Transaxle - 2.3L: Overview

Fig 1: Identifying Torque Converter Pilot Hub

G04321570

Courtesy of MAZDA MOTORS CORP.

Lubricate the torque converter pilot hub with grease.

Fig 2: Torque Converter Holding Tool
Courtesy of MAZDA MOTORS CORP.
Install the special tool.

Fig 3: Identifying Position Transaxle In Place
Courtesy of MAZDA MOTORS CORP.
Position the transaxle in place.

Fig 4: Torque Converter Holding Tool
Courtesy of MAZDA MOTORS CORP.
Once the transaxle is in place, prior to bolting it to the engine, remove the special tool.

Fig 5: Installing Transaxle Bolt With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Move the transaxle assembly toward the engine assembly and install the bolt.

Fig 6: Tightening Transaxle Retaining Bolt With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the transaxle retaining bolt.

Fig 7: Installing Lower Transaxle Retaining Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the lower transaxle retaining bolts.

Fig 8: Installing Torque Converter And Nuts
Courtesy of MAZDA MOTORS CORP.
Install the four new torque converter nuts.
Tightening Torque:

40 Nm {4.1 kgf-m, 30 ft-lbf} (vehicles built through 9/2005)

Fig 9: Installing Rubber Access Cover
Courtesy of MAZDA MOTORS CORP.
Install the rubber access cover.

Fig 10: Installing Transaxle Fluid Cooler Tube With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the transaxle fluid cooler tube.

Fig 11: Installing Output Shaft Speed (OSS) Sensor
Courtesy of MAZDA MOTORS CORP.
Install the output shaft speed (OSS) sensor.
Tightening Torque:

12 Nm {1.2 kgf-m, 9 ft-lbf} (vehicles built through 9/2005)

Fig 12: Installing The Fluid Cooler Tube
Courtesy of MAZDA MOTORS CORP.
Install the fluid cooler tube.
1. Install the fluid cooler tube.
2. Install the bolt.
3. Connect the OSS sensor.
4. Connect the turbine shaft speed (TSS) sensor (white connector).
  
  Fig 13: Installing Starter Motor Isolator
  Courtesy of MAZDA MOTORS CORP.
Install the starter motor isolator.

Fig 14: Installing Starter Motor With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the starter motor.

Fig 15: Installing Starter Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the wire harness clip retainer and the ground wire to the starter bolts.

Fig 16: Installing Harness Terminals With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the harness terminals.

Fig 17: Installing Lower Rear Mount Bracket With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
If installing a new or remanufactured transaxle, install the lower rear mount bracket.

Fig 18: Tightening Upper Transaxle Mount Bolts And Nuts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the bolt and tighten the upper transaxle mount nuts.
1. Install the through bolt.
2. Install the mount nuts.
  
  Fig 19: Removing Special Tools
  Courtesy of MAZDA MOTORS CORP.
Remove the special tools.

Fig 20: Removing Special Tools
Courtesy of MAZDA MOTORS CORP.
Remove the special tools.

Fig 21: Removing Special Tools
Courtesy of MAZDA MOTORS CORP.
Remove the special tools.

Fig 22: Tightening Upper Transaxle Bolts
Courtesy of MAZDA MOTORS CORP.
Install the upper transaxle bolts.
Tightening Torque:

40 Nm {4.1 kgf-m, 30 ft-lbf} (vehicles built through 9/2005)

Fig 23: Connecting Transaxle Range (TR) Sensor Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Connect the transaxle range (TR) sensor electrical connector.

Fig 24: Connecting Shift Cable To Manual Lever With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Connect the shift cable to the manual lever and install the two bolts.

Fig 25: Installing Shift Cable Bracket With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the shift cable bracket, ground wires and plug in the bulkhead electrical connector.

Fig 26: Aligning Digital TR Sensor Using Special Tool With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
NOTE:
- If installing an exchange transaxle, the digital TR sensor must be aligned.
Using the special tool, align the digital TR sensor.

Fig 27: Tightening Rear Transaxle Mount Center Bolt With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the rear transaxle mount center bolt.
If the vehicle is not equipped with a power takeoff (PTO), install the dampener.

Fig 28: Installing PTO Assembly With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the PTO assembly.

Fig 29: Installing Driveshaft With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
If equipped with a PTO, install the driveshaft.

Fig 30: Installing Bracket With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the bracket.

Fig 31: Installing Exhaust-To-Engine Bracket Front Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the front bolts on the exhaust-to-engine bracket.

Fig 32: Installing Exhaust-To-Engine Bracket Rear Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the nuts on the rear of the exhaust-to-engine bracket.

Fig 33: Installing Exhaust Manifold And Nut With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the flexpipe on the exhaust manifold and install the nuts.

Fig 34: Installing Intermediate Shaft
Courtesy of MAZDA MOTORS CORP.
Install the intermediate shaft.

Fig 35: Installing Intermediate Shaft Retaining Nuts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the intermediate shaft retaining nuts.

Fig 36: Installing RH Halfshaft And Lower Control Arm Bolt With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the RH halfshaft and lower control arm bolt.

Fig 37: Installing LH Halfshaft In to Wheel Knuckle And Nut With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the LH halfshaft into the wheel knuckle and install a new nut.

Fig 38: Installing Cross Brace And Rear Nut
Courtesy of MAZDA MOTORS CORP.
Install the cross brace and the rear nut.
Tightening Torque:

150 Nm {15.3 kgf-m, 111 ft-lbf} (vehicles built through 9/2005)

Fig 39: Installing Motor Mount And Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the bolt for the motor mount and install the two bolts for the cross brace.

Fig 40: Installing Cross Brace With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the cross brace

Fig 41: Installing LH Splash Shield And Retainers
Courtesy of MAZDA MOTORS CORP.
Install the LH splash shield and the seven retainers.

Fig 42: Installing RH Splash Shield And Retainers
Courtesy of MAZDA MOTORS CORP.
Install the RH splash shield and the seven retainers.

Fig 43: Installing Vent Tube To Fluid Level Indicator
Courtesy of MAZDA MOTORS CORP.
Install the vent tube to the fluid level indicator.

Fig 44: Installing Air Cleaner Assembly
Courtesy of MAZDA MOTORS CORP.
Install the air cleaner assembly.
NOTE:
- Before installing the battery tray, check the vent tube hose for any obstructions, kinks or incorrect routing position.
Install the battery tray. See BATTERY TRAY - 2.3L .
Fill the transaxle with clean automatic transaxle fluid.
Check the fluid level and correct as necessary.