2002 MAZDA 6 torque

AUTOMATIC TRANSAXLE
K2–79
K2
Automatic Transaxle Fluid (ATF) Level Inspection
Caution
•The ATF amount varies according to ATF's temperature. Therefore, when checking the ATF level or
replacing the ATF, use a thermometer to measure the temperature then adjust the ATF amount to
the specified level according to the specified temperature.
1. Park the vehicle on level ground.
2. Apply the parking brake and position wheel chocks securely to prevent the vehicle from rolling.
3. Adjust the length of the thermistor probe measure to the measure same as the dipstick and hold the probe with
a paper holder.
4. Insert into the filler tube and measure the
temperature.
5. Warm up the engine until the ATF reaches (60—
70 °C {140—158 °F}).
Caution
•Do not warm the transaxle by performing
stalls. This will damage the torque
converter.
Note
•In some cases it may be necessary to
inspect the ATF in the cool range 15—25 °C
{59—77 °F} before warming up the engine.
6. While depressing the brake pedal, shift the selector lever to each range (P—M), pausing momentarily in each
range.
7. Shift back to P position.
Note
•If the ATF level is too high or too low in hot condition, the following problems may be the cause.
8. While the engine is idling, verify that the ATF level
is in the HOT (65 °C {149 °F}) range. Add the
ATF specified type of, if necessary. (See K2–80
AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT.)
ATF type
ATF M-III or equivalent (e.g. Dexron
®III)
Capacity (Approximate quantity)
8.3 L {8.8 US qt, 7.3 Imp qt}
End Of Sie
ATF level Condition Possible cause
Too lowLine pressure is
lower than the
specificationAir in transaxle oil passage
due to slipping or damaged
clutch mechanism
Too high ATF is hotATF deteriorated due to
slipping clutch or stuck
valve
A6E5614W003
A6E5714W105

K2–80
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENTA6E571419001202
Warning
•When the transaxle and ATF are hot, they can badly burn you. Turn off the engine and wait until
they are cool before changing the ATF.
1. Remove the oil dipstick.
2. Remove the oil drain plug and washer.
3. Drain the ATF into a container.
4. Install a new washer and the drain plug.
Tightening torque
39—54 N·m {3.9—5.6 kgf·m, 29—40 ft·lbf}
5. Add the specified type of ATF through the oil filler
tube, until ATF level reaches lower notch of
dipstick.
ATF type
ATF M-III or equivalent (e.g. Dexron
®III)
Capacity (Approximate quantity)
8.3 L {8.8 US qt, 7.3 Imp qt}
6. Verify that the ATF level is in the HOT (65 °C {149 °F}) range.
•Add ATF to the specified level as necessary.
End Of Sie
TRANSAXLE RANGE (TR) SWITCH INSPECTIONA6E571419440201
Note
•Input signals of the TR switch can be inspected with a WDS or equivalent. (See K2–90 TCM
INSPECTION.)
Inspection of Operation
1. Verify that the starter operates only with the ignition switch at the START position and the selector lever in P
and N positions.
•If not as specified, inspect for continuity at the TR switch. (See K2–80 Inspection of Continuity.)
2. Verify that the back-up lights illuminate when shifted to R position with the ignition switch at the ON position.
•If not as specified, inspect for continuity at the TR switch.
Inspection of Continuity
1. Disconnect the TR switch connector.
2. Inspect for continuity at the TR switch.
•If not as specified, adjust the TR switch, then
reinspect the TR switch. (See K2–83
TRANSAXLE RANGE (TR) SWITCH
ADJUSTMENT.)
A6E5714W106
TR SWITCHTR SWITCH
CONNECTOR
A6E5714W107
Position/
Range
H
P
R
N
DBCAEDGI FConnector terminal: Continuity
A6E5714W108

K2–82
AUTOMATIC TRANSAXLE
11. Using the SST and by turning the TR switch,
adjust the positions of the manual shaft and the
TR switch neutral hole.
12. Tighten the TR switch mounting bolts.
Tightening torque
4.9—6.9 N·m
{50—70 kgf·cm, 44—61 in·lbf}
13. Inspect for continuity at the TR switch between
terminals C and D.
14. Remove the SST.
15. Install the manual shaft lever and washer.
Caution
•Do not use an impact wrench. Hold the
manual shaft lever when tightening the
manual shaft nut, or the transaxle may be
damaged.
16. Set the adjustable wrench as shown to hold the
manual shaft lever.
17. Tighten the manual shaft nut using a torque
wrench.
Tightening torque
31.36—46.06 N·m
{3.198—4.696 kgf·m, 23.13—33.96 ft·lbf}
18. Install the spring as shown in the figure.
•If it is bend, replace a new spring.
19. Verify that the selector lever range position and
TR switch are aligned, then connect the selector
cable.
20. Inspect for continuity at the TR switch. (See K2–
80 Inspection of Continuity.)
21. Connect the TR switch connector.
22. Install the air cleaner component. (See Section
F.)
23. Connect the negative battery cable.
24. Inspect operation of the TR switch. (See K2–80
Inspection of Operation.)
49 L019 013
A6E5714W113
BC AE
DG
I
FH
A6E5714W109
A6E5714W150
SPRING
SELECTOR CABLE
A6E5714W114
SELECTOR CABLE
MANUAL SHAFT LEVERSPRING
UPWARD
A6E5714W115

AUTOMATIC TRANSAXLE
K2–83
K2
End Of SieTRANSAXLE RANGE (TR) SWITCH ADJUSTMENTA6E571419440203
Caution
•Water or foreign objects entering the connector can cause a poor connection or corrosion. Be
sure not to drop water or foreign objects on the connector when disconnecting it.
1. Disconnect the TR switch connector.
2. Remove the spring and disconnect the selector
cable.
Note
•Do not reuse the clip when any of the hooks
are deformed.
3. Remove the selector cable from the cable
bracket.
4. Rotate the manual shaft to the right fully, then
return 2 notches to set the N position.
5. Loosen the TR switch mounting bolts.
Caution
•Improper adjustment of the TR switch will
cause abnormal operation of the
automatic transaxle. Be sure to use the
SST to adjust the TR switch correctly.
6. Using the SST and by turning the TR switch,
adjust the positions of the manual shaft and the
TR switch neutral hole.
7. Tighten the TR switch mounting bolts.
Tightening torque
4.9—6.9 N·m
{50—70 kgf·cm, 44—61 in·lbf}
8. Remove the SST.
9. Inspect for continuity at the TR switch. (See K2–
80 Inspection of Continuity.)
10. Connect the TR switch connector.
11. Connect the selector cable and install a spring.
12. Inspect operation of the TR switch. (See K2–80 Inspection of Operation.)
End Of Sie
SPRING
SELECTOR
CABLE
MANUAL
SHAFT
LEVER
A6E5714W110
CABLE
BRACKET
SELECTOR
CABLE
A6E5714W116
TO VEHICLE FRONT
MANUAL SHAFT
D, MN
R
P
A6E5714W112
49 L019 013
A6E5714W113

K2–90
AUTOMATIC TRANSAXLE
SOLENOID VALVE REMOVAL/INSTALLATIONA6E5714212802031. Remove the control valve body. (See K2–105 CONTROL VALVE BODY REMOVAL/INSTALLATION.)
2. Remove the solenoid valves and manual valve.
.
3. Apply ATF to a new O-ring and install it on the solenoid valve.
4. Install the solenoid valve and manual valve in the control valve body.
Tightening torque
8.34—10.30 N·m
{85.0—105.0 kgf·cm, 73.78—91.13 in·lbf}
5. Install the control valve body. (See K2–105 CONTROL VALVE BODY REMOVAL/INSTALLATION.)
6. Add the ATF while the engine is idling, and inspect the ATF level and leakage. (See K2–80 AUTOMATIC
TRANSAXLE FLUID (ATF) REPLACEMENT.) (See K2–79 Automatic Transaxle Fluid (ATF) Level Inspection.)
7. Carry out the time lag test and line pressure test. (See K2–72 MECHANICAL SYSTEM TEST.)
8. Carry out the road test. (See K2–75 ROAD TEST.)
End Of Sie
TCM INSPECTIONA6E571418901211Terminal Voltage Table (Reference)
Note
•Use the ground of terminal 1C and 1Y of the TCM when measuring terminal voltage, as an error may
occur when connecting the negative circuit tester to ground.
5
44
3
10
687
9
1
2
A6E5714W122
1 Manual valve
2 2-4 brake solenoid valve
3 Neutral shift solenoid valve
4 TCC solenoid valve
5 Shift solenoid C6 Shift solenoid B
7 Reduction timing solenoid valve
8 Shift solenoid A
9 Pressure control solenoid
10 High clutch solenoid valve

AUTOMATIC TRANSAXLE
K2–99
K2
AUTOMATIC TRANSAXLE AND TRANSFER REMOVAL/INSTALLATIONA6E5714190902011. Disconnect the negative battery cable.
2. Remove the battery and battery tray.
3. Remove the aircleaner component. (See Sectin F.)
4. Remove the front tires and splash shield.
5. Remove the under cover.
6. Separate the steering shaft and steering hose. (See N–13 STEERING GEAR AND LINKAGE (4WD)
REMOVAL/INSTALLATION.)
7. Remove the front auto leveling sensor. (See Section T.)
8. Drain the ATF. (See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.)
Warning
•Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.
Caution
•To prevent the torque converter and transaxle from separating, remove the transaxle without
tilting it toward the torque converter.
9. Remove in the order shown in the figure.
10. Install in the reverse order of removal.
11. Adjust the headlight zeroset. (See Section T.)
12. Add ATF to the specified level. (See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.)
13. Carry out the mechanical system test. (See K2–72 MECHANICAL SYSTEM TEST.)
×: Test to be performed after the service work
14. Carry out the road test. (See K2–75 ROAD TEST.)
Service itemTest item
Line
pressure
testStall testTime lag
test
ATX replacement×
ATX overhaul×××
Torque converter
replacement××
Oil pump
replacement×
Clutch system
replacement××

AUTOMATIC TRANSAXLE
K2–101
K2
No.1 Engine Mount Bracket Removal Note
1. Support the engine using the SST before removing the No.1 engine mount.
2. Remove the No.1 engine mount.
Transaxle Removal Note
1. Loosen the part marked A and lean the engine
toward the transaxle.
2. Support the transaxle on a jack.
3. Remove the transaxle mounting bolts.
4. Remove the transaxle.
1O2 sensor connector
2 Terminal component No.1, No.2 connector
3 TR switch connector
4 GND harness
5 Selector cable
(See K2–104 Selector Cable Installation Note)
6 Cable bracket
7 Oil hose
8 Transaxle mounting bolt (upper side)
9 Starter (See Section G)
10 Endplate cover
11 Lower arm (front, rear) ball joint (See Section R)
12 Damper fork
13 Tie-rod end ball joint
(See N–13 STEERING GEAR AND LINKAGE
(4WD) REMOVAL/INSTALLATION)
14 Stabilizer control link
15 Drive shaft (left side) (See Section M)16 Drive shaft (right side) (See Section M)
17 Joint shaft (See Section M)
18 No.1 engine mount
(See K2–101 No.1 Engine Mount Bracket Removal
Note)
(See K2–103 No.1 Engine Mount Installation Note)
19 Crossmember bracket
20 Crossmember, steering gear (See Section R)
21 Torque converter installation nuts
(See K2–102 Torque Converter Nuts Removal
Note)
(See (SeeK2–102 Torque Converter Nuts
Installation Note)
22No.4 engine mount
(See K2–103 No.4 Engine Mount Installation Note)
23 Transaxle mounting bolt (lower side)
24 Transaxle
(See K2–101 Transaxle Removal Note)
(See K2–102 Transaxle Installation Note)
49 E017 5A0
A6E5714W132
A
A6E5714W133
A6E5714W134

K2–102
AUTOMATIC TRANSAXLE
Transaxle Installation Note
1. Set the transaxle on a jack and lift it.
2. Install the transaxle mounting bolts.
Tightening torque
37—52 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
Torque Converter Nuts Removal Note
1. Hold the cankshaft pulley to prevent drive plate
from rotating.
2. Remove the torque converter nuts from the
starter installation hole.
Torque Converter Nuts Installation Note
1. Hold the cankshaft pulley to prevent drive plate
from rotating.
Caution
•Loosely and equally tighten the torque
converter nuts, then further tighten them
to the specified tightening torque.
A6E5714W135
A6E5614W091
A6E5714W136
A6E5614W091