2002 MAZDA 6 Workshop Manual Suplement

MANUAL TRANSAXLE
J2–7
J2
NEUTRAL SWITCH REMOVAL/INSTALLATIONA6E5212190102041. Remove the neutral switch.
2. Apply a light coat of silicone sealant to the screw
of the neutral switch.
Sealant
Three Bond product: TB1215
3. Install the neutral switch to the transaxle case.
Tightening torque
22.5—33.3 N·m
{2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}
End Of Sie
MANUAL TRANSAXLE REMOVAL/INSTALLATIONA6E5212010292011. Remove the battery and battery tray.
2. Remove the air cleaner compornent. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the air hose above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
4. Remove the air pipe above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
5. Remove the solenoid bracket.
6. Remove the wheels, tires and splash shields.
7. Remove the under cover.
8. Separate the steering hose.
9. Remove the steering gear and linkage, and pipe assembly installation bolts from the front crossmember, then
suspend the steering gear and linkage with a cable. (See N–8 STEERING GEAR AND LINKAGE (MZR-CD
(RF Turbo)) REMOVAL/INSTALLATION.)
Tightening torque
•Pipe assembly: 7.8—10.8 N·m {79.6—110.0 kgf·cm, 69.1—95.5 in·lbf}
10. Remove the front auto leveling sensor. (See Section T.)
11. Drain the transaxle oil into a suitable container.
12. Remove in the order indicated in the table.
13. Install in the reverse order of removal.
14. Adjust the headlight zeroset. (See Section T.)
15. Add the specified amount of specified transaxle oil. (See J2–4 TRANSAXLE OIL REPLACEMENT.)
16. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transaxle operation.
NEUTRAL
SWITCH
A6E5212W015

J2–8
MANUAL TRANSAXLE
.
2
6
3
5
8
1
7
16
13
10
11
21
20
4
9
18
19
17
15
22
22
1423
12
R
R
R
R
85.3—116.6
{8.70—11.88, 62.91—85.98}
58.8—80.4
{6.00—8.19, 43.4—59.2}
58.8—80.4
{6.00—8.19, 43.4—59.2}
93.1—131.3
{9.50—13.38, 68.67—96.84} 119.6—154.8
{12.20—15.78,
88.22—114.1} 43—61 {4.6—6.3, 32—45}
18.6—25.5
{1.90—2.60, 13.8—18.8}
89.3—116
{9.1—11.8, 65.9—85.5}
89.3—116 {9.1—11.8, 65.9—85.5}
37.3—51.9 {3.81—5.29, 27.5—38.2}166.6—200.0
{16.99—20.39,
122.9—147.5} 43.1—60.8
{4.40—6.19, 31.8—44.8} 33.0—44.1
{3.21—4.49, 23.2—32.5}
38—51
{3.9—5.2,
28—37}
27.4—40.2
{2.80—4.09,
20.2—29.6}
93.1—116.6
{9.50—11.88,
68.66—85.98}93.1—126.4
{9.50—12.88,
68.67—93.22}
66.6—93.1
{6.80—9.49, 49.2—68.6}
A
B
B
A
D
D
N·m {kgf·m, ft·lbf}
A6E5212W018
1 Shift cable
2 Select cable
3 Reverse switch connector
4 Neutral switch connector
5 Clutch release cylinder6Starter
(See G–9 STARTER REMOVAL/INSTALLATION)
7 GND harness, harness bracket
8 Transaxle mounting bolt (upper side)

MANUAL TRANSAXLE
J2–9
J2
No.1 Engine Mount Bracket Removal Note
1. Separate the fuel pipe nearby engine hanger.
2. Support the engine using the SST before
removing the No.1 engine mount.
3. Remove the No.1 engine mount.
Manual Transaxle Removal Note
1. Remove the stud of the No.4 engine mount.
2. Loosen the SST (49 E017 5A0)and lean the
engine toward the transaxle.
3. Support the transaxle on a jack.
4. Remove the transaxle mounting bolts.
5. Remove the transaxle.
9 Lower arm (front, rear) ball joint
(See Section R)
10 Damper fork
11 Tie-rod end ball joint
(See N–8 STEERING GEAR AND LINKAGE
(MZR-CD (RF Turbo)) REMOVAL/INSTALLATION)
12 Stabilizer control link
13 Drive shaft (left side)
(SeeSection M)
14 Drive shaft (right side)
(SeeSection M)
15 Joint shaft
(SeeSection M)
16 Flexible pipe
(See F2–57 EXHAUST SYSTEM REMOVAL/
INSTALLATION)17 No.1 engine mount
(See J2–9 No.1 Engine Mount Bracket Removal
Note)
(See J2–11 No.1 Engine Mount Installation Note)
18 Crossmember bracket
19 Crossmember, steering pipe
(See Section R)
20 No.4 engine mount bracket
(See J2–10 No.4 Engine Mount Installation Note)
21 No.4 engine mount rubber
(See J2–10 No.4 Engine Mount Installation Note)
22 Transaxle mounting bolt (lower side)
23 Manual transaxle
(See J2–9 Manual Transaxle Removal Note)
(See J2–10 Manual Transaxle Installation Note)
49 E017 5A0
A6E5212W019
STUD
A6E5212W020
A6E5212W021

J2–10
MANUAL TRANSAXLE
Manual Transaxle Installation Note
1. Set the transaxle on a jack and lift into place.
2. Install the transaxle mounting bolts.
3. Install the stud of the No.4 engine mount.
Tightening torque
27.4—40.2 N·m
{2.80—4.09 kgf·m, 20.2—29.6 ft·lbf}
4. Tighten the SST (49 E017 5A0)so that the engine
is located at the specified position.
No.4 Engine Mount Installation Note
1. Verify that the No.4 engine mount rubber is installed as shown.
2. Lightly tighten the bolt A and B.
3. Align the contacted area to front frame of the bolt C to the front frame.
4. Tighten the bolt A, then bolt B.
5. Tighten the bolt C, then bolt D.
Tightening torque
A,B,C,D: 58.8—80.4 N·m
{6.00—8.19 kgf·m, 43.4—59.2 ft·lbf}
6. Verify that the No.4 engine mount bracket is
installed as shown.
7. Lightly tighten the bolt E.
8. Set the transaxle on a garage jack and lift it.
9. Align the hole of the No.4 engine mount bracket
with the stud bolts of transaxle.
10. Lightly tighten the nut F, G and bolt H.
11. Tighten the nut F, G in order of F→G, then bolt H.
A6E5212W022
STUD
A6E5212W020
D
H
C
FB
A
GE
A6E5212W024
TRANSAXLE
GARAGE JACK
A6E5212W023

MANUAL TRANSAXLE
J2–11
J2
12. Tighten the bolt E.
Tightening torque
E: 85.3—116.6 N·m
{8.70—11.88 kgf·m, 62.91—85.98 ft·lbf}
F,G,H: 66.6—93.1 N·m
{6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
No.1 Engine Mount Installation Note
1. Tighten the bolt A, then bolt B.
Tightening torque
93.1—116.6 N·m
{9.50—11.88 kgf·m, 68.66—85.98 ft·lbf}
2. Align the hole of the No.1 engine mount rubber with the crossmember.
3. Lightly tighten the bolt C, then tighen the bolt C.
Tightening torque
93.1—116.6 N·m
{9.50—11.88 kgf·m, 68.66—85.98 ft·lbf}
4. Remove the SST (49 E017 5A0).
End Of Sie
D
H
C
FB
A
GE
A6E5212W024
TRANSAXLE
CB
A
A6E5212W025

J2–12
SHIFT MECHANISM
SHIFT MECHANISM REMOVAL/INSTALLATIONA6E5214460102011. Remove the battery and battery tray.
2. Remove the air cleaner component. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the dashboard compleat. (See Section S.)
4. Remove the SAS control module. (See Section T.)
5. Remove the climate control unit. (See Section U.)
6. Remove the rear heat duct. (See Section U.)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. After installation, verify that the shift lever can be shifted smoothly into each position.
.
SHIFT MECHANISM
7
5
A
A
4
3
3
6
6.86—9.8
{70—99 kgf·cm, 61—85 in·lbf}
15.68—22.54
{1.599—2.298,
11.57—16.62} 7.8—10.8
{80—110 kgf·cm,
69.5—95.4 in·lbf}
1
2
N·m {kgf·m, ft·lbf}
15.68—22.54
{1.599—2.298,
11.57—16.62}
A6E5214W001
1 Shift lever knob
2 Boot panel
3 Clip
4 Seal plate5 Select cable
(See J2–13 Select Cable Installation Note)
6 Shift cable
7 Sift lever component

SHIFT MECHANISM
J2–13
J2
Select Cable Installation Note
1. Remove the center console.
2. Make sure that the shift lever (transaxle side) is in neutral.
3. Unlock the lock pice of the select cable (shift lever
side) in the order shown in the figure.
4. Shift the sift lever to neutral.
5. Lock the lock pice of the selector cable (shift
cable side) in the order shown in the figure.
6. Install the center console.
7. Shift the shift lever from neutral to other position,
and make sure that there are no other
components in that area to interfere with the
lever.
End Of Sie
LOCK PIECE SAFETY
LOCK
1
2
A6E5214W002
LOCK PIECE SAFETY
LOCK
2
1
A6E5214W003

K2–1
K2
K2AUTOMATIC TRANSAXLE [JA5AX-EL]
OUTLINE.............................................................. K2-3
FEATURES ........................................................ K2-3
SPECIFICATIONS ............................................. K2-3
AUTOMATIC TRANSAXLE.................................. K2-4
OUTLINE ........................................................... K2-4
CROSS-SECTIONAL VIEW .............................. K2-6
ELECTRONIC CONTROL SYSTEM
STRUCTURAL VIEW...................................... K2-8
AUTOMATIC TRANSAXLE CONTROL SYSTEM
WIRING DIAGRAM ....................................... K2-10
AUTOMATIC TRANSAXLE BLOCK
DIAGRAM ..................................................... K2-11
AUTOMATIC TRANSAXLE DEVICE
RELATIONSHIP CHART .............................. K2-13
POWERTRAIN DESCRIPTION ....................... K2-15
TORQUE CONVERTER DESCRIPTION......... K2-40
OIL PUMP DESCRIPTION .............................. K2-41
CENTRIFUGAL BALANCE CLUTCH
DESCRIPTION ............................................. K2-42
CONTROL VALVE BODY DESCRIPTION ...... K2-43
TRANSAXLE FLUID TEMPERATURE
(TFT) SENSOR DESCRIPTION ................... K2-45
INPUT/TURBINE SPEED SENSOR
DESCRIPTION ............................................. K2-45
INTERMEDIATE SENSOR DESCRIPTION..... K2-46
VEHICLE SPEEDOMETER SENSOR
DESCRIPTION ............................................. K2-46
SOLENOID VALVE DESCRIPTION ................ K2-47
CONTROLLER AREA NETWORK (CAN)
DESCRIPTION ............................................. K2-50
TRANSAXLE CONTROL MODULE
(TCM) DESCRIPTION .................................. K2-51
SHIFT CONTROL DESCRIPTION .................. K2-51
MANUAL MODE SHIFT CONTROL
DESCRIPTION ............................................. K2-52
LINE PRESSURE CONTROL DESCRIPTION K2-54
FEEDBACK CONTROL DESCRIPTION ......... K2-57
N-D SELECT CONTROL DESCRIPTION........ K2-59
TORQUE CONVERTER CLUTCH
(TCC) CONTROL DESCRIPTION ................ K2-59
SLOPE MODE CONTROL DESCRIPTION ..... K2-63
ON-BOARD DIAGNOSTIC (OBD)
SYSTEM DESCRIPTION.............................. K2-64
COOLING SYSTEM DESCRIPTION ............... K2-69
LOCATION INDEX............................................. K2-70
AUTOMATIC TRANSAXLE LOCATION
INDEX ........................................................... K2-70
AUTOMATIC TRANSAXLE................................ K2-72
MECHANICAL SYSTEM TEST ....................... K2-72
ROAD TEST .................................................... K2-75AUTOMATIC TRANSAXLE FLUID
(ATF) INSPECTION ...................................... K2-78
AUTOMATIC TRANSAXLE FLUID
(ATF) REPLACEMENT ................................. K2-80
TRANSAXLE RANGE (TR) SWITCH
INSPECTION ................................................ K2-80
TRANSAXLE RANGE (TR) SWITCH
REMOVAL/INSTALLATION .......................... K2-81
TRANSAXLE RANGE (TR) SWITCH
ADJUSTMENT .............................................. K2-83
TRANSAXLE FLUID TEMPERATURE
(TFT) SENSOR INSPECTION ...................... K2-84
TRANSAXLE FLUID TEMPERATURE
(TFT) SENSOR REMOVAL/INSTALLATION K2-85
INPUT/TURBINE SPEED SENSOR
INSPECTION ................................................ K2-85
INPUT/TURBINE SPEED SENSOR
REMOVAL/INSTALLATION .......................... K2-86
INTERMEDIATE SENSOR INSPECTION ....... K2-86
INTERMEDIATE SENSOR
REMOVAL/INSTALLATION .......................... K2-86
VEHICLE SPEEDOMETER SENSOR
(VSS) INSPECTION...................................... K2-87
VEHICLE SPEEDOMETER SENSOR
(VSS) REMOVAL/INSTALLATION ............... K2-87
SOLENOID VALVE INSPECTION ................... K2-88
SOLENOID VALVE
REMOVAL/INSTALLATION .......................... K2-90
TCM INSPECTION .......................................... K2-90
TCM REMOVAL/INSTALLATION .................... K2-96
AUTOMATIC TRANSAXLE AND
TRANSFER REMOVAL/INSTALLATION...... K2-99
OIL SEAL REMOVAL/INSTALLATION .......... K2-104
CONTROL VALVE BODY
REMOVAL/INSTALLATION ........................ K2-105
OIL COOLER FLUSHING .............................. K2-106
OIL COOLER REMOVAL/INSTALLATION .... K2-108
OIL COOLER DISASSEMBLY/ASSEMBLY .. K2-110
DRIVE PLATE REMOVAL/INSTALLATION... K2-112
TRANSFER....................................................... K2-114
TRANSFER OIL INSPECTION ...................... K2-114
TRANSFER OIL REPLACEMENT ................. K2-114
TRANSFER REMOVAL/INSTALLATION....... K2-115
BREATHER PLUG
REMOVAL/INSTALLATION ........................ K2-116
AUTOMATIC TRANSAXLE SHIFT
MECHANISM................................................. K2-117
SELECTOR LEVER INSPECTION ................ K2-117
SELECTOR LEVER COMPONENT
INSPECTION .............................................. K2-117
SELECTOR CABLE ADJUSTMENT .............. K2-118
SELECTOR LEVER
REMOVAL/INSTALLATION ........................ K2-119
SELECTOR LEVER
DISASSEMBLY/ASSEMBLY ...................... K2-122
ON-BOARD DIAGNOSTIC............................... K2-123
FOREWORD .................................................. K2-123 FEATURES
SERVICE