wheel MAZDA 6 2002 Suplement Repair Manual

K2–12
AUTOMATIC TRANSAXLE
Electronic Control Item and Control
Component Description (Electronic Control)
Control item Contents
Shift control•Detects engine load condition and vehicle speed. Shifts to the best gear
position according to the programmed automatic shift diagram.
Line pressure control•Generates line pressure matching the engine load condition and driving
conditions. Optimizes line pressure for each shift. When the ATF
temperature is low, automatically optimizes line pressure for quick clutch
engagement.
Revers inhibition control•When the shift lever is shifted to R position while the vehicle is running
forward at approx. 30 km/h{19 mph} or more, the TCM turns the neutral
shift solenoid valve on and drains the low and reverse brake hydraulic
pressure. Due to this, the transaxle shifts to neutral.
Shift transient control•Adjusts transient hydraulic pressure according to engine load and
vehicle driving conditions when shifting using the pressure control
solenoid, 2-4 brake solenoid valve, the high clutch solenoid valve, and
each accumulator control valve.
•Temporarily lowers engine torque during shift (up and down) to improve
shift feel
•The lock timing for the reduction brake band is controlled by the control
of the reduction timing solenoid valve ON/OFF timing.
•The lock timing for the clutch brake is controlled by the control of shift
solenoid A, B, and C ON/OFF timing.
Feedback control•Corrects clutch engagement pressure and timing on drain side to
compensate for changes in engine performance and changes in
transaxle
TCC control•Controls TCC according to the programmed TCC points
N-D select control•When a driving range is selected from P/N, the fuel injection amount is
controlled to prevent fluctuation in engine speed.
Slope mode control•Changes the shift point to prevent frequent shifting up/down when
climbing hills
OBD system•Detects and/or memorizes failure of input/output part and transaxle
condition
Part name Function
Input system TR switch•Detects selector lever ranges/positions
Input/turbine speed sensor•Detects reverse clutch drum revolution speed
Intermediate sensor•Detects output gear revolution speed
Vehicle speedometer sensor•Detects parking gear revolution speed
TFT sensor•Detects the ATF temperature
Brake switch•Detects the brake pedal depressed
Cruise control module (in cruise actuator)•When the cruise control is in use, the signal detects when the
difference between the target speed and actual speed
exceeds specification
M range switch•Detects selector lever shifted M range
Up switch•Detects up shift in M range
Down switch•Detects down shift in M range
CAN signal Throttle position signal•Input throttle opening angle from PCM
Engine torque signal
(without torque down)•Input engine torque from PCM
Engine torque signal (with
torque down)•Input engine torque from PCM
Engine torque signal (loss
torque)•Input engine loss torque from PCM
Torque reduced signal•Detects signals indicating torque down availability
Engine coolant
temperature signal•Input engine coolant temperature from PCM
Engine speed signal•Input engine speed from PCM
Battery OFF signal•Detect negative battery cable disconnected
4 wheel speed signal•Input wheel speed from ABS HU/CM or DSC HU/CM

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
K2–79
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

L–4
PROPELLER SHAFT
PROPELLER SHAFT INSPECTION ON VEHICLEA6E611025002204Joint Play Inspection
1. Move the joint shaft by hand, and verify that there is no play.
If there is play, perform the following service operations.
•Yoke : Universal joint replacement (See L–7 PROPELLER SHAFT DISASSEMBLY/ASSEMBLY.)
•Constant velocity joint : Propeller shaft
replacement (See L–7 PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY.)
Propeller Shaft Runout Inspection
Caution
•Do not rotate the propeller shaft by starting the engine.
1. Shift the select lever to N position and release the parking brake.
2. Rotate the rear wheel by hand, and measure the
propeller shaft runout at 9 points as shown in the
figure.
Limit
0.4 mm {0.02 in}
PROPELLER SHAFT
A6J6110W002
A6J6110W003
A6J6110W004

M–1
M
MFRONT AND REAR AXLES
OUTLINE............................................................... M-2
OUTLINE OF CONSTRUCTION ........................ M-2
FEATURES ......................................................... M-2
SPECIFICATIONS .............................................. M-2
REAR AXLE.......................................................... M-4
REAR AXLE OUTLINE ....................................... M-4
CROSS-SECTIONAL VIEW ............................... M-4
DRIVE SHAFT....................................................... M-5
DRIVE SHAFT OUTLINE.................................... M-5
STRUCTURAL VIEW.......................................... M-5
REAR DRIVE SHAFT ......................................... M-5
REAR DIFFERENTIAL.......................................... M-6
REAR DIFFERENTIAL OUTLINE ....................... M-6
CROSS-SECTIONAL VIEW ............................... M-6
ELECTRONIC 4WD CONTROL SYSTEM............ M-7
OUTLINE ............................................................ M-7
ELECTRONIC CONTROL COUPLING .............. M-9
DIFFERENTIAL OIL TEMPERATURE
SENSOR ........................................................ M-12
4WD WARNING LIGHT .................................... M-12
4WD CONTROL MODURE .............................. M-13
4WD SYSTEM CONTROL................................ M-14
CONTROLLER AREA NETWORK (CAN) ........ M-15
ON-BOARD DIAGNOSTIC ............................... M-16
OUTLINE............................................................. M-18
SUPPLEMENTAL SERVICE
INFORMATION .............................................. M-18
LOCATION INDEX.............................................. M-19
AXLE/DRIVE SHAFT LOCATION INDEX ......... M-19
REAR DIFFERENTIAL/ELECTRONIC
4WD CONTROL SYSTEM LOCATION
INDEX ............................................................ M-20
GENERAL PROCEDURES................................. M-21
PRECAUTION (FRONT AND REAR AXLE) ..... M-21
REAR AXLE........................................................ M-22
WHEEL HUB BOLT REPL
ACEMENT ..................................................... M-22
WHEEL HUB, KNUCKLE
REMOVAL/INSTALLATION ........................... M-22
FRONT DRIVE SHAFT........................................ M-29
JOINT SHAFT (MZR-CD (RF TURBO))
DISASSEMBLY/ASSEMBLY ......................... M-29
JOINT SHAFT (4WD)
DISASSEMBLY/ASSEMBLY ......................... M-31
FRONT DRIVE SHAFT
(MZR-CD (RF TURBO))
DISASSEMBLY/ASSEMBLY ......................... M-34
FRONT DRIVE SHAFT (4WD)
DISASSEMBLY/ASSEMBLY ......................... M-39REAR DRIVE SHAFT.......................................... M-42
REAR DRIVE SHAFT PRE-INSPECTION ........ M-42
REAR DRIVE SHAFT
REMOVAL/INSTALLATION ........................... M-43
REAR DRIVE SHAFT
DISASSEMBLY/ASSEMBLY ......................... M-45
REAR DIFFERENTIAL........................................ M-48
DIFFERENTIAL OIL INSPECTION ................... M-48
DIFFERENTIAL OIL REPLACEMENT .............. M-48
OIL SEAL (SIDE GEAR) REPLACEMENT ....... M-49
OIL SEAL (COMPANION FLANGE)
REPLACEMENT ............................................ M-49
REAR DIFFERENTIAL
REMOVAL/INSTALLATION ........................... M-51
REAR DIFFERENTIAL DISASSEMBLY ........... M-52
REAR DIFFERENTIAL ASSEMBLY ................. M-56
ELECTRONIC 4WD CONTROL SYSTEM.......... M-65
DIFFERENTIAL OIL TEMPERATURE
SENSOR INSPECTION ................................. M-65
DIFFERENTIAL OIL TEMPERATURE
SENSOR REMOVAL/INSTALLATION ........... M-65
4WD SOLENOID INSPECTION........................ M-66
4WD CONTROL MODURE INSPECTION ........ M-66
4WD CONTROL MODURE
REMOVAL/INSTALLATION ........................... M-67
COUPLING COMPONENT
REMOVAL/INSTALLATION ........................... M-68
COUPLING COMPONENT
DISASSEMBLY .............................................. M-69
COUPLING COMPONENT ASSEMBLY........... M-72
ON-BOARD DIAGNOSTIC.................................. M-75
WIRING DIAGRAM ........................................... M-75
ELECTRONIC 4WD CONTROL SYSTEM
ON-BOARD DIAGNOSIS ............................... M-76
DTC P1887 ....................................................... M-77
DTC P1888 ....................................................... M-79
DTC U0100 ....................................................... M-80
DTC U0101 ....................................................... M-80
DTC U0121 ....................................................... M-80
TROUBLESHOOTING......................................... M-81
SYSTEM WIRING DIAGRAM ........................... M-81
FOREWORD ..................................................... M-82
SYMPTOM TROUBLESHOOTING ................... M-82
NO.1 FREQUENT FRONT WHEEL SLIP ......... M-82
NO.2 TIGHT CORNER BRAKING .................... M-83
NO.3 ABNORMAL NOISE AND/OR
VIBRATION FROM COUPLING
COMPONENT ................................................ M-84 FEATURES
SERVICE

M–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E630201018201•The construction and operation of the front and rear axles is the same as that of the current Mazda6 (GG)
model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
End Of Sie
FEATURESA6E630201018202Improved rigidity, reduced noise and vibration
•Concurrent with the MZR-CD (RF Turbo) engine, the configuration of the front drive shaft and the joint shaft
has been optimized.
•Concurrent with the 4WD system, the configuration of the rear axle, the front/rear drive shafts and the joint
shaft has been optimized.
Improved handling stability and marketability
•An electronic 4WD control system has been adopted.
End Of Sie
SPECIFICATIONSA6E6302010182032WD
Bold frames:New specifications
OUTLINE
ItemSpecification
New Mazda6 (GG)(4SD, 5HB),
New Mazda6 (GY)(Wagon 2WD)Current Mazda6
(GG)(4SD, 5HB)
Engine L8, LF, L3MZR-CD
(RF Turbo)L8, LF, L3
Transaxle MTX ATX MTX MTX ATX
Front axle Bearing type Angular ball bearing
Rear axle Bearing type Angular ball bearing
Drive shaftJoint
typeWheel side Bell joint
Differential sideDouble offset
jointTripod joint
(With free ring)Double offset
jointDouble offset
jointTripod joint
(With free ring)
Shaft diameter (mm {in}) 24.5 {0.96} 24.0 {0.94} 24.0 {0.94} 24.5 {0.96} 24.0 {0.94}
Joint shaft Shaft diameter (mm {in}) 26.0 {1.02} 29.0 {1.14} 26.0 {1.02}

OUTLINE
M–3
M
4WD
Bold frames:New specifications
End Of Sie
ItemSpecification
New Mazda6 (GY)(Wagon 4WD)
EngineL3
TransaxleATX
Front axle Bearing type Angular ball bearing
Rear axle Bearing type Angular ball bearing
Front drive shaftJoint typeWheel side Bell joint
Differential side Tripod joint (With free ring)
Shaft diameter (mm {in}) 24.0 {0.94}
Joint shaft Shaft diameter (mm {in}) 29.0 {1.14}
Rear drive shaftJoint typeWheel side Bell joint
Differential side Double offset joint
Shaft diameter (mm {in}) 22.0 {0.87}
Rear and front wheel torque distribution unit Electronic control coupling
Rear differentialReduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 6.5
Final gear ratio 2.928
Gears:
Number of teethDrive pinion 14
Ring gear 41
Differential oilTypeGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Amount
(Approximate quantity)(L {US qt, lmp qt}) 1.0 {1.1, 0.9}

DRIVE SHAFT
M–5
M
DRIVE SHAFT OUTLINEA6E631625500201Features
Improved drivability, reduced noise and vibration
•Concurrent with the MZR-CD (RF Turbo) engine and 4WD system, the configuration of the front drive shaft and
the joint shaft has been optimized.
•For 4WD models, a constant velocity joint system has been adopted for the rear drive shaft.
End Of Sie
STRUCTURAL VIEWA6E631625500202
.
End Of Sie
REAR DRIVE SHAFTA6E631625500203Structure
•Engine noise and vibration have been reduced due to adoption of a bell joint on the wheel side of the constant
velocity joint.
•A low noise and vibration double offset joint with low slide resistance has been adopted for the differential side
of the constant velocity joint. Due to this booming resonance at high speed is reduced.
•An extremely durable plastic has been adopted for the wheel side boot.
.
DRIVE SHAFT
3
1
2
A6E63162101
1 Front drive shaft
2 Joint shaft3 Rear drive shaft
5
4
31
2
A6E63162102
1 Wheel side
2 Bell joint
3 Differential side4 Double offset joint
5 Plastic boot

ELECTRONIC 4WD CONTROL SYSTEM
M–7
M
OUTLINEA6E632227100201Features
Improved off-road mobility, handling stability, operability, fuel economy and marketability
•An electronic 4WD control system, which automatically optimizes traction distribution to the front and rear
wheels, has been adopted.
Improved serviceability
•A self-diagnostic function has been adopted for the electronic 4WD control system.
Electronic 4WD control system outline
•The newly adopted electronic 4WD control system automatically and optimally controls drive torque distribution
for the front and rear wheels. Due to this off-road mobility, driving stability and fuel economy are improved.
•Based on the input signals from each sensor, the 4WD control modure (4WD CM) determines vehicle driving
and road conditions, and controls output current to the electronic control coupling (4WD solenoid) inside the
rear differential. This control allows for optimal distribution of the drive torque from the engine to the rear
wheels.
•Also, the 4WD CM automatically controls the 4WD, greatly reducing the load on the driver and improving
operability.
Structural view
.
ELECTRONIC 4WD CONTROL SYSTEM
87
5
4
3
6
9
8
7
5
4
3
10
6
1
2
9
10
A6E63222001
1L.H.D.
2 R.H.D.
3 4WD warning light
4 4WD control modure
5 DSC HU/CM6PCM
7TCM
8 Electronic control coupling (4WD solenoid)
9 Differential oil temperature sensor
10 Rear differential

M–8
ELECTRONIC 4WD CONTROL SYSTEM
Components and Functions
System Diagram
.
Part name Function
Electronic control coupling
(4WD solenoid)•Based on a signal from the 4WD CM, it operates the electromagnetic clutch and
transmits drive torque to the rear wheels.
Differential oil temperature
sensor•Informs the 4WD CM of the rear differential oil temperature.
4WD CM•Controls operation of the electronic control coupling (4WD solenoid) based on signals
input from the throttle opening angle, speed, differential oil temperature and other
sensors.
•Outputs coupling control condition and 4WD warning control information as a CAN
signal.
•Controls the on-board diagnostic system and the fail-safe system if there is a malfunction
in the 4WD system.
4WD warning light•Illuminates or flashes to alert driver of a malfunction or control failure in the 4WD system.
PCM•Sends the throttle opening angle and engine speed signals, as CAN signals, to the 4WD
CM.
TCM•Sends the selector lever position and gear position signals, as CAN signals, to the 4WD
CM.
DSC HU/CM•Sends the four-wheel speed and DSC operating condition signals, as CAN signals, to the
4WD CM.
•Sends the coupling torque request signal, as a CAN signal, to the 4WD CM.
KO
P I
A
C
NH G
9
8
7
5
4
3
10
13
11
12
6
1
2
A6E63222002
1 Battery
2 Ignition switch
3 Differential oil temperature sensor
4 4WD control modure (4WD CM)
5 Electronic control coupling
6 4WD solenoid
7 Instrument cluster8 DSC HU/CM
9TCM
10 PCM
11 CAN-H
12 CAN-L
13 CAN driver