2002 MAZDA 6 Workshop Manual Suplement

K2–114
TRANSFER
TRANSFER OIL INSPECTIONA6E5718170012011. Park the vehicle on level ground.
2. Remove the PTO heat shield.
3. Remove the filler plug.
4. Verify that the oil is near the brim of the plug port.
•If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Specified oil grade
API Service GL-5
Specified oil viscosity
SAE 80W-90
5. Apply a sealant to the thread area of filler plug.
Specified sealant
TB1215
6. Install the filler plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
7. Install the PTO heat shield. (See K2–116 PTO Heat Shield Installation Note.)
End Of Sie
TRANSFER OIL REPLACEMENTA6E5718170012021. Remove the drain plug.
2. Drain the oil into a suitable container.
3. Apply a sealant to the thread area of drain plug.
Specified sealant
TB1215
4. Install the drain plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
5. Remove the PTO heat shield.
6. Remove the filler plug and add the specified amount and type of oil through the filler plug hole until the level
reaches the bottom of the filler plug hole.
Specified oil grade
API Service GL-5
Specified oil viscosity
SAE 80W-90
Capacity (approximate quantity)
0.62 L {0.65 US qt, 0.54 lmp qt}
7. Apply a sealant to the thread area of filler plug.
Specified sealant
TB1215
8. Install the filler plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
9. Install the PTO heat shield. (See K2–116 PTO Heat Shield Installation Note.)
TRANSFER
TRANSFER
FILLER PLUG
DRAIN PLUG
A6E5718W101
TRANSFER
FILLER PLUG
DRAIN PLUG
A6E5718W101

TRANSFER
K2–115
K2
End Of SieTRANSFER REMOVAL/INSTALLATIONA6E5718170012041. Disconnect the negative battery cable.
2. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the TWC. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
4. Remove the front tires and splash shield of right side.
5. Remove the under cover.
6. Remove the drive shaft of right side. (See Section M.)
7. Remove the joint shaft. (See Section M.)
8. Remove the exhaust manifold insulator. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
9. Remove the exhaust manifold. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
10. Remove in the order shown in the figure.
11. Install in the reverse order of removal.
.
No.1 Engine Mount Installation Bolt Removal Note
1. Support the engine using the SST before
removing the No.1 engine mount.
2. Loosen the bolt A.
3. Remove the bolt B.
4. Remove the bolt C and D.
1 No.1 engine mount installation bolt
(See K2–115 No.1 Engine Mount Installation Bolt
Removal Note)
(See K2–116 No.1 Engine Mount Installation Bolt
Installation Note)
2 PTO heat shield
(See K2–116 PTO Heat Shield Installation Note)
3Transfer
2
3
N·m { kgf·m, ft·lbf} 8—11
{82—112 kgf·cm, 72—96 in·lbf}
64—89
{6.6—9.0, 48—65}
185.3—116.6
{8.70—11.88,
62.91—85.98}
A6E5718W102
49 E017 5A0
A6E5714W132
AC
B
D
A6E5714W138

K2–116
TRANSFER
No.1 Engine Mount Installation Bolt Installation Note
1. Tighten the bolt C and D.
2. Lightly tighten the bolt B, then bolt A.
3. Tighten the bolt B and A.
Tightening torque
A, C, D: 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}
PTO Heat Shield Installation Note
1. Lightly tighten the bolt A.
2. Tighten the bolt B, then bolt C.
3. Tighten the bolt A.
Tightening torque
8—11 N·m
{82—112 kgf·cm, 72—97 in·lbf}
End Of SieBREATHER PLUG REMOVAL/INSTALLATIONA6E5718170012031. Remove the PTO heat shield.
2. Remove the breather plug.
Caution
•Allowing the breather hole to the close
during apply a sealant can affect the
transfer operation.
3. Apply a sealant to the thread area of filler plug.
Specified sealant
TB1215
4. Install the filler plug.
Tightening torque
7.9—11.7 N·m
{81—119 kgf·cm, 71—103 in·lbf}
5. Install the PTO heat shield. (See K2–116 PTO Heat Shield Installation Note.)
End Of Sie
AC
B
D
A6E5714W138
PTO HEAT SHIELD
A
B C
A6E5718W104
TRANSFER BREATHER PLUG
A6E5718W105

AUTOMATIC TRANSAXLE SHIFT MECHANISM
K2–117
K2
SELECTOR LEVER INSPECTIONA6E5716461022011. Turn the ignition switch to the ON position (engine off).
2. With the brake pedal depressed, verify that a “click” sound is heard at each range when shifted in the pattern
shown.
3. Verify that the selector lever can only be shifted
as shown.
4. Verify that the position of the selector lever and
the selector indicator light correspond.
•If not as specified, adjust the TR switch. (See
K2–83 TRANSAXLE RANGE (TR) SWITCH
ADJUSTMENT.)
5. Verify that the vehicle operates in each selected
range.
End Of SieSELECTOR LEVER COMPONENT INSPECTIONA6E5716461022041. Disconnect the negative battery cable.
2. Remove the console.
3. Remove the dashboard completely. (See section S.)
4. Disconnect the selector lever component connector.
5. Inspect for continuity at the selector lever
component.
•If not as specified, adjust the selector cable.
(See K2–118 SELECTOR CABLE
ADJUSTMENT.)
End Of Sie
AUTOMATIC TRANSAXLE SHIFT MECHANISM
P
R
N
DM
P
R
N
DM
OPERATION WHEN
BRAKE PEDAL IS
DEPRESSED
OPERATION WHEN
BRAKE PEDAL IS
RELEASED
A6E5716W101
SELECTOR LEVER COMPONENT
PART SIDE CONNECTOR
A6A5616W013
A6A5616W012

K2–118
AUTOMATIC TRANSAXLE SHIFT MECHANISM
SELECTOR CABLE ADJUSTMENTA6E5716465002011. Remove the center console.
2. Shift the selector lever to P position.
3. Unlock the lock piece of the selector cable
(selector lever side) in the order shown in the
figure.
4. Verify that the manual shaft is in P position.
5. Lock the lock piece of the selector cable (selector
lever side) in the order shown in the figure.
6. Install the center console.
7. Shift the selector lever from P position to M range,
and make sure that there are no other
components in that area to interfere with the lever.
End Of Sie
1
2
SAFETY
LOCK
LOCK PIECE
A6E5716W102
2
1
SAFETY
LOCK
LOCK PIECE
A6E5716W103

AUTOMATIC TRANSAXLE SHIFT MECHANISM
K2–119
K2
SELECTOR LEVER REMOVAL/INSTALLATIONA6E5716461022021. Disconnect the negative battery cable.
2. Remove the battery and battery tray.
3. Remove the air cleaner compornent. (See Section F.)
4. Remove the console.
5. Remove the dashboard compleat. (See Section S.)
6. Remove the SAS control module. (See Section T.)
7. Remove the climate control unit. (See Section U.)
8. Remove the rear heat duct. (See Section U.)
9. Remove in the order shown in the figure.
10. Install in the reverse order of removal.
.
1
2
A
A
B
15.68—22.5
{1.60—2.29, 11.6—16.5}
B6.86—9.8 N·m
{70—99 kgf·cm, 61—86 in·lbf}
N·m {kgf·m, ft·lbf}
A6E5716W104
1 Selector cable
(See K2–120 Selector Cable Removal Note.)
(See K2–120 Selector Cable Installation Note.)2Selector lever

K2–120
AUTOMATIC TRANSAXLE SHIFT MECHANISM
Selector Cable Removal Note
1. Remove the spring.
2. Remove the selector cable.
Selector Cable Installation Note
1. Install the selector cable to the selector lever certainly.
2. Install the selector cable to the bracket certainly.
Note
•Step 3, 4 is for the selector cable
replacement only.
3. Verify that the selector lever is in P position.
4. Lock the lock piece of the selector cable (selector
lever side) in the order shown in the figure.
5. Verify that the manual shaft is in P position.
SPRING SELECTOR CABLE
A6E5716W105
SELECTOR CABLE
A6E5616W020
2
1
SAFETY
LOCK
LOCK PIECE
A6E5716W103
DO NOT BEND
A6E5616W007

AUTOMATIC TRANSAXLE SHIFT MECHANISM
K2–121
K2
Caution
•Bending the selector cable in the manner
shown in the figure will damage the cable
and it may become loose when shifted.
When installing the selector cable, hold it
straight.
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.
6. Install the selector lever to the manual shaft lever
in such a way that the selector cable does not bear a load.
7. Confirm that the end of the manual shift lever sticks out of the end of the selector cable.
8. Install the selector cable to the selector cable securely bracket.
End Of Sie
SELECTOR CABLE
MANUAL SHAFT LEVERSPRING
UPWARD
A6E5714W115