perform the disassembly in a dust free environment.

3. Clean the disassembled parts using degreaser and dry them using compressed air.

4. Clean the oil holes and oil grooves using compressed air and verify that they are not plugged.

5. Always wear protective eye wear when using compressed air.

6. When disassembling a connecting part of a light-alloy part for the transaxle case, use a plastic hammer.

7. Organize and store the disassembled parts to protect them from dirt.

8. If using a vise, always secure the component using an aluminum plate to prevent component damage.

9. Disassemble while verifying damage, cracks, deformation, scratches, and the assembly condition of each part.

Cleaning

1. Thoroughly wash the exterior of the transaxle using steam or degreaser before disassembly.

2. Clean the removed parts using degreaser and dry them using compressed air. Clean the oil holes and oil

passages using compressed air.

Assembly

1. Before assembly, verify that each part is clean and dried.

2. Apply a sufficient amount of the specified oil (SAE 75W-80, API service GL-4) to moving parts and sliding

surfaces when performing assembly.

3. For parts such as gaskets, springs, or pins which are designated for replacement with every disassembly,

always use a new part.

4. Clean off remaining silicone sealant before applying new silicone sealant.

5. After applying silicone sealant, install the transaxle case before the applied silicone sealant starts to harden,

and wait for 30 min or more before adding oil.

6. When using a vise, always secure the component using an aluminum plate to prevent component damage.

End Of Sie

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MANUAL TRANSAXLE

05-15–3

05-15

TRANSAXLE DISASSEMBLY

id051500168100

Step 1

1. Assemble the SST (49 G019 0A0) to the SST (49

0107 680A).

Bolt used

Part No.: 9YA02 A220 or M12×1.75 length 40

mm {1.6 in}

Tightening torque

88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}

2. Assemble the MTX to the SST.

Bolt A

Part No.: 99450 1055 or M10×1.25 length 55

mm {2.2 in}, and nut (M10×1.25)

Bolt A tightening torque

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

Bolt B

SST (49 G019 033 part of 49 G019 0A0)

Bolt B tightening torque

88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}

Bolt C

Part No.: 9YA02 1080 or M10×1.5 length 55

mm {2.2 in}

Bolt C tightening torque

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

Bolt D

Part No.: 99450 1030 or M10×1.25 length 30

mm {2.2 in}

Bolt D tightening torque

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

49 G019 0A0

49 0107 680A

bc61um00000001

49 G019 0A0

A

C

D

B

bc61um00000126

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MANUAL TRANSAXLE

05-15–4

3. Remove the parts around the MTX using the procedure shown in the figure..

2

1

9

8

7

5

4

3

10

6

R

17

16

R

13

11

18

12

R

15

R

14

17

R

bc61um00000127

1Breather

2 Neutral switch

3Gasket

4Plug

5Gasket

6Spring

7 Detent ball pin

8 Back-up light switch

9Gasket

10 Shift control module

11 O-ring

12 Oil level plug

13 Gasket

14 Reverse gear shaft anchor bolt

15 Drain plug

16 Gasket

17 Oil seal

18 Stud bolt

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MANUAL TRANSAXLE

05-15–5

05-15

Step 2

1. Disassemble the MTX in the order shown in the figure.

.

2. Remove the silicone sealant of the transaxle case component and clutch housing component, and clean all the

parts.

A

11

A

9

8

B

C

D

C

D

6

2

1

3

5

R

2

4

5

6

7

10

12

13

SELECTIVE

bc61um00000004

1

Transaxle case component

(See 05-15-6 Transaxle case component removal

note.)

2Shim

3 Bearing outer race

4 Magnet

5 Shift rod

6 Shift rod end

7 Shift fork

8 Oil path

9 Reverse idler gear component

10

Primary shaft component

(See 05-15-6 Primary shaft component, secondary

shaft component removal note.)

11 Secondary shaft component

(See 05-15-6 Primary shaft component, secondary

shaft component removal note.)

12 Differential

13 Clutch housing component

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MANUAL TRANSAXLE

05-15–6

Transaxle case component removal note

1. Tap the locations shown in the figure using a

plastic hammer to remove the transaxle case

component.

Primary shaft component, secondary shaft component removal note

1. Remove the primary shaft component and

secondary shaft component as a single unit.

End Of Sie

TRANSAXLE CASE AND CLUTCH HOUSING DISASSEMBLY

id051500168200

1. Disassemble the transaxle case component and clutch housing component in the order shown in the figure.

.

bc61um00000005

SECONDARY SHAFT

COMPONENT

PRIMARY SHAFT

COMPONENT

bc61um00000006

SST

1

6

4

3

2

SST

5

R

6

A

9

8

7

10

7

SELECTIVE

bc61um00000161

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MANUAL TRANSAXLE

05-15–7

05-15

Oil Path Removal Note

1. Remove the oil path.

2. As shown in the figure, verify that the oil path

connection area is not broken.

• If the oil path connection area is broken,

replace the oil path.

Oil Seal Removal Note

1. Remove the oil seal using a flathead screwdriver.

Bearing Outer Race (Differential) Removal Note

1. Remove the bearing outer race (differential) from

the transaxle case using the SST.

1

Oil path

(See 05-15-7 Oil Path Removal Note.)

2 Funnel

3

Oil seal

(See 05-15-7 Oil Seal Removal Note.)

4 Bearing outer race

5 Funnel

6 Dowel pin

7

Bearing outer race (differential)

(See 05-15-7 Bearing Outer Race (Differential)

Removal Note.)

8Shim

9 Transaxle case

10 Clutch housing

OIL PATH

bc61um00000167

OIL SEAL

FLATHEAD

SCREWDRIVER

bc61um00000168

49 W032 2A0

BEARING

OUTER RACE

TRANSAXLE CASE

bc61um00000008

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MANUAL TRANSAXLE

05-15–8

2. Remove the bearing outer race (differential) from

the clutch housing using the SST.

End Of Sie

SHIFT CONTROL MODULE DISASSEMBLY

id051500170100

1. Disassemble the shift control module in the order shown in the figure.

.

49 W032 2A0

BEARING

OUTER RACE

CLUTCH HOUSING

bc61um00000011

A

R

8

14

13

11

12

1

9

7

5

4

3

10

6

2

R

bc61um00000102

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MANUAL TRANSAXLE

05-15–9

05-15

Pin Removal Note

1. Secure the shift control module in a vise.

2. Mark the switch pin and interlock sleeve.

Note

• The switch pin has a particular installation

direction.

3. Remove the pin (switch pin) using a punch.

1Select lever

2

(See 05-15-9 Pin Removal Note.)

3

Clip

(See 05-15-10 Clip Removal Note.)

4 Spring seat

5Spring

6 Washer

7 Switch pin

8 Shift lever

9 Interlock sleeve

10 Control lever component

11 Holder plate

12 Guide plate

13 Oil seal

14 Control case

SHIFT CONTROL MODULE

VISE

bc61um00000103

MARK

INTERLOCK

SLEEVE

SWITCH PIN

bc61um00000125

PUNCH

VISE

SWITCH PIN

bc61um00000105

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Mazda 6 2014 -Manual Transaxle Workshop Manual

Mazda 6 2014 -Manual Transaxle Workshop Manual

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