2002 MAZDA 6 differential

GI–16
SCHEDULED MAINTENANCE
Evaporative system (if installed) IIIIIIII
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity IIIIIIII
All electrical system *5IIIIIIII
CHASSIS AND BODY
Brake lines, hoses and connections IIIIIIII
Brake fluid *3IIIRIIIRIIIRIIIR
Parking brake IIIIIIIIIIIIIIII
Power brake unit and hoses IIIIIIII
Disc brakes IIIIIIIIIIIIIIII
Power steering fluid, lines, hoses, and connections I I I I I I I I I I I I I I I I
Steering operation and linkages IIIIIIII
Manual transaxle oilR
Automatic transaxle fluid level IIIIIIII
Rear differential oil (for 4WD)
*6*7
Transfer oil (for 4WD)
*7
Front and rear suspension and ball joints I I I I
Driveshaft dust boots I I I I
Bolts and nuts on chassis and body TTTTTTTT
Exhaust system and heat shields Inspect every 80,000 km (50,000 miles)
Cabin air filter (if installed) RRRRRRRR
Body condition
(for rust, corrosion and perforation)Inspect annually
Tyres (including spare tyre)
(with inflation pressure adjustment)IIIIIIII Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 6 121824303642485460667278849096
×1000 km
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
×1000 miles6.25 12.5 18.75 25 31.25 37.5 43.75 50 56.25 62.5 68.75 75 81.25 87.5 93.75 100

GI–18
SCHEDULED MAINTENANCE
End Of Sie
Rear differential oilCheck oil level and inspect for leakage.
Replace rear differential oil.
Transfer oil (for 4×4)Check oil level and inspect for leakage.
Replace transfer oil.
Driveshaft dust boots Inspect for grease leakage, cracks, damage and looseness.
Body condition
(for rust, corrosion and perforation)Inspect body surface for paint damage, rust, corrosion and perforation.
Exhaust system and heat shields Inspect for damage, corrosion, looseness of connections and gas leakage.
Tires
(including spare tire)
(with inflation pressure adjustment)Check air pressure and inspect tires for tread wear, damage and cracks;
and wheels for damage and corrosion.
AIR CONDITIONER SYSTEM (IF EQUIPPED)
Cabin air filter Replace cabin air filter.Maintenance Item Specific Work Required

J2–1
J2
J2MANUAL TRANSAXLE [A65M-R]
OUTLINE.............................................................. J2-2
OUTLINE OF CONSTRUCTION........................ J2-2
FEATURES ........................................................ J2-2
SPECIFICATIONS ............................................. J2-2
LOCATION INDEX............................................... J2-3
MANUAL TRANSAXLE LOCATION INDEX ...... J2-3
MANUAL TRANSAXLE........................................ J2-4
TRANSAXLE OIL INSPECTION ........................ J2-4
TRANSAXLE OIL REPLACEMENT ................... J2-4
OIL SEAL (DIFFERENTIAL) REPLACEMENT .. J2-5
REVERSE SWITCH INSPECTION .................... J2-5
REVERSE SWITCH
REMOVAL/INSTALLATION ............................ J2-6
NEUTRAL SWITCH INSPECTION .................... J2-6
NEUTRAL SWITCH
REMOVAL/INSTALLATION ............................ J2-7
MANUAL TRANSAXLE
REMOVAL/INSTALLATION ............................ J2-7
SHIFT MECHANISM........................................... J2-12
SHIFT MECHANISM
REMOVAL/INSTALLATION .......................... J2-12 FEATURES
SERVICE

LOCATION INDEX
J2–3
J2
MANUAL TRANSAXLE LOCATION INDEXA6E520001036201
.
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LOCATION INDEX
2
5
36
4
1
A6E5200W001
1 Manual transaxle
(See J2–7 MANUAL TRANSAXLE REMOVAL/
INSTALLATION)
2 Shift mechanism
(See J2–12 SHIFT MECHANISM REMOVAL/
INSTALLATION)
3 Transaxle oil
(See J2–4 TRANSAXLE OIL INSPECTION)
(See J2–4 TRANSAXLE OIL REPLACEMENT)4 Oil seal (differential)
(See J2–5 OIL SEAL (DIFFERENTIAL)
REPLACEMENT)
5 Reverse switch
(See J2–5 REVERSE SWITCH INSPECTION)
(See J2–6 REVERSE SWITCH REMOVAL/
INSTALLATION)
6 Neutral switch
(See J2–6 NEUTRAL SWITCH INSPECTION)
(See J2–7 NEUTRAL SWITCH REMOVAL/
INSTALLATION)

MANUAL TRANSAXLE
J2–5
J2
OIL SEAL (DIFFERENTIAL) REPLACEMENTA6E5212192402011. On level ground, jack up the vehicle and support it evenly on safety stands.
2. Drain the oil from the transaxle.
3. Remove the front wheels and splash shields.
4. Separate the drive shaft and joint shaft from the transaxle. (See Section M.)
5. Remove the oil seals using a screwdriver.
6. Using the SSTs and a hammer, tap each new oil
seal in evenly until the SSTs contact the transaxle
case.
7. Coat the lip of each oil seal with transaxle oil.
8. Insert the drive shaft and joint shaft into the
transaxle. (See Section M.)
9. Install the wheels and splash shields.
10. Add the specified amount and type of oil. (See
J2–4 TRANSAXLE OIL REPLACEMENT.)
End Of SieREVERSE SWITCH INSPECTIONA6E5212190102011. Disconnect the reverse switch connector.
2. Shift the shift lever to each position, and inspect
for continuity between terminals A and B.
•If not as specified, replace the reverse switch.
(See J2–6 REVERSE SWITCH REMOVAL/
INSTALLATION.)
3. Connect the reverse switch connector.
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AME5212W005
49 G030 797
49 U027 003
A6E5212W011
REVERSE SWITCH
A6E5212W012
BA REVERSE SWITCH
PART SIDE CONNENTOR
A6E5212W013
Shift positionConnector terminal
AB:
Continuity
Reverse
Others
A6E5212W014

K2–4
AUTOMATIC TRANSAXLE
Bold frames:New specifications
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OUTLINEA6E571401030201•Adopted new JA5AX-EL automatic transaxle.
•Newly designed FF type five-speed automatic transaxle.
—Use of 3 sets of planetary gears, and a wider gear ratio setting realizes improvement of acceleration-from-
standing-start performance, fuel economy, and quietness. Also, by placement of two sets of planetary gears
in parallel with one set, the automatic transaxle is more compact.
•Adopted 2-4 brake clutch.
—Adopted a wet-type, multi-plate 2-4 brake clutch instead of the 2-4 brake band used in the past, for
smoother gear switching performance.
•Adopted centrifugal balance clutch
—The newly adopted centrifugal balance clutch pushes the clutch piston forcefully to low and high clutch by
centrifugal hydraulic pressure for smoother gear switching with batter response.
•Adopted controller area network (CAN)
—By adopting CAN, The TCM is always in contact with other computers in the car and controls the automatic
transaxle properly. This has also made troubleshooting diagnosis easier for the entire vehicle.
•Solenoid, sensor
—Adoption of four duty-type solenoids, five ON-OFF type solenoids, and three revolving sensors realizes
finer, more expedient control of gear shifting performance.
•Adoption of revers inhibit control
—If the reverse position is selected by mistake while driving in forward motion, the reverse inhibit control
system will cancel the operation electronically and set the position to neutral as a safety enhancement.
Outline of Operation
•The operation of the electronic automatic transaxle is classified into three systems: the electronic control
system, the hydraulic pressure control system, and the powertrain system (includes the torque converter
system.)
Electronic control system
•According to the signals from the switches and sensors in the input system, the TCM outputs the signal
which matches the present driving condition to the ON/OFF type solenoids and the duty-cycle type
solenoids in the hydraulic pressure control system.
Hydraulic pressure control system
•According to the signals from the TCM, each solenoid operates to switch the hydraulic passages in the
control valve body and controls the clutch engagement pressure.
•The line pressure is adjusted by the duty-cycle type pressure control solenoid. The hydraulic passages
are switched by the ON/OFF type solenoids and the clutch engagement pressure is controlled by the
duty-cycle type solenoids.
Powertrain system
•The driving force from the engine is transmitted through the torque converter to the transaxle.
•The transmitted driving force operates each clutch and brake according to the clutch engagement
pressure from the duty-cycle type solenoid, and the planetary gears change the gear ratio to the
optimal driving force. The changed driving force is transmitted through the differential to the axle shaft
and then the tires.
AUTOMATIC TRANSAXLE

AUTOMATIC TRANSAXLE
K2–77
K2
M Range Test
1. Perform road test preparation. (See K2–75 Road Test Preparation.)
2. Shift the selector lever to M range.
3. Verify that 1→2, 2→3, 3→4, and 4→5 upshifts and 5→4, 4→3, 3→2, and 2→1 downshifts are obtained by
manual shifting of the selector lever forward and back. The shift points must be as shown in the table below.
•If not as specified, inspect the TCM and ATX. (See K2–183 AUTOMATIC TRANSAXLE SYMPTOM
TROUBLESHOOTING.)
4. Decelerate the vehicle and verify that 5→4, 4→3, 3→1, and 2→1 downshifts are obtained. The shift points
must be as shown in the table below.
•If not as specified, inspect the TCM and ATX.(See K2–183 AUTOMATIC TRANSAXLE SYMPTOM
TROUBLESHOOTING.)
5. Decelerate the vehicle and verify that engine braking effect is felt in all gears.
•If not as specified, inspect the TCM and ATX. (See K2–183 AUTOMATIC TRANSAXLE SYMPTOM
TROUBLESHOOTING.)
6. Drive the vehicle and verify that TCC operation is obtained in 5GR. The operation points must be as shown in
the table below.
•If not as specified, inspect the TCM and ATX. (See K2–183 AUTOMATIC TRANSAXLE SYMPTOM
TROUBLESHOOTING.)
Vehicle speed at shift point table
Noise and Vibration Test
1. Drive the vehicle and listen closely for any noise or vibration. The torque converter, drive shaft, and differential
can be sources of noise and vibration if they are not functioning properly. Inspect these when searching for
sources of noise and vibration.
P Position Test
1. Shift into P position on a gentle slope. Release the brake, and verify that the vehicle does not roll.
•If the vehicle rolls, inspect the ATX. (See K2–183 AUTOMATIC TRANSAXLE SYMPTOM
TROUBLESHOOTING.)
Range ModeThrottle
conditionShiftVehicle speed
(km/h {mph})Turbine speed
(rpm)
MManualHalf throttleTCC ON (M
5)
106—129 {66—79} 2,200—2,600
All roundM
5→M430—36 {19—22} 650—700
M
4→M323—29 {15—17} 650—800
M
2→M14—10 {3—6} 300—600
M
3→M14—10 {3—6} 200—400

K2–104
AUTOMATIC TRANSAXLE
4. Tighten the bolt A.
Tightening torque
A: 93.1—116.6 N·m
{9.50—11.88 kgf·m, 68.66—85.98 ft·lbf}
B: 85.3—116.6 N·m
{8.70—11.88 kgf·m, 62.91—85.98 ft·lbf}
Selector Cable Installation Note
1. Install the selector lever to the manual shaft lever
in such a way that the selector cable does not
bear a load.
Note
•Install the selector lever to the manual shaft
lever with the spring side of the selector
cable end facing the upward of the vehicle.
2. Confirm that the end of the manual shaft lever
sticks out of the end of the selector cable.
End Of SieOIL SEAL REMOVAL/INSTALLATIONA6E571419240201Differential side
1. Drain the ATF. (See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.)
2. Remove the drive shaft. (See Section M.)
3. Remove and discard the oil seal using a screwdriver.
4. Using the SSTs and a hammer, tap a new oil seal
in evenly until the SSTs contacts the transaxle
case.
5. Coat the lip of the oil seal with ATF.
Caution
•The oil seal is easily damaged by the
sharp edges of the drive shaft splines. Do
not let the splines contact the oil seal.
6. Install the drive shaft. (See Section M.)
7. Add ATF to the specified level. (See K2–80
AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT.)
8. Carry out the mechanical system test. (See K2–72 MECHANICAL SYSTEM TEST.)
Transfer side
1. Remove the drive shaft and joint shaft. (See Section M.)
2. Remove and discard the oil seal using a screwdriver.
3. Using the SST and a hammer, tap a new oil seal
in evenly until the SST contacts the transfer case.
AC
B
D
A6E5714W138
SELECTOR CABLE
MANUAL SHAFT LEVERSPRING
UPWARD
A6E5714W115
49 G030 79749 L019 016
-1.1—-0.1 mm
{-0.043—-0.004 in}
A6E5714W142
49 B010 001
A6E5714W129