Transaxle - Assembly

Fig 1: Exploded View Of Transaxle Assembly (1 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 2: Exploded View Of Transaxle Assembly (2 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 3: Exploded View Of Transaxle Assembly (3 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 4: Exploded View Of Transaxle Assembly (4 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 5: Exploded View Of Transaxle Assembly (5 Of 5)

Courtesy of MAZDA MOTORS CORP.

Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.

Fig 6: Identifying Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Assemble the Handle and Seal Installer. Install a new LH seal on the Seal Installer.

Fig 7: Identifying Handle And Seal Installer
Courtesy of MAZDA MOTORS CORP.
Using the Seal Installer 307-626 and Handle 205-153, install the halfshaft seal in the transaxle case.

Fig 8: Installing Halfshaft Seal In Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install a new manual control shaft seal on Manual Lever Seal Installer.

Fig 9: Identifying Manual Lever Seal Installer
Courtesy of MAZDA MOTORS CORP.
Using the Manual Lever Seal Installer, install the manual control shaft seal in the transaxle case.

Fig 10: View Of Installing Manual Control Shaft Seal In Transaxle Case
Courtesy of MAZDA MOTORS CORP.
If not previously installed, install the clutch support tower and the 3 bolts.
- Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
  
  Fig 11: Locating Clutch Support Tower And Bolts
  Courtesy of MAZDA MOTORS CORP.
Remove Input Shaft Support Seal Installer.

Fig 12: View Of Removing Input Shaft Support Seal Installer
Courtesy of MAZDA MOTORS CORP.
Install Clutch Piston Seal Protector.

Fig 13: Identifying Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Lubricate the seals on the intermediate (2, 6) clutch piston with clean transaxle fluid.

Fig 14: Locating Seals
Courtesy of MAZDA MOTORS CORP.
Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.
CAUTION:
- Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.
  
  Fig 15: Locating Intermediate (2, 6) Clutch Piston
  Courtesy of MAZDA MOTORS CORP.
Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
1. Outer tabs.
2. Open area at the bottom of the transaxle case.
3. Bleed hole.
4. Inner double tabs.
  
  Fig 16: Identifying Outer Tabs, Bleed Hole And Inner Double Tabs
  Courtesy of MAZDA MOTORS CORP.
Remove the intermediate (2, 6) clutch piston return spring.

Fig 17: Locating Intermediate (2, 6) Clutch Piston Return Spring
Courtesy of MAZDA MOTORS CORP.
Install 2-6 Spring Compressor on the intermediate (2, 6) clutch piston.

Fig 18: Locating 2-6 Spring Compressor On Intermediate (2, 6) Clutch Piston
Courtesy of MAZDA MOTORS CORP.
Using 2-6 Spring Compressor, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.

Fig 19: Pushing Intermediate (2, 6) Clutch Piston Into Clutch Cylinder
Courtesy of MAZDA MOTORS CORP.
Remove 2-6 Spring Compressor and Clutch Piston Seal Protector.

Fig 20: Identifying 2-6 Spring Compressor And Clutch Piston Seal Protector
Courtesy of MAZDA MOTORS CORP.
Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
1. Outer tabs.
2. Outer tabs.
3. Inner double tabs.
  CAUTION:
  - Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.
    
    Fig 21: Identifying Outer Tabs And Inner Double Tabs
    Courtesy of MAZDA MOTORS CORP.
Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
1. Snap ring
2. Snap ring gap
3. low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transaxle case)
  CAUTION:
  - Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.
    
    Fig 22: Identifying Snap Ring Gap
    Courtesy of MAZDA MOTORS CORP.
Install Snap Ring Installer on the transaxle case to center the intermediate (2, 6) clutch return spring.

Fig 23: Identifying Snap Ring Installer On Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install Snap Ring Installer on the snap ring.

Fig 24: Identifying Snap Ring Installer On Snap Ring
Courtesy of MAZDA MOTORS CORP.
Install Forward Clutch Spring Compressor on the transaxle case.

Fig 25: Identifying Forward Clutch Spring Compressor On Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Using Forward Clutch Spring Compressor and Snap Ring Installer, install the intermediate (2, 6) clutch snap ring in the groove
CAUTION:
- Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.
  
  Fig 26: Using Special Tool To Install Intermediate (2, 6) Clutch Snap Ring In Groove
  Courtesy of MAZDA MOTORS CORP.
Remove Forward Clutch Spring Compressor and Snap Ring Installer.

Fig 27: Using Special Tool To Remove Forward Clutch Spring Compressor And Snap Ring Installer
Courtesy of MAZDA MOTORS CORP.
Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool.

Fig 28: Locating Intermediate (2, 6) Clutch Apply Ring
Courtesy of MAZDA MOTORS CORP.
Install the No. 1 thrust bearing with the flat side facing up.
CAUTION:
- Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.
  
  Fig 29: Locating No. 1 Thrust Bearing
  Courtesy of MAZDA MOTORS CORP.
Install the overdrive/direct clutch assembly.

Fig 30: Identifying Overdrive/Direct Clutch Assembly
Courtesy of MAZDA MOTORS CORP.
Install the No. 3 thrust bearing with the flat side facing down.
CAUTION:
- Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.
  
  Fig 31: Identifying No. 3 Thrust Bearing
  Courtesy of MAZDA MOTORS CORP.
Install the direct/intermediate clutch hub and rear sun gear assembly.

Fig 32: Locating Direct/Intermediate Clutch Hub And Rear Sun Gear Assembly
Courtesy of MAZDA MOTORS CORP.
Install the intermediate (2, 6) wave spring assembly.

Fig 33: Locating Intermediate (2, 6) Wave Spring Assembly
Courtesy of MAZDA MOTORS CORP.
Soak the intermediate (2, 6) clutch assembly in clean transaxle fluid.

Fig 34: Identifying Intermediate (2, 6) Clutch Assembly In Clean Transaxle Fluid
Courtesy of MAZDA MOTORS CORP.
Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement

Fig 35: Locating Intermediate (2, 6) Clutch Assembly
Courtesy of MAZDA MOTORS CORP.
Install Shim Selection Gauge on the transaxle case.

Fig 36: Installing Shim Selection Gauge On Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim Selection Gauge to the top of the intermediate (2, 6) clutch pack at 3 different points. Average the 3 distances.

Fig 37: Measuring Distance From Shim Selection Gauge To Top Of Intermediate (2, 6) Clutch Pack Different Points
Courtesy of MAZDA MOTORS CORP.
Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the top of the transaxle case step above the intermediate (2, 6) clutch.

Fig 38: Measuring Distance From Top Of Shim Selection Gauge To Top Of Transaxle Case Step Above Intermediate (2, 6) Clutch
Courtesy of MAZDA MOTORS CORP.

Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.0094 in) and 2.60 mm (0.1024 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.

MEASUREMENT REFERENCE

Description	Reading
Measurement B
Measurement A

Subtract measurement A from measurement B and check to see if it is within range of 0.240 mm (0.0094 in) and 2.60 mm (0.1024 in).

Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.
NOTE:
- When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
  
  Fig 39: Identifying Steel Plate
  Courtesy of MAZDA MOTORS CORP.
Install the OWC assembly.

Fig 40: Identifying OWC Assembly
Courtesy of MAZDA MOTORS CORP.
Install the rear planetary carrier/center ring gear assembly.

Fig 41: Identifying Rear Planetary Carrier/Center Ring Gear Assembly
Courtesy of MAZDA MOTORS CORP.
Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC and install the low/reverse pressure plate.
NOTE:
- Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC.
  
  Fig 42: Locating Low/Reverse Pressure Plate
  Courtesy of MAZDA MOTORS CORP.
Soak the low/reverse clutch in clean automatic transaxle fluid.

Fig 43: Identifying Low/Reverse Clutch
Courtesy of MAZDA MOTORS CORP.
Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case temporarily reversing the wave spring and top steel plate.

Fig 44: Aligning Low/Reverse Clutch Pack
Courtesy of MAZDA MOTORS CORP.
Install Shim Selection Gauge on the side of the center support with the long support legs.

Fig 45: Identifying Shim Selection Gauge On Side Of Center Support With Long Support Legs
Courtesy of MAZDA MOTORS CORP.
Using a suitable depth gauge, measure and record as measurement A, the distance from the top of Shim Selection Gauge to the top contact surface of the low/reverse clutch piston.

Fig 46: Measuring Distance From Top Of Shim Selection Gauge To Top Contact Surface Of Low/Reverse Clutch Piston
Courtesy of MAZDA MOTORS CORP.
Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the leg surface of the center support.

Fig 47: Measuring Distance From Top Of Shim Selection Gauge To Leg Surface Of Center Support
Courtesy of MAZDA MOTORS CORP.

Subtract measurement B from measurement A and record as measurement C.

MEASUREMENT REFERENCE

Description	Reading
Measurement A
Measurement B

Install Shim Selection Gauge on the transaxle case.

Fig 48: Identifying Shim Selection Gauge On Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Using a suitable depth micrometer, measure and record as measurement D, the distance from the Shim Selection Gauge to the top of the OWC.

Fig 49: Measuring Distance From Shim Selection Gauge To Top Of OWC
Courtesy of MAZDA MOTORS CORP.
Using a suitable depth gauge, measure and record as measurement E, the distance from the top of Shim Selection Gauge to the top of the low/reverse clutch at 3 different points and average the 3 distances.

Fig 50: Measuring Distance From Top Of Shim Selection Gauge To Top Of Low/Reverse Clutch Different Points
Courtesy of MAZDA MOTORS CORP.

Subtract measurement E from measurement D and record as measurement F.

MEASUREMENT REFERENCE

Description	Reading
Measurement D
Measurement E

Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.0165 in) and 2.000 mm (0.0787 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.

MEASUREMENT REFERENCE

Description	Reading
Measurement C
Measurement F
Measurement F

Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.0165 in) and 2.000 mm (0.0787 in).

Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case
NOTE:
- When the low/reverse clutch is correctly installed, the wave spring is on top.
  
  Fig 51: Identifying Low/Reverse Clutch Steel Plate
  Courtesy of MAZDA MOTORS CORP.
Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transaxle case.
1. Long center support legs face down.
2. Feed holes face the front of the transaxle case.
  NOTE:
  - Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transaxle.
    
    Fig 52: Aligning Feed Holes In Transaxle Case
    Courtesy of MAZDA MOTORS CORP.
Install the No. 5 and No. 6 thrust bearings.
1. No. 5 thrust bearing.
2. No. 6 thrust bearing.
  
  Fig 53: Identifying No. 5 And No. 6 Thrust Bearings
  Courtesy of MAZDA MOTORS CORP.
Install the center sun gear.

Fig 54: Locating Center Sun Gear
Courtesy of MAZDA MOTORS CORP.
Install the center carrier/front ring gear assembly.

Fig 55: Locating Center Carrier/Front Ring Gear Assembly
Courtesy of MAZDA MOTORS CORP.
Install the No. 7 and No. 8 thrust bearings.
1. No. 7 thrust bearing.
2. No. 8 thrust bearing.
  
  Fig 56: Locating No. 7 And No. 8 Thrust Bearings
  Courtesy of MAZDA MOTORS CORP.
Install the front planetary/rear ring gear assembly.

Fig 57: Locating Front Planetary/Rear Ring Gear Assembly
Courtesy of MAZDA MOTORS CORP.
Install the forward (1, 2, 3, 4) clutch wave spring.

Fig 58: Locating Forward (1, 2, 3, 4) Clutch Wave Spring
Courtesy of MAZDA MOTORS CORP.
Soak the forward (1, 2, 3, 4) clutch pack in clean automatic transaxle fluid.

Fig 59: Locating Forward (1, 2, 3, 4) Clutch Pack In Clean Automatic Transaxle Fluid
Courtesy of MAZDA MOTORS CORP.
Install the forward (1, 2, 3, 4) clutch pack.

Fig 60: Locating Forward (1, 2, 3, 4) Clutch Pack
Courtesy of MAZDA MOTORS CORP.
Install the forward (1, 2, 3, 4) clutch pressure plate.

Fig 61: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate
Courtesy of MAZDA MOTORS CORP.
Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle.
1. Forward (1, 2, 3, 4) clutch snap ring.
2. Forward (1, 2, 3, 4) clutch snap ring gap.
  CAUTION:
  - Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transaxle.
    
    Fig 62: Identifying Clutch Snap Ring Gap
    Courtesy of MAZDA MOTORS CORP.
Using a suitable tool, seat the snap ring in the snap ring groove.

Fig 63: Setting Snap Ring In Snap Ring Groove
Courtesy of MAZDA MOTORS CORP.
Install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.

Fig 64: Identifying Suitable Dial Indicator On Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Install the low/reverse and forward (1, 2, 3, 4) clutch feed seals in the transaxle case.

Fig 65: Identifying Low/Reverse And Forward (1, 2, 3, 4) Clutch Feed Seals In Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.0039 in) and 1.840 mm (0.0724 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.

Fig 66: Applying Of Air Pressure To Forward (1, 2, 3, 4) Clutch Piston Port
Courtesy of MAZDA MOTORS CORP.
Install the front planetary sun gear and shell assembly.

Fig 67: Locating Front Planetary Sun Gear And Shell Assembly
Courtesy of MAZDA MOTORS CORP.
Install the No. 10 thrust bearing.

Fig 68: Locating No. 10 Thrust Bearing
Courtesy of MAZDA MOTORS CORP.
Install the park pawl.

Fig 69: Locating Park Pawl
Courtesy of MAZDA MOTORS CORP.
Install the park pawl pin and spring.

Fig 70: Locating Park Pawl Pin And Spring
Courtesy of MAZDA MOTORS CORP.
Install the park pawl actuator rod in the TR sensor.

Fig 71: Locating Park Pawl Actuator Rod In TR Sensor
Courtesy of MAZDA MOTORS CORP.
Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the transaxle case.

Fig 72: Identifying TR Sensor
Courtesy of MAZDA MOTORS CORP.
Install the manual control shaft and align the roll pin holes.

Fig 73: Identifying Manual Control Shaft
Courtesy of MAZDA MOTORS CORP.
Install the manual control shaft roll pin.

Fig 74: Tapping Manual Control Shaft Roll Pin
Courtesy of MAZDA MOTORS CORP.
Install the manual control lever and the nut.
- Tighten to 24 N.m {2.4 kgf.m, 18 ft.lbf}.
  CAUTION:
  - Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
    
    Fig 75: Locating Manual Lever Nuts
    Courtesy of MAZDA MOTORS CORP.
Install the 5 clutch feed seals.

Fig 76: Locating Clutch Feed Seals
Courtesy of MAZDA MOTORS CORP.
Position the transmission fluid baffle in place.

Fig 77: Locating Transmission Fluid Baffle
Courtesy of MAZDA MOTORS CORP.
Install the lube funnel and position the alignment pin in the alignment hole.

Fig 78: Aligning Pin In Hole
Courtesy of MAZDA MOTORS CORP.
Position the lube funnel hold-down bracket in place and install the 2 bolts.
- Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
  
  Fig 79: Identifying Transaxle Fluid Reservoir Hold-Down Bracket
  Courtesy of MAZDA MOTORS CORP.
Install the No. 12 thrust bearing.

Fig 80: Locating No. 12 Thrust Bearing
Courtesy of MAZDA MOTORS CORP.
Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven sprocket to be sure it is fully seated in the case.

Fig 81: Identifying Drive/Driven Sprocket And Chain
Courtesy of MAZDA MOTORS CORP.
Install the No. 11 thrust bearing.

Fig 82: Identifying No. 11 Thrust Bearing
Courtesy of MAZDA MOTORS CORP.
Install the No. 13 thrust washer.

Fig 83: Identifying No. 13 Thrust Washer
Courtesy of MAZDA MOTORS CORP.
Install the final drive sun gear.

Fig 84: Locating Final Drive Sun Gear
Courtesy of MAZDA MOTORS CORP.
Install the differential assembly

Fig 85: Locating Differential Assembly
Courtesy of MAZDA MOTORS CORP.
Install the No. 15 thrust bearing.

Fig 86: Locating No. 15 Thrust Bearing
Courtesy of MAZDA MOTORS CORP.
Install the Turbine Shaft Seal Protector on the input shaft.

Fig 87: Locating Turbine Shaft Seal Protector On Input Shaft
Courtesy of MAZDA MOTORS CORP.
Clean the torque converter housing sealing surface.

Fig 88: Locating Torque Converter Housing Sealing Surface
Courtesy of MAZDA MOTORS CORP.
Assemble the Handle and Seal Installer. Install a new RH seal on the Seal Installer.

Fig 89: Identifying RH Seal On Seal Installer
Courtesy of MAZDA MOTORS CORP.
Using the Handle and Seal Installer, install the RH halfshaft seal.

Fig 90: Installing RH Halfshaft Seal
Courtesy of MAZDA MOTORS CORP.
Install the differential ring gear in the torque converter housing.

Fig 91: Identifying Differential Ring Gear In Torque Converter Housing
Courtesy of MAZDA MOTORS CORP.
Install the beveled differential ring gear snap ring with the flat side facing down.
CAUTION:
- Be sure the flat side of the beveled snap ring is facing down or the ring can come loose, causing damage to the transaxle.
  
  Fig 92: Locating Differential Ring Gear Snap Ring
  Courtesy of MAZDA MOTORS CORP.
Seat the snap ring using a suitable tool.

Fig 93: Setting Snap Ring
Courtesy of MAZDA MOTORS CORP.
Install the pump and filter assembly in the torque converter housing and install the pump bolts.
1. Tighten to 35 N.m {3.5 kgf.m, 26 ft.lbf}.
2. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
  
  Fig 94: Identifying Pump And Filter Assembly With Bolts
  Courtesy of MAZDA MOTORS CORP.
Install the transmission fluid baffle and the 2 bolts.
- Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
  
  Fig 95: Locating Torque Converter Housing
  Courtesy of MAZDA MOTORS CORP.
Apply silicone to the sealing surface of the transaxle case.
NOTE:
- Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.
  
  Fig 96: Identifying Silicone Applying Area
  Courtesy of MAZDA MOTORS CORP.
Install the torque converter housing on the transaxle case and install the 17 bolts.
1. Tighten to 24 N.m {2.4 kgf.m, 18 ft.lbf}.
2. Stud bolt location.
  NOTE:
  - Be sure the stud bolt is in the correct location as noted during disassembly.
    
    Fig 97: Locating Torque Converter Housing Bolts
    Courtesy of MAZDA MOTORS CORP.
Remove the Turbine Shaft Seal Protector.

Fig 98: Using Special Tool To Remove Turbine Shaft Seal Protector
Courtesy of MAZDA MOTORS CORP.
Install the TSS sensor and the bolt.
- Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
  
  Fig 99: Locating TSS Sensor And Bolt
  Courtesy of MAZDA MOTORS CORP.
Install the OSS sensor and the bolt.
- Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
  
  Fig 100: Locating OSS Sensor And Bolt
  Courtesy of MAZDA MOTORS CORP.
Assemble the bypass valve in the sleeve and install the assembly in the case.
1. Bypass valve
2. Bypass valve sleeve
  
  Fig 101: Assembling Bypass Valve In Sleeve
  Courtesy of MAZDA MOTORS CORP.
Install the bypass valve spring.

Fig 102: Illustrating Installing Bypass Valve Spring
Courtesy of MAZDA MOTORS CORP.
Install the separator plate and align it on the stud and the guide pin.

Fig 103: Identifying Separator Plate
Courtesy of MAZDA MOTORS CORP.
Position the main control assembly in place and align the manual valve on the TR sensor.
NOTE:
- Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
  
  Fig 104: Aligning Manual Valve On TR Sensor
  Courtesy of MAZDA MOTORS CORP.
Install the nut hand-tight.

Fig 105: Locating Nut Hand-Tight
Courtesy of MAZDA MOTORS CORP.
Install the short bolts hand-tight.

Fig 106: Locating Short Bolts Hand-Tight
Courtesy of MAZDA MOTORS CORP.
Install the long bolts hand-tight.

Fig 107: Locating Long Bolts Hand-Tight
Courtesy of MAZDA MOTORS CORP.
Tighten the main control bolts and the nut.
- Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
  
  Fig 108: Locating Main Control Bolts And Nut
  Courtesy of MAZDA MOTORS CORP.
Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the bolt.
- Tighten to 13 N.m {1.3 kgf.m, 115 in.lbf}.
  
  Fig 109: Locating TR Sensor Detent Spring
  Courtesy of MAZDA MOTORS CORP.
Install the solenoid body-to-main control cover seal.
NOTE:
- Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.
  
  Fig 110: Identifying Solenoid Body-To-Main Control Cover Grommet
  Courtesy of MAZDA MOTORS CORP.
Connect the TR sensor electrical connector.

Fig 111: Locating Transmission Range Sensor Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Connect the OSS sensor electrical connector.

Fig 112: Locating OSS Sensor Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Clean the main control cover sealing surface.

Fig 113: Locating Main Control Cover Sealing Surface
Courtesy of MAZDA MOTORS CORP.
Apply silicone to the main control sealing surface of the transaxle case.

Fig 114: Applying Silicone To Main Control Sealing Surface Of Transaxle Case
Courtesy of MAZDA MOTORS CORP.
Position the main control cover in place.

Fig 115: Locating Main Control Cover
Courtesy of MAZDA MOTORS CORP.
Install the main control cover bolts.
- Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
  1. Bolt location.
  2. Stud bolt location.
    NOTE:
    Install the main control cover stud bolts in the correct location as noted during disassembly.
    
    Fig 116: Locating Main Control Cover Bolts
    Courtesy of MAZDA MOTORS CORP.
Using the Torque Converter Handle, install the torque converter.
NOTE:
- The torque converter is heavy. Be careful not to drop it or damage will result.
  
  Fig 117: View Of Removing/Installing Torque Converter
  Courtesy of MAZDA MOTORS CORP.
Remove the Torque Converter Handle.

Fig 118: Identifying Torque Converter Handle
Courtesy of MAZDA MOTORS CORP.
Install the Torque Converter Retainer.

Fig 119: Identifying Torque Converter Retainer
Courtesy of MAZDA MOTORS CORP.
Remove the transaxle from the bench-mounted holding fixture.

Fig 120: Identifying Bench-Mounted Holding Fixture
Courtesy of MAZDA MOTORS CORP.
Remove the Holding Fixture.

Fig 121: Identifying Holding Fixture
Courtesy of MAZDA MOTORS CORP.