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MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R]

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Special Service Tool (SST)

1.  : Mazda SST number 2.  : Global SST number
1: 49 C017 5A0 2: –   Engine support set		1: 49 UN30 3050 2: 303–050   Engine lifting bracket		1: 49 L017 5A0 2: –   Support hanger

Caution

•  Performing the following procedures could cause an open circuit in the front ABS wheel-speed sensor wiring harness if it is pulled by mistake. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.

•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

Removal

1.  Disconnect the negative battery terminal .

2.  Remove the plug hole plate.

3.  Remove the tunnel cover.

4.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

5.  Remove the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

6.  Remove the front deflector. (See DEFLECTOR REMOVAL/INSTALLATION.)

7.  Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

8.  Drain the manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R].)

9.  Drain the engine coolant.

10.  Disconnect the revolution sensor connector and wiring harness clip.

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11.  Disconnect or remove the following parts in the engine compartment.

(1)  Remove the following parts as a single unit.

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

(2)  Remove the battery.

(3)  Remove the battery tray and PCM component as a single unit.

(4)  Disconnect the control cable from the manual transaxle. (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R].)

(5)  Remove the control cable bracket from the manual transaxle.

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(6)  Remove the bolt shown in the figure, and set the ground cable aside.

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(7)  Remove the bracket from the manual transaxle and the exhaust manifold.

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(8)  Disconnect the neutral sensor connector from the manual transaxle. (See NEUTRAL SENSOR REMOVAL/INSTALLATION [C66M-R].)

(9)  Disconnect the back-up light switch connector from the manual transaxle. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [C66M-R].)

(10)  Remove the lower radiator hose component.

(11)  Remove the wiring harness clip and bolts, and set the wiring harnesses and wiring harness brackets in a place which does not interfere with servicing.

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12.  Remove the joint cover.

13.  Disconnect the intermediate shaft (lower side) from the steering gear and linkage.

14.  Disconnect or remove the following parts related to the suspension and axle.

(1)  Remove the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

(2)  Disconnect the tie-rod ends from the steering knuckles.

(3)  Disconnect the front lower arm ball joints from the steering knuckle.

(4)  Disconnect the front drive shaft (LH) from the manual transaxle.

(5)  Disconnect the front drive shaft (RH) from the manual transaxle.

15.  Remove the following parts from the underside of the vehicle.

(1)  Remove the clutch release cylinder with the clutch pipe still connected and set it out of the way. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R].)

(2)  Remove the starter.

(3)  Remove the front crossmember component and No.1 engine mount rubber as a single unit.

(4)  Remove the No.1 engine mount bracket from the manual transaxle.

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16.  Install the SST using the following procedure.

Caution

•  Refer to the SST instruction manual for the basic handing procedure.

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(1)  Install one front foot No.2 to each of the left and right front shafts of the SST.

(2)  Protect the positions shown in the figure using tape.

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(3)  Remove the coolant reserve tank.

(4)  To enable to install the SST, disconnect the clip shown in the figure and set the wiring harness aside.

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(5)  Install the SST using a bolt with part number 99794 1025 or an M10—1.25, length 25 mm {0.98 in} bolt, and a washer as shown in the figure.

Engine front side

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Engine rear side

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(6)  As shown in the figure, set the rear shafts of the SST to the left and right front shock absorber nuts.

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(7)  Set the front shafts of the SST (49 C017 5A0) as shown in the figure.

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(8)  To prevent interference of the SST with the hose when assembling the SST (49 L017 5A0), disconnect the hose clip from the bracket shown in the figure and set the fuel hose and vacuum hose aside.

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(9)  Install the SST (49 L017 5A0) to the SST (49 C017 5A0) as shown in the figure.

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(10)  Install the SST (49 L017 5A0) to the SST (49 UN30 3050) with the hook of the SST (49 L017 5A0) facing outward.

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(11)  Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.

(12)  Apply tension to the chain to support the engine and verify that the engine is securely hung.

17.  Remove in the order indicated in the table.

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1	Transaxle mounting bolt (upper side)
2	No.4 engine mount bracket (See No.4 engine mount rubber and No.4 engine mount bracket removal note.)
3	No.4 engine mount rubber (See No.4 engine mount rubber and No.4 engine mount bracket removal note.)
4	Stud bolt No.1
5	Stud bolt No.3
6	Transaxle mounting bolt (lower side) (See Transaxle mounting bolt removal note.)
7	Manual transaxle

No.4 engine mount rubber and No.4 engine mount bracket removal note

Caution

•  Slots have been adopted for the No.4 engine mount rubber and No.4 engine mount bracket installation holes. If the No.4 engine mount rubber and No.4 engine mount bracket deviate from their original positions when they are installed, engine noise or vibration could increase. When installing the No.4 engine mount rubber and No.4 engine mount bracket, align them to the alignment marks placed during removal and install them to their original positions.

1.  Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal.

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Note

•  Place the alignment marks so that the contour of the nuts and bolts are outlined.

2.  Remove the No.4 engine mount rubber and the No.4 engine mount bracket.

Transaxle mounting bolt removal note

Warning

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

1.  Adjust the SST and lean the engine toward the manual transaxle.

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2.  Support the manual transaxle on a jack.

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3.  Remove the transaxle mounting bolts (lower side).

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4.  Remove the manual transaxle.

Installation

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.

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

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2.  Install the manual transaxle to the engine, and tighten the transaxle mounting bolts.

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3.  Install stud bolt No.1.

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4.  Install stud bolt No.3.

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5.  Measure the projection of the stud bolts.

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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.

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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.

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8.  Install the No.1 engine mount bracket, and tighten the installation bolts in the order shown in the figure.

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9.  Install the front crossmember component and No.1 engine mount rubber as a single unit.

10.  Temporarily tighten the No.1 engine mount rubber installation bolts.

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11.  Align the nuts and bolts shown in the figure with the alignment marks.

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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.

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13.  Remove the SST (49 C017 5A0).

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

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15.  Install the following parts to the underside of the vehicle.

(1)  Install the starter.

(2)  Install the clutch release cylinder to the manual transaxle. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R].)

16.  Connect or Install the following parts related to the suspension and axle.

(1)  Connect the front drive shaft (RH) to the manual transaxle.

(2)  Connect the front drive shaft (LH) to the manual transaxle.

(3)  Connect the front lower arm ball joint to the steering knuckles.

(4)  Connect the tie-rod ends to the steering knuckles.

(5)  Install the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

17.  Connect the intermediate shaft (lower side) to the steering gear and linkage.

18.  Install the joint cover.

19.  Connect or install the following parts in the engine compartment.

(1)  Install the coolant reserve tank.

(2)  Connect the hose clip to the bracket shown in the figure.

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(3)  Connect the clip shown in the figure.

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(4)  Install the wiring harness clip and wiring harness bracket.

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(5)  Install the lower radiator hose component.

(6)  Connect the back-up light switch connector. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [C66M-R].)

(7)  Connect the neutral sensor connector. (See NEUTRAL SENSOR REMOVAL/INSTALLATION [C66M-R].)

(8)  Install the bracket to the manual transaxle and the exhaust manifold using the following procedure.

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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.

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(10)  Install the control cable bracket to the manual transaxle.

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(11)  Connect the control cable to the manual transaxle. (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R].)

(12)  Install the battery tray and PCM component as a single unit.

(13)  Install the battery.

(14)  Install the following parts as a single unit.

•  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.

23.  Connect the revolution sensor connector and wiring harness clip.

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24.  Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R].)

25.  Install the tunnel cover.

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.

29.  Install the plug hole plate.

30.  If the manual transaxle is overhauled, perform the “INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL”. (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL [C66M-R].)