oil MAZDA 6 2002 Workshop Manual Suplement

STARTING SYSTEM
G–9
G
STARTER REMOVAL/INSTALLATIONA6E471418400202
Warning
•When the battery cables are connected, touching the vehicle body with starter terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the battery negative cables before performing the following operation.
1. Disconnect the negative battery cable.
2. Remove the plug hole plate. (L8, LF, and L3 engine models)
3. Remove the engine cover. (MZR-CD (RF Turbo) engine model) (See B2–9 TIMING BELT REMOVAL/
INSTALLATION.)
4. Remove the air cleaner assembly. (L8, LF, and L3 engine models).
5. Remove the under cover.
6. Remove the oil filter and oil cooler component with the cooling hose connected. Position the oil filter and oil
cooler component so that it is out of the way. (L3 engine model (4WD))
7. Remove the solenoid valve assembly with the vacuum hose and the connector connected. Position the
solenoid valve assembly so that it is out of the way. (MZR-CD (RF Turbo) engine model)
8. Remove the release cylinder with the oil pipe connected. Position the release cylinder so that it is out of the
way. (MTX)
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
STARTING SYSTEM

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

J2–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E520201025203•The construction and operation of the manual transaxle is the same as those of the current A65M-R type
manual transaxle, except for the following features. (See MPV Workshop Manual supplement 1737-1*-02D.)
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FEATURESA6E520201025201Improved drivability
•The gear ratio has been changed.
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SPECIFICATIONSA6E520201025202
Bold frames:New specifications
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OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
Transaxle typeA65M-R
Transaxle control Floor-shift
Operation system Cable
Shift assistForward
Synchromesh
Reverse
Gear ratio1st 3.416
2nd 1.944 1.789
3rd 1.258 1.193
4th 0.902
5th 0.659
Reverse 3.252
Final gear ratio 3.588 4.133
OilGrade API service GL-4 or GL-5
Viscosity (All season) SAE 75W-90
Capacity (approximate quantity)
(L {US qt, Imp qt})2.30 {2.40, 2.00}

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)

J2–4
MANUAL TRANSAXLE
TRANSAXLE OIL INSPECTIONA6E5212270012011. Park the vehicle on level ground.
2. Remove the filler plug and gasket.
3. 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-4 or GL-5
Specified oil viscosity
SAE 75W-90
4. Install a new gasket and the filler plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
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TRANSAXLE OIL REPLACEMENTA6E5212270012021. Remove the drain plug with the gasket.
2. Drain the oil into a suitable container.
3. Install a new gasket and the drain plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
4. Remove the filler plug with gasket 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-4 or GL-5
Specified oil viscosity
SAE 75W-90
Capacity (approximate quantity)
2.30 L {2.40 US qt, 2.00 lmp qt}
5. Install a new gasket and the filler plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
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MANUAL TRANSAXLE
DRAIN PLUG FILLER PLUG
A6E5212W010
DRAIN PLUG FILLER PLUG
A6E5212W010

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

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}
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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

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

OUTLINE
K2–3
K2
FEATURESA6E570201030201ATX
Improved marketability
•New JA5AX-EL automatic transaxle for 4WD is used with on L3 engine.
Improved shift quality
•Five speed automatic transaxle has been adopted.
•The feedback control system has been adopted.
•The centrifugal balance clutch chambers have been adopted.
•A plate-type clutch pack replaces the band brake in the 2-4 brake.
High efficiency, compactness, and light weight
•Miniature trochoid gear type oil pump with torque converter direct drive has been adopted.
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SPECIFICATIONSA6E570201030202
OUTLINE
ItemNew Mazda6 (GY) Current MPV (LW)
–For General
(R.H.D.)
specs.Except for
General
(R.H.D.)
specs.
Transaxle type JA5AX-EL JA5A-EL
Gear ratio1GR 3.801
2GR 2.131
3GR 1.364
4GR 0.935
5GR (O/D) 0.685
Reverse 2.970
Final gear ratio 3.491 3.290 3.491
ATFType
ATF M-III or equivalent (e.g. Dexron
®III)
Capacity (approximate quantity)
(L {US qt, Imp qt})8.3 {8.8, 7.3} 9.7 {10.3, 8.5}
Torque converter stall torque ratio 1.86:1
Hydraulic system (Number of
drive/driven plates)Low clutch 6/6 7/7
2-4 brake 3/4
High clutch 5/5
Direct clutch 3/5 4/4
Reverse clutch 2/2
Low and reverse brake 6/5
Band servo (mm {in})Reduction accumulator piston outer
dia./reduction band servo piston
outer dia.49.66/57.64
Number of front planetary gear
teethRing gear 74
Sun gear 34
Pinion gear 20
Number of rear planetary gear
teethRing gear 75
Sun gear 42
Pinion gear 17
Number of reduction planetary
gear teethRing gear 85
Sun gear 31
Pinion gear 27
Number of output gear teeth 41
Number of idler gear teeth 47
Number of reduction gear teeth 22 23 22
Number of ring gear teeth 67 66 67
Transfer oilTypeSAE 80W-90
API Service GL-5–
Capacity (approximate quantity)
(L {US qt, Imp qt})0.62 {0.66, 0.55}–

AUTOMATIC TRANSAXLE
K2–9
K2
.
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1918
17
15
16
14
13
12
A6E5714W011
12 Cruise control module (In cluise actuator)
13 Solenoid valve
14 TFT sensor
15 TR switch16 Input/turbine speed sensor
17 Intermediate sensor
18 VSS
19 Oil cooler