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Manual Transaxle Removal/Installation: Installation

WARNING: This page is about a different variant/trim than selected.
WARNING:
  • Install the manual transaxle carefully, holding it steady. If the manual transaxle falls it could be damaged or cause injury.
CAUTION:
  • To prevent the stud bolts from contacting the front side frame, remove stud bolts No. 1 and No. 3 from the manual transaxle component when replacing the manual transaxle component.
G13176425Courtesy of MAZDA MOTORS CORP.
  1. Set the manual transaxle on a jack and lift into place.
    G09759417Courtesy of MAZDA MOTORS CORP.
  2. Install the manual transaxle to the engine, and tighten the transaxle mounting bolts.
    Fig 1: Transaxle Mounting Bolts With Torque Specification
    G13176427Courtesy of MAZDA MOTORS CORP.
  3. Install stud bolt No. 1.
    G13176428Courtesy of MAZDA MOTORS CORP.
  4. Install stud bolt No. 3.
    G13176429Courtesy of MAZDA MOTORS CORP.
  5. Measure the projection of the stud bolts.
    G13176430Courtesy of MAZDA MOTORS CORP.

    Projection A of stud bolt No. 1 

    40.0-42.0 mm {1.58-1.65 in}

    Projection B of stud bolt No. 2 

    30.7-32.7 mm {1.21-1.28 in}

    Projection C of stud bolt No. 3 

    70.7-72.7 mm {2.79-2.86 in}

    NOTE:
    • If the projection amount is not within the range, adjust the projection amount of the stud bolts.
  6. Install the No. 4 engine mount bracket and the No. 4 engine mount rubber, and temporarily tighten the bolts shown in the figure.
    G13176431Courtesy of MAZDA MOTORS CORP.
  7. Lift up the transaxle using the SSTs, pass the stud bolt through the No. 4 engine mount rubber, and temporarily tighten the No. 4 engine mount rubber installation nuts.
    G13176432Courtesy of MAZDA MOTORS CORP.
  8. Install the No. 1 engine mount bracket, and tighten the installation bolts in the order shown in the figure.
    Fig 2: No. 1 Engine Mount Bracket Installation Bolts Tightening Sequence
    G13176433Courtesy of MAZDA MOTORS CORP.
  9. Install the front crossmember component and No. 1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(US)] .)
  10. Temporarily tighten the No. 1 engine mount rubber installation bolts.
    G13176434Courtesy of MAZDA MOTORS CORP.
  11. Align the nuts and bolts shown in the figure with the alignment marks.
    G13176435Courtesy of MAZDA MOTORS CORP.
  12. Tighten the No. 4 engine mount rubber installation nuts and the No. 4 engine mount bracket installation bolts in the order shown in the figure.
    Fig 3: No. 4 Engine Mount Bracket Installation Bolts Tightening Sequence
    G13176436Courtesy of MAZDA MOTORS CORP.
  13. Remove the SST (49 C017 5A0).
  14. Tighten the No. 1 engine mount rubber installation bolts in the order shown in the figure.
    Fig 4: No. 1 Engine Mount Rubber Installation Bolts Tightening Sequence
    G13176437Courtesy of MAZDA MOTORS CORP.
  15. Install the following parts to the underside of the vehicle.
    1. Install the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
    2. Install the clutch release cylinder to the manual transaxle. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION .)
  16. Connect or Install the following parts related to the suspension and axle.
    1. Connect the front drive shaft (RH) to the manual transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(US)] .)
    2. Connect the front drive shaft (LH) to the manual transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(US)] .)
    3. Connect the front lower arm ball joint to the steering knuckles. (See FRONT LOWER ARM REMOVAL/INSTALLATION [(US)] .)
    4. Connect the tie-rod ends to the steering knuckles. (See TIE-ROD END REPLACEMENT .)
    5. Install the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
  17. Connect the intermediate shaft (lower side) to the steering gear and linkage. (See INTERMEDIATE SHAFT REMOVAL/INSTALLATION [(US)] .)
  18. Install the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [(US)] .)
  19. Connect or install the following parts in the engine compartment.
    1. Install the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
    2. Connect the hose clip to the bracket shown in the figure.
      G13176417Courtesy of MAZDA MOTORS CORP.
    3. Connect the clip shown in the figure.
      G13176412Courtesy of MAZDA MOTORS CORP.
    4. Install the wiring harness clip and wiring harness bracket.
      Fig 5: Wiring Harness Bracket Bolts With Torque Specification
      G13176440Courtesy of MAZDA MOTORS CORP.
    5. Install the lower radiator hose component. (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
    6. Connect the back-up light switch connector. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION .)
    7. Connect the neutral sensor connector. (See NEUTRAL SENSOR REMOVAL/INSTALLATION .)
    8. Install the bracket to the manual transaxle and the exhaust manifold using the following procedure.
      Fig 6: Bracket Bolts With Torque Specification
      G13176441Courtesy of MAZDA MOTORS CORP.
      1. Tighten bolt A.
      2. Temporarily tighten bolt B and C.
      3. Tighten bolt B.
      4. Tighten bolt C.
    9. Connect the ground cable to the No. 4 engine mount rubber.
      Fig 7: Ground Cable Bolts With Torque Specification
      G13176442Courtesy of MAZDA MOTORS CORP.
    10. Install the control cable bracket to the manual transaxle.
      Fig 8: Control Cable Bracket Bolts With Torque Specification
      G13176443Courtesy of MAZDA MOTORS CORP.
    11. Connect the control cable to the manual transaxle. (See CONTROL CABLE REMOVAL/INSTALLATION .)
    12. Install the battery tray and PCM component as a single unit. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
    13. Install the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
    14. Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
      • Air cleaner cover
      • Air cleaner element
      • Fresh-air duct
      • Air cleaner case
      • Air hose
      • Resonance chamber
  20. Install the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
  21. Install the front deflector. (See DEFLECTOR REMOVAL/INSTALLATION .)
  22. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G (VIN L (US))] .) (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G (VIN M (US))] .)
  23. Connect the revolution sensor connector and wiring harness clip.
    G13176404Courtesy of MAZDA MOTORS CORP.
  24. Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT .)
  25. Install the tunnel cover. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
  26. Install the front under cover No. 1. (See FRONT UNDER COVER No. 1 REMOVAL/INSTALLATION .)
  27. Install the front under cover No. 2. (See FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
  28. Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(US)] .)
  29. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (VIN L (US))] .) (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (VIN M (US))] .)
  30. If the manual transaxle is overhauled, perform the "INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL". (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL .)
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