engine MAZDA 6 2002 Workshop Manual Suplement

AUTOMATIC TRANSAXLE
K2–67
K2
P0758Shift solenoid B malfunction
(open/short)•Open or short in shift
solenoid B circuit (Voltage
different from on/off signal
relayed by CPU in TCM is
detected while TCM is
monitoring solenoid output
voltage.)•Stops driving all ON/OFF
type solenoids (OFF) and
TCC solenoid valve (OFF)Inhibition
P0761Shift solenoid C malfunction
(stuck off)•Difference between actual
gear ratio and gear ratio set
in TCM is large—Available
P0762Shift solenoid C malfunction
(stuck on)•Difference between actual
gear ratio and gear ratio set
in TCM is large—Available
P0763Shift solenoid C malfunction
(open/short)•Open or short in shift
solenoid C circuit (Voltage
different from on/off signal
relayed by CPU in TCM is
detected while TCM is
monitoring solenoid output
voltage.)•Stops driving all ON/OFF
type solenoids (OFF) and
TCC solenoid valve (OFF)Inhibition
P0768Reduction timing solenoid valve
malfunction (open/short)•Open or short in reduction
timing solenoid valve circuit
(Voltage different from on/off
signal relayed by CPU in
TCM is detected while TCM
is monitoring solenoid
output voltage.)•Stops driving of reduction
timing solenoid valve (OFF)Available
P0773Neutral shift solenoid valve
malfunction (open/short)•Open or short in neutral shift
solenoid valve circuit
(Voltage different from on/off
signal relayed by CPU in
TCM is detected while TCM
is monitoring solenoid
output voltage.)•Stops driving of neutral shift
solenoid valve (OFF)Available
P07782-4 brake solenoid valve
malfunction (open/short)•Open or short in 2-4 brake
solenoid valve circuit
(Voltage different from on/off
signal relayed by CPU in
TCM is detected while TCM
is monitoring solenoid
output voltage.)•Stops driving of pressure
control solenoid, 2-4 brake
solenoid valve, and high
clutch solenoid valve (OFF)
•Inhibit feedback control.Available
P0791Intermediate sensor malfunction
(open/short)•Rotation speed of output
gear (intermediate sensor)
is low when vehicle speed
and engine speed exceed
the pre programmed value•Inhibit feedback control
•Inhibits torque reduction
controlAvailable
P0798High clutch solenoid valve
malfunction (open/short)•Open or short in high clutch
solenoid valve circuit
(Voltage different from on/off
signal relayed by CPU in
TCM is detected while TCM
is monitoring solenoid
output voltage.)•Stops driving of pressure
control solenoid, 2-4 brake
solenoid valve, and high
clutch solenoid valve (OFF)
•Inhibit feedback control.Available
P1710 GND return malfunction•TCM detects open in GND
return signal of solenoid.—Available
U0073 CAN BUS OFF•CAN controller damaged.•Throttle valve opening angle
is fixed (4/8) at the time in
order to determine shift
•Maximizes line pressureInhibition
U0100TCM cannot receive any signals
from PCM•TCM cannot receive any
signals from PCM DTC
No.On-board diagnostic function Detection condition Fail-safe TCC

K2–68
AUTOMATIC TRANSAXLE
Parameter Identification (PID) Access
Monitor item table
End Of Sie
Display on the
testerDefinitionUnit/
ConditionTCM
terminal
2-4 B Duty 2-4 brake solenoid valve control signal in TCM ON/OFF 2V
BOO Brake switch ON/OFF 1U
DWN_SW Down switch ON/OFF 1S
GEAR Calculated gear range in TCM1ST/2ND/
3RD/4TH/5TH–
H/C Duty High clutch solenoid valve control signal in TCM % 2U
LPS Pressure control solenoid control signal in TCM % 2Y
MNL_SW M range switch ON/OFF 1AA
NSFT TIM Neutral shift solenoid valve control signal in TCM ON/OFF 2D
OSS Intermediate sensor rpm 1K, 1X
PNP TR switch (P/N position switch) ON/OFF–
RDCN TIM Reduction timing solenoid valve control signal in TCM ON/OFF 2G
RPM Engine speed rpm–
SSA/SS1 Shift solenoid A control signal in TCM ON/OFF–
SSB/SS2 Shift solenoid B control signal in TCM ON/OFF–
SSC/SS3 Shift solenoid C control signal in TCM ON/OFF–
TCCC TCC solenoid valve control signal in TCM % 2S
TCIL AT warning light control signal in TCM ON/OFF 1E
TFT ATF temperature°C1B, 1F
TFTV ATF temperature signal voltage V 1B, 1F
THOP Throttle position %–
TRD Tr switch (D range switch) ON/OFF 1Z
TRR TR switch (R position switch) ON/OFF 1W
TSS Input/turbine speed sensor rpm 1N, 2F
UP_SW Up switch ON/OFF 2C
VPWR Battery voltage V 1P
VSS Vehicle speed km/h 1V, 1M

K2–72
AUTOMATIC TRANSAXLE
MECHANICAL SYSTEM TESTA6E571401030209Mechanical System Test Preparation
1. Apply the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant. (See Section E.)
3. Inspect the engine oil. (See D–8 ENGINE OIL INSPECTION.)
4. Inspect the ATF levels. (See K2–79 Automatic Transaxle Fluid (ATF) Level Inspection.)
5. Inspect the idle speed and ignition timing in P position. (See F1–22 IDLE SPEED INSPECTION (4WD).)
Line Pressure Test
Note
•Line pressure cannot be measured on the JA5AX-EL automatic transaxle. Measure the low clutch
pressure in place of D and M range line pressures. Measure the reverse clutch pressure in place of R
position line pressure.
1. Engine idling.
(1) Perform mechanical system test preparation. (See K2–72 Mechanical System Test Preparation.)
Warning
•Removing the plug when the ATF is hot can be dangerous. Hot ATF can come out of the opening
and badly burn you. Before removing the square-head plug, allow the ATF to cool.
(2) Remove the plug and O-ring shown in the
figure.
AUTOMATIC TRANSAXLE
LINE PRESSURE INSPECTION PORT
D,M RANGES
FRONT
A6E5714W101
LINE PRESSURE INSPECTION PORT
R POSITION
FRONT
A6E5714W102

AUTOMATIC TRANSAXLE
K2–73
K2
(3) Connect the SSTs (49 L019 014, 49 B019
901B, and 49 0378 400C) to the low clutch
pressure inspection port (D and M range line
pressures) or reverse clutch pressure
inspection port (R position line pressure).
(4) Start the engine and warm it up until the ATF
reaches 60—70 °C {140—158 °F}.
(5) Shift the selector lever to D range.
(6) Read the line pressure at idle for the
remaining ranges in the same manner.
•M range (1GR, 2GR)
•R range
ATF temperature
60—70 °C {140—158 °F}
Turn off all electrical loads
(7) Turn the engine off.
2. Engine stall speed.
Caution
•Perform the line pressure test at engine idling prior to performing the test at engine stall. If line
pressure is low at idle, do not perform the test at engine stall or further transaxle damage will
occur.
(1) Replace the SST (49 B019 901B) with the gauge of the SST (49 0378 400C).
(2) Start the engine.
Caution
•Do not maintain WOT in any gear range for more than 5 seconds or transaxle damage will occur.
(3) Firmly depress the brake pedal with the left foot, and then gradually depress the accelerator pedal to the
floor (WOT) with the right.
(4) When the engine speed no longer increases, quickly read the line pressure and release the accelerator
pedal.
(5) Shift the selector lever to N position and let the engine idle for 1 minute or more to cool the ATF.
(6) Read the line pressure at the engine stall speed for the remaining ranges in the same manner.
•M range (1GR, 2GR)
•R range
ATF temperature
60—70 °C {140—158 °F}
Turn off all electrical loads
(7) Shift the selector lever to P position.
(8) Turn off the engine.
(9) Remove the SSTs and install a new square head plug and O-ring in the line pressure inspection port.
Tightening torque
4.91—9.80 N·m {50—100 kgf·cm, 43.4—86.7 in·lbf}
Position/
RangeLine pressure (kPa {kgf/cm2, psi})
Idle
D, M (2GR) 290—490 {3.0—5.0, 42—71}
M (1GR), R 550—750 {5.6—7.6, 80—109}
Position/
RangeLine pressure (kPa {kgf/cm
2, psi})
Stall
D, M (2GR) 1,550—1,750 {15.8—17.8, 225—254}
M (1GR), R 1,550—1,750 {15.8—17.8, 225—254}
49 B019 901B
49 0378 400C
49 0378 400C
49 L019 014
49 L019 014
49 B019 901B
D,M RANGES
R POSITION
A6E5714W103

K2–74
AUTOMATIC TRANSAXLE
Evaluation of line pressure test
Stall Speed Test
1. Perform mechanical system test preparation. (See K2–72 Mechanical System Test Preparation.)
2. Connect a tachometer.
3. Start the engine.
4. Shift the selector lever to D range.
Caution
•Do not maintain WOT in any gear range for more than 5 seconds or transaxle damage will occur.
•If engine speed recorded by the tachometer exceeds maximum specified rpm, release the
accelerator pedal immediately. Clutch or band slippage is indicator.
5. Firmly depress the brake pedal with the left foot, and gently depress the accelerator pedal to the floor (WOT)
with the right.
6. When the engine speed no longer increases, quickly read the engine speed and release the accelerator pedal.
7. Shift the selector the to N position and let the engine idle for 1 minute or more to cool the ATF.
8. Perform stall tests for the remaining ranges and position in the same manner.
•R position
•Mrange (1GR, 2GR)
Engine stall speed
ATF temperature : 60—70 °C {140—158 °F}
Turn off all electrical loads
2,200—2,600 rpm
9. Turn off the engine.
Evaluation of stall test
Condition Possible cause
IdleBelow specificationLow pressure in all rangesWorn oil pump
Poor operation of each solenoid
Fluid leaking from oil strainer, oil pump, pressure regulator
valve, torque converter relief valve, and/or pressure relief valve
Pressure regulator valve or pilot valve sticking
Damaged pressure regulator valve spring or pilot valve spring
Low pressure in D and M
rangeFluid leaking from hydraulic circuit of low clutch
Low pressure in R position
onlyFluid leaking from hydraulic circuit of reverse clutch
Fluid leaking from hydraulic circuit of low and reverse brake
clutch
Above specification High pressure in all rangesThrottle position sensor out of adjustment
TFT sensor malfunction
Poor operation of shift solenoid
Pilot valve sticking
Pressure reducing valve or plug sticking
Stall Below specification Low pressure in all rangesThrottle position sensor out of adjustment
Pressure control solenoid malfunction
Poor operation of shift solenoid
Pilot valve sticking
Pressure reducing valve or plug sticking
Condition Possible cause
Above specificationIn all forward ranges and R
positionInsufficient line pressure
Worm oil pump
Poor operation of low clutch
Poor adjustment or malfunction of TR switch
Oil leaking from oil pump, control valve, and/or transmission
case
Pressure regulator valve or pilot valve sticking
In all forward ranges Low clutch slippage
Low one-way clutch slippage
Reduction one-way clutch slippage
In R positionLow and reverse brake slippage
Reverse clutch slippage
Reduction brake slippage
Below specificationIn all forward ranges and R
positionEngine out of tune
One-way clutch slippage within torque converter

AUTOMATIC TRANSAXLE
K2–75
K2
Time Lag Test
1. Perform mechanical system test preparation. (See K2–72 Mechanical System Test Preparation.)
2. Start the engine.
3. Warm up the engine until the ATF temperature reaches 60—70°C {140—158°F}. Shift the selector lever from N
position to D range.
4. Use a stopwatch to measure the time it takes from shifting until engagement is felt. Take three measurements
for each test and average the results using the following formula.
Formula
Average time lag = (Time 1 + Time 2 + Time 3) / 3
5. Perform the test for the following shifts in the same manner.
•N position → P position
Time lag
N → D range ... approx. 0.5—1.0 second
N → R position ... approx. 0.6— 1.0 second
Evaluation of time lag test
End Of SieROAD TESTA6E571401030210Road Test Preparation
1. Inspect the engine coolant. (See Section E.)
2. Inspect the engine oil. (See D–8 ENGINE OIL INSPECTION.)
3. Inspect the ATF levels. (See K2–78 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION.)
4. Inspect the idle speed and ignition timing in P position. (See F1–22 IDLE SPEED INSPECTION (4WD).)
5. Bring up the engine and transaxle to normal operating temperature.
Shift Diagram
D range (normal mode)
Condition Possible Cause
Above specificationN → D shiftInsufficient line pressure in all forward ranges
Low clutch slippage
Low one-way clutch slippage
Reduction one-way clutch slippage
N → R shiftInsufficient line pressure in R position
Low and reverse brake slippage
Reverse clutch slippage
Reduction brake slippage
0/8 1/8
2/8
3/8
4/8
5/8
6/8
7/8
8/8
TCC OPERATION AVAILABLE
VEHICLE SPEED km/h {mph}
THROTTLE OPENING
SHIFT UP
4GR
TCC
OFF
SHIFT DOWN
0
{0}20
{12}40
{25}60
{37}80
{50}100
{63}120
{75}140
{87}160
{99}180
{112}220
{137} 200
{124} 112 23
2
2 232
34
4534
45
5GR TCC ON
4GR TCC ON
5GR TCC OFF
A6E5714W104

K2–76
AUTOMATIC TRANSAXLE
D Range Test
Note
•The NORMAL mode and SLOPE mode are automatically selected by the TCM in D range. The TCM shifts
to SLOPE mode when the upgrade is approx. 5 % or more, and shifts to NORMAL mode when the
upgrade is approx. 3 % or less.
1. Perform road test preparation. (See K2–75 Road Test Preparation.)
2. Shift the selector lever to D range.
3. Accelerate the vehicle with half and WOT, then verify that 1→2, 2→3, 3→4, and 4→5 upshifts and 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.)
4. Drive the vehicle in 5GR, 4GR, 3GR, and 2GR and verify that kickdown occurs for 5→4, 4→3, 3→2, and 2→1
downshifts, and that the shift points are 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 5GR.
•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. 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.)
Note
•The shift solenoid electrical ON-OFF pattern is this chart describes the stabilized condition before and
after shift control. The pattern may oscillate between ON and OFF momentarily while shifting-up or down.
This is normal.
Vehicle speed at shift point table
Range ModeThrottle
conditionShiftVehicle speed
(km/h {mph})Turbine speed
(rpm)
DNORMALWide open
throttleD
1→D250—56 {31—34} 5,800—6,450
D
2→D389—97 {56—60} 5,800—6,250
D
3→D4139—149 {87—92} 5,800—6,150
TCC ON (D
4)
127—137 {79—84} 3,650—3,850
D
4→D5195—205 {121—127} 5,550—5,800
TCC ON (D
5)
195—205 {121—127} 4,100—4,250
Half throttleD
1→D225—34 {16—21} 2,850—3,950
D
2→D345—62 {28—38} 2,900—4,000
D
3→D472—99 {45—61} 3,000—4,100
TCC ON (D
4)
93—121 {58—75} 2,650—3,450
D
4→D5124—149 {77—92} 3,550—4,200
TCC ON (D
5)
124—149 {77—92} 2,600—3,100
Closed throttle
positionD
5→D455—61 {35—37} 1,1500—1,250
D
4→D323—29 {15—17} 700—800
D
3→D17—13 {5—8} 300—500
KickdownD
5→D4185—195 {115—120} 3,850—4,050
D
4→D3127—137 {79—84} 3,650—3,850
D
3→D277—85 {48—52} 3,200—3,500
D
2→D137—43 {23—26} 2,400—2,750

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

K2–78
AUTOMATIC TRANSAXLE
Evaluation
End Of SieAUTOMATIC TRANSAXLE FLUID (ATF) INSPECTIONA6E571419001201Automatic Transaxle Fluid (ATF) Condition Inspection
1. One way of determining whether the transaxle should be replaced is by noting:
•If the ATF is muddy or varnished.
•If the ATF smells strange or unusual.
ATF Condition
Condition Possible Cause
No 1-2 up- or downshiftStuck shift solenoid C
Stuck shift valve C
Wore 2-4 brake
Trouble intermediate sensor
No 2-3 up- or downshiftStuck shift solenoid A
Stuck shift valve A
Wore high clutch
No 3-4 up- or downshiftStuck shift solenoid B
Stuck shift valve B
Wore 2-4 brake
No 4-5 up- or downshiftStuck shift solenoid A
Stuck shift valve A
Wore direct clutch
Trouble TFT
TCC non operation shiftStuck TCC solenoid valve
Stuck TCC valve
Incorrect shift pointTrouble VSS output signal
Trouble TR switch
Trouble TP signal and engine torque signal
Excessive shift shock slippageStuck pressure control solenoid
Stuck pressure regulator valve
Stuck pressure modifier valve
Stuck accumulator valve A, B, or C
Stuck 2-4 brake solenoid valve
Stuck high clutch solenoid valve
Stuck low clutch accumulator
Stuck 2-4 brake accumlator
Stuck high clutch accumlator
Stuck direct clutch accumlator
Stuck reduction accumlator
Trouble VSS
No Engine braking effect Wore reduction brake band
Stuck reduction reducing valve
Stuck reduction timing valve
Stuck reduction timing solenoid valve
Condition Possible cause
Clear dark red Normal—
Light red (pink) Contaminated with water•Broken oil cooler inside of radiator
•Poor filler tube installation:
Problem could be occurring to parts inside the
transaxle by water contamination. If necessary,
exchange transaxle.
Reddish
brownHas burnt smell and metal
specs are foundDeteriorated ATFDefect powertrain components inside of transaxle:
Specks cause wide range of problems by plugging up
in oil pipe, control valve body and oil cooler in radiator.
•When large amount of metal specks are found.
Exchange transaxle if necessary.
•Implement flushing operation as there is a
possibility to have specks plugging up oil pipe and/
or oil cooler inside of radiator.
Has no burnt smell Normal•Discoloration by oxidation

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