Manual Transaxle Removal/Installation: Installation

WARNING: This page is about a different car, the 2018 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Install the manual transaxle carefully, holding it steady. If the manual transaxle falls it could be damaged or cause injury.

Set the manual transaxle on a jack and lift into place.

Fig 1: Setting Manual Transaxle On Jack
Courtesy of MAZDA MOTORS CORP.
Install the manual transaxle to the engine, and tighten the transaxle mounting bolts.

Fig 2: Locating Transaxle Mounting Bolts
Courtesy of MAZDA MOTORS CORP.

Tightening torque

38-52 N.m {3.9-5.3 kgf.m, 29-38 ft.lbf}
Measure the projection of the stud bolts.

Fig 3: Measuring Projection Of Stud Bolts
Courtesy of MAZDA MOTORS CORP.
1. Projection A of stud bolt No. 1
2. 40.0-42.0 mm {1.58-1.65 in}
3. Projection B of stud bolt No. 2
4. 30.7-32.7 mm {1.21-1.28 in}
5. Projection C of stud bolt No. 3
6. 40.0-42.0 mm {1.58-1.65 in}
NOTE:
- If the projection amount is not within the range, adjust the projection amount of the stud bolts.
Install the No. 4 engine mount bracket to No. 4 engine mount rubber, and temporarily tighten the installation bolt.

Fig 4: No. 4 Engine Mount Bracket To No. 4 Engine Mount Rubber
Courtesy of MAZDA MOTORS CORP.
Lift up the manual transaxle using the SSTs, pass the manual transaxle stud bolts through the No. 4 engine mount bracket, and temporarily tighten the No. 4 engine mount installation nuts.

Fig 5: Lifting Up Manual Transaxle Using SSTs
Courtesy of MAZDA MOTORS CORP.
Install the No. 1 engine mount bracket, and tighten the installation bolts in the order shown in the figure below.

Fig 6: No. 1 Engine Mount Bracket Bolts Tightening Sequence
Courtesy of MAZDA MOTORS CORP.

Tightening torque

84-98 N.m {8.6-9.9 kgf.m, 62-72 ft.lbf}
Install the front crossmember component and No. 1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
Temporarily tighten the No. 1 engine mount rubber installation bolts.

Fig 7: Locating No. 1 Engine Mount Rubber Installation Bolts
Courtesy of MAZDA MOTORS CORP.
Align the positions of the No. 4 engine mount bracket installation nuts with the No. 4 engine mount bracket.

Fig 8: Aligning No. 4 Engine Mount Bracket Installation Nuts With No. 4 Engine Mount Bracket Positions
Courtesy of MAZDA MOTORS CORP.

Tighten the No. 4 engine mount bracket installation nuts and bolt in the order shown in the figure below.

Fig 9: No. 4 Engine Mount Bracket Installation Nuts And Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

No.	Tightening Torque
1, 2, 3	92-116 N.m {9.4-11 kgf.m, 68-85 ft.lbf}
4	81-99 N.m {8.3-10 kgf.m, 60-73 ft.lbf}

Remove the SST (49 C017 5AO).

Tighten the No. 1 engine mount rubber installation bolts in the order shown in the figure below.

Fig 10: No. 1 Engine Mount Rubber Installation Bolts Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Tightening torque

Installation Position	Tightening Torque
1	141-172 N.m {15-17 kgf.m, 104-126 ft.lbf}
2	130-164 N.m {14-16 kgf.m, 96-120 ft.lbf}

Connect and/or Install the following parts to the underside of the vehicle.
1. Install the starter. (See STARTER REMOVAL/INSTALLATION .)
2. Install the clutch release cylinder to the manual transaxle. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION .)
Connect and/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 .)
2. Connect the front drive shaft (LH) to the manual transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
3. Connect the front lower arms to the steering knuckles. (See FRONT LOWER ARM REMOVAL/INSTALLATION .)
4. Connect the front stabilizer control links to the front stabilizer. (See FRONT STABILIZER INSTALLATION .)
5. Connect the tie rod end ball joints to the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
6. Connect the front ABS wheel-speed sensors to the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION .)
7. Connect the clip securing the brake hose to the front shock absorber. (See FRONT BRAKE HOSE REMOVAL/INSTALLATION .)
8. Install the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
Connect the intermediate shaft to the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
Install the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
Connect and/or install the following parts in the engine compartment.
1. Connect the hose clip to the bracket shown in the figure below.
  
  Fig 11: Connecting Hose Clip To Bracket
  Courtesy of MAZDA MOTORS CORP.
2. Connect the clip shown in the figure below.
  
  Fig 12: Locating Intake Manifold Clip
  Courtesy of MAZDA MOTORS CORP.
3. Install the wiring harness brackets.
  
  Fig 13: Installing Wiring Harness Brackets
  Courtesy of MAZDA MOTORS CORP.
4. Install the lower radiator hose component. (See RADIATOR REMOVAL/INSTALLATION .) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION .)
5. Connect the back-up light switch connector. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION .)
6. Connect the neutral switch connector. (See NEUTRAL SWITCH REMOVAL/INSTALLATION .)
7. Install the bracket to the manual transaxle and the exhaust manifold using the following procedure:
  
  Fig 14: Bracket To Manual Transaxle And Exhaust Manifold
  Courtesy of MAZDA MOTORS CORP.
  1. Tighten the bolt A.
    Tightening torque
    
    8-10 N.m {82-101 kgf.cm, 71-88 in.lbf}
  2. Temporarily tighten the bolt Band C.
  3. Tighten the bolt B.
    Tightening torque
    
    38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf}
  4. Tighten the bolt C.
    Tightening torque
    
    38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf}
8. Connect the ground cable to the No. 4 engine mount bracket.
  
  Fig 15: Connecting Ground Cable To No. 4 Engine Mount Bracket
  Courtesy of MAZDA MOTORS CORP.
9. Install the control cable bracket to the manual transaxle.
  
  Fig 16: Control Cable Bracket And Bolts With Torque Specification
  Courtesy of MAZDA MOTORS CORP.
10. Connect the control cable to the manual transaxle. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
11. Install the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)] .)
12. Install the PCM component. (See PCM REMOVAL/INSTALLATION .)
13. Install the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)] .)
14. Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  - Air cleaner cover
  - Air cleaner element
  - Fresh-air duct
  - Air cleaner case
  - Air hose
  - Resonance chamber
Install the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
Install the front under cover No. 1. (See FRONT UNDER COVER No. 1 REMOVAL/INSTALLATION .)
Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT .)
Install the front under cover No. 2. (See FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
If the manual transaxle is overhauled, perform the "INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL". (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL .)