SERVICE_1874-1U-06B(03-60).

fm 1 ページ ２００６年３月１３日 月曜日 午後９時４３分

SERVICE TOOLS
03-60 SERVICE TOOLS
SERVICE TOOLS . . . . . . . . . . . . . . . . . . 03-60–1

End of Toc
SERVICE TOOLS
AT: DRIVELINE/AXLE

id036000500100
03-60
49 0107 680A 49 M005 561 49 W032 201

Engine stand Differential Body

carrier hanger

49 B025 001 49 T032 316 49 T032 317

(Dust Seal Shaft Weight

Installer) Body

49 S019 005 49 W032 202 49 0839 425C

Oil seal puller Attachment Bearing puller

set

49 0636 145 49 S120 710 49 L027 004

Water pump Coupling flange Gear case

pulley boss holder remover
puller

49 H027 002 49 T034 201A 49 T032 302

Bearing Dust boot Bearing installer

remover installer

49 G033 105 49 F027 003 49 F027 005

Attachment Handle Attachment for

62

49 F027 007 49 8531 565 49 L019 301

Attachment for Drive pinion Installer

72 model

03-60–1
SERVICE_1874-1U-06B(03-60).fm 2 ページ ２００６年３月１３日 月曜日 午後９時４３分

SERVICE TOOLS
49 H025 003A 49 0727 570 49 0305 555

Bearing installer Pinion height Block Gauge

gauge body (20mm)

49 8531 555 49 F401 331 49 F401 337A

Block Gauge Body Attachment C

(11mm)

49 U027 003 49 H028 202 49 L011 201

Oil seal installer Block L Shaft

49 G030 797 49 0710 520 49 S019 006

Handle Universal Oil seal installer

bearing puller

End Of Sie

03-60–2
SERVICE_1874-1U-06B(05-17).fm 1 ページ ２００６年３月１３日 月曜日 午後９時４４分

TRANSMISSION/TRANSAXLE 05SECTION

Toc of SCT
AUTOMATIC TRANSAXLE . . . . 05-17 SERVICE TOOLS . . . . . . . . . . . 05-60 05-17
TECHNICAL DATA . . . . . . . . . . 05-50
Toc of SCT
05-17 AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE REAR PLANETARY GEAR COMPONENT
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-17–2 AND ONE-WAY CLUTCH COMPONENT
Precaution . . . . . . . . . . . . . . . . . . . . . . . 05-17–2 DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05-17–56
Disassembly . . . . . . . . . . . . . . . . . . . . . 05-17–3 Components . . . . . . . . . . . . . . . . . . . . . 05-17–56
Disassembly procedure. . . . . . . . . . . . . 05-17–9 Disassembly Procedure . . . . . . . . . . . . 05-17–56
OIL PUMP REAR PLANETARY GEAR
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–26 INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–57
Components . . . . . . . . . . . . . . . . . . . . . 05-17–26 REAR PLANETARY GEAR COMPONENT
Disassembly Procedure . . . . . . . . . . . . 05-17–27 AND ONE-WAY CLUTCH COMPONENT
Assembly Procedure . . . . . . . . . . . . . . . 05-17–28 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-17–58
B1 BRAKE PISTON Components . . . . . . . . . . . . . . . . . . . . . 05-17–58
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–29 Assembly Procedure . . . . . . . . . . . . . . 05-17–59
Components . . . . . . . . . . . . . . . . . . . . . 05-17–29 C2 CLUTCH COMPONENT
Disassembly Procedure . . . . . . . . . . . . 05-17–30 DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05-17–60
Assembly Procedure . . . . . . . . . . . . . . . 05-17–30 Components . . . . . . . . . . . . . . . . . . . . . 05-17–60
C3 CLUTCH COMPONENT Disassembly Procedure . . . . . . . . . . . . 05-17–61
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-17–31 C2 CLUTCH INSPECTION . . . . . . . . . . . 05-17–63
Components . . . . . . . . . . . . . . . . . . . . . 05-17–31 C2 CLUTCH COMPONENT
Disassembly Procedure . . . . . . . . . . . . 05-17–32 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-17–64
C3 CLUTCH INSPECTION. . . . . . . . . . . . 05-17–33 Components . . . . . . . . . . . . . . . . . . . . . 05-17–64
C3 CLUTCH COMPONENT Assembly Procedure . . . . . . . . . . . . . . 05-17–65
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 05-17–34 TRANSAXLE CASE AND B2 BRAKE
Components . . . . . . . . . . . . . . . . . . . . . 05-17–34 DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–68
Assembly Procedure . . . . . . . . . . . . . . . 05-17–35 Low and Reverse Brake Piston
FRONT PLANETARY GEAR Disassembly Note . . . . . . . . . . . . . . . 05-17–69
COMPONENT INPUT SHAFT Low and Reverse Brake Piston
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–37 Assembly Note . . . . . . . . . . . . . . . . . . 05-17–70
Components . . . . . . . . . . . . . . . . . . . . . 05-17–37 Low and Reverse Brake Return Spring
Disassembly Procedure . . . . . . . . . . . . 05-17–38 Assembly Note . . . . . . . . . . . . . . . . . . 05-17–70
Assembly Procedure . . . . . . . . . . . . . . . 05-17–39 TRANSAXLE CASE AND B2 BRAKE
C1 CLUTCH COMPONENT INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–71
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-17–42 CONTROL VALVE BODY
Components . . . . . . . . . . . . . . . . . . . . . 05-17–42 DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–72
Disassembly Procedure . . . . . . . . . . . . 05-17–43 Components . . . . . . . . . . . . . . . . . . . . . 05-17–72
C1 CLUTCH INSPECTION. . . . . . . . . . . . 05-17–44 Disassembly Procedure . . . . . . . . . . . . 05-17–73
C1 CLUTCH COMPONENT Assembly Procedure . . . . . . . . . . . . . . 05-17–74
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 05-17–45 AUTOMATIC TRANSAXLE
Components . . . . . . . . . . . . . . . . . . . . . 05-17–45 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 05-17–75
Assembly Procedure . . . . . . . . . . . . . . . 05-17–46 Assembly . . . . . . . . . . . . . . . . . . . . . . . 05-17–75
COUNTER DRIVE GEAR Components . . . . . . . . . . . . . . . . . . . . . 05-17–77
DISASSEMBLY/ASSEMBLY . . . . . . . . . 05-17–49 Assembly Procedure . . . . . . . . . . . . . . 05-17–83
Components . . . . . . . . . . . . . . . . . . . . . 05-17–49 AUTOMATIC TRANSAXLE
Disassembly Procedure . . . . . . . . . . . . 05-17–50 INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–104
Assembly Procedure . . . . . . . . . . . . . . . 05-17–52 B2 Brake Inspection . . . . . . . . . . . . . . . 05-17–104
ONE-WAY CLUTCH COMPONENT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-17–55

End of Toc

05-17–1
SERVICE_1874-1U-06B(05-17).fm 2 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE DISASSEMBLY
AT: AUTOMATIC TRANSAXLE

id051700502100
Precaution
The following are precautions that must be followed when performing removal/installation.
1. Handle electronic parts with care
• Do not pull the wiring harness forcibly when disconnecting the connector. Unlock the lock first and pull the
connector.
• When connecting the connector, verify to insert it until it is properly locked. (Verify that a click sound is
heard.)
• Do not shock electronic parts. Replace with new parts if they have been dropped or subjected to shock.
2. Prevent foreign matter from penetrating
• Be sure to remove foreign matter such as dust and sand from the automatic transaxle before removing
parts.
• Protect removed parts from dust with an object such as a vinyl sheet.
• Do not use cotton work gloves or shop rags as frayed strings might get caught in the unit. Thus work with
bare hands or use vinyl gloves.
3. Prevent scratching
• Do not pry with a screwdriver forcibly. Slightly hit the case with a plastic hammer when separating
component cases at seams.
• Do not pull the valve forcibly.
• Be careful not to get the wire harness caught between parts during installation.
4. Prevent incorrect installation and lack of or missing parts
• Be careful not to install parts incorrectly or lose parts since there are similar types of O-rings, snap rings,
bearings and races. Take great care for straightening parts and checking installation direction.
• Be careful not to drop small parts such as check balls or lose them during installation.
5. Wash parts and apply oil
• Wash each part before installing and dry using compressed air, and then apply the specified ATF type
JWS3309.
• Soak disks in ATF type JWS3309 before installing. In particular, soak new disks for 2 h or more so that the
oil seeps into the lining.
• If the thrust bearing or race falls during installation, use a small amount of yellow petrolatum grease.
• Apply ATF type JWS3309 to contact and rotating surfaces.
• Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave it for one
hour or more.
• Do not wash aluminum parts or rubber parts with alkaline chemicals.
• Do not wash the rubber parts with white gasoline.
6. Handling ATF with care
• If you spill ATF on the floor, wipe it off immediately, as it is quite slippery and dangerous.
• Be sure to use JWS3309 type ATF.

05-17–2
SERVICE_1874-1U-06B(05-17).fm 3 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly
Components

5
15 R
7
20 R
05-17
R 21 R 6 R 22

13 R

18 R 14
16 R

12

19 R

R 4 R 11
10

8 R
3

17
*1

2
bawuua00000279
.

1 Oil pipe and O-ring 7 TCM

2 Torque converter 8 Control valve body cover
3 Drain plug 9 Lock plate
4 Gasket 10 Suction cover
5 Filler plug 11 Gasket
6 O-ring 12 Control valve body component

05-17–3
SERVICE_1874-1U-06B(05-17).fm 4 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
13 Coupler component lock plate 18 Oil seal (converter housing side)
14 Coupler component 19 O-ring (converter housing side) (2WD)
15 O-ring 20 Oil seal (transaxle case side)
16 Gasket 21 O-ring (transaxle case side)
17 Input/turbine speed sensor 22 Oil seal (manual shaft)

*1
: The figure shows Mazda6 specification.

05-17–4
SERVICE_1874-1U-06B(05-17).fm 5 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE

1 3
22
R 2
10
5

23
05-17

15

6
14

4 13

12
37
35

38

29
7 36
34
24 R
33
R 39
32
31
30 21

20
28 19
27 25 17
16
26
11

18

9
8

bawuua00000280

1 Breather pipe 4 Gasket

2 O-ring 5 Gasket
3 Transaxle case gasket 6 Oil Pump component

05-17–5
SERVICE_1874-1U-06B(05-17).fm 6 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
7 Oil strainer 24 Lock washer
8 C3 clutch component 25 Counter drive gear
9 Front planetary gear component and input shaft 26 Vehicle speed sensor (VSS)
10 Brake band anchor bolt 27 Spacer
11 B1 brake band 28 Snap Ring
12 Snap ring 29 Rear planetary gear component and one-way clutch
13 Brake piston cover component
14 B1 brake piston 30 Bearing race
15 Piston return spring 31 Thrust bearing
16 Thrust bearing 32 Bearing race
17 Bearing race 33 Snap ring
18 C1 clutch component 34 Retaining plate
19 Thrust bearing 35 Drive plate
20 Bearing race 36 Driven plate
21 Sun gear input drum 37 Retaining plate
22 Counter gear component 38 C2 clutch component
23 Differential component 39 Thrust bearing

05-17–6
SERVICE_1874-1U-06B(05-17).fm 7 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE

1
2

05-17

bawuua00000281

1 Tube clamp 3 Magnet

2 Oil reservoir lock plate 4 Oil pipe

05-17–7
SERVICE_1874-1U-06B(05-17).fm 8 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE

4
1 R
5

12 10

8
7
6
20
11

2
19
3
R 17
18
14

17 R

13

15
16

bawuua00000282

05-17–8
SERVICE_1874-1U-06B(05-17).fm 9 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
1 Stud bolt 11 Parking rod
2 Detent spring cover 12 Parking pin
3 Detent spring 13 Pipe clamp
4 Parking pawl shaft 14 Transaxle case No.1 plate
5 Pawl return spring 15 Wiring harness clip
6 Spring guide sleeve 16 Oil cooler outlet tube
7 Torsion spring 17 O-ring
8 Parking pawl bracket 18 Seal ring
9 Parking pawl 19 Transaxle case plate No.2 05-17
10 Manual valve lever 20 Transaxle case plate No.3

Disassembly procedure
1. Remove the oil pipes and O-rings. (Refer to Workshop Manual.)

Caution
• Do not damage the oil seal.
• Do not drop the torque converter.

2. Remove the torque converter.

bawuua00000283

3. Remove the drain plug and gasket.

4. Drain the ATF.

Caution
• Do not repair the threads using a tap or
other tools.

bawuua00000284

05-17–9
SERVICE_1874-1U-06B(05-17).fm 10 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
5. Remove the stud bolts.

bawuua00000285

Caution
• Do not touch the terminals.

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6. Remove the TCM. TCM

MOUNTING
BOLT

TCM

bawuua00000287

7. Set the SST as shown in the figure.

49 L010 1A0
Caution
• When installing the SST to the transaxle,
use bolts (M12×1.25) with a thread length
of 90 mm {3.54 in}.

49 0107 680A

bawuua00000288

05-17–10
SERVICE_1874-1U-06B(05-17).fm 11 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
8. Install the SST to the position where the transaxle
stud bolts were removed.

05-17
bawuua00000289

9. Remove the control valve body cover installation

bolt.

Caution
• Do not damage the fitting surface of the
transaxle case and the control valve body
cover.
• Do not deform the control valve body
cover.

bawuua00000290

10. Using a plastic hammer, tap the control valve

body cover to remove it.

Caution
• Be careful not to damage the solenoid
valves and connectors.
• Do not pull the wiring harnesses when
removing the connector.

Note
• Disconnect the solenoid connector
according to the following procedure:
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(1) Insert a precision screwdriver from the

backside into the connector as shown in the
figure.

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05-17–11
SERVICE_1874-1U-06B(05-17).fm 12 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
(2) Pry the screwdriver in the direction of the
arrow and disconnect the connector.

Caution
• Do not damage the solenoid valves and
connectors with the screwdriver.
• When disconnecting connectors, grasp
the connectors, not the wiring harnesses.
Otherwise, the wiring harnesses may be
pulled out of the connector causing poor
contact.
bawuua00000293

11. Disconnect the solenoid connectors, VSS

connector and the input/turbine speed sensor CLAMP
connector.
12. Disconnect the coupler component from the CLAMP
clamp.

bawuua00000294

13. Remove the lock plate, and pull out the TFT
sensor from the control valve body.
14. Remove the O-ring from the TFT sensor.

Note
• Be sure to secure the coupler component
with tape so that it will not interfere with the
control valve body component.

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15. Fix the coupler component with tape to the

transaxle case as shown in the figure.

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05-17–12
SERVICE_1874-1U-06B(05-17).fm 13 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
16. Remove the VSS connector and input/turbine speed sensor connector from the solenoid clamp.

05-17

VSS CONNECTOR INPUT/TURBINE SPEED SENSOR

CONNECTOR

bawuua00000297

Note
• Be sure to secure the VSS and input/turbine speed sensor with tape so that they do not interfere with the
control valve body component.

17. Secure the VSS wiring harness and input/turbine

speed sensor wiring harness with tape to the
transaxle case as shown in the figure.

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18. Remove the suction cover and the gasket.

Caution
• Loosen the bolts evenly a little at a time
in the order shown in the figure.

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05-17–13
SERVICE_1874-1U-06B(05-17).fm 14 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
19. Remove the control valve body installation bolts.

Caution
2
• Do not drop the control valve body
component.
3
6
5

4 1

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20. Disconnect the manual valve link and remove the

control valve body component.

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21. Remove the coupler component lock plate.

Caution
• Do not damage the wiring harness.
• Do not pull hard on the wiring harness.

22. Remove the coupler component from the

transaxle case.

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23. Remove the O-ring and the gasket from the

coupler component.

Caution
• Do not damage the input/turbine speed O-RING
sensor.

GASKET

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05-17–14
SERVICE_1874-1U-06B(05-17).fm 15 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
24. Remove the input/turbine speed sensor.
25. Remove the bolts as shown in the figure.

05-17
bawuua00000304

bawuua00000305

Caution
• Do not damage the fitting surface of the converter housing and the transaxle case.

26. Using a plastic hammer, tap the converter

housing to remove it.

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05-17–15
SERVICE_1874-1U-06B(05-17).fm 16 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
27. Remove the transaxle case gaskets as shown in
the figure.

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28. Remove the gaskets as shown in the figure.

Caution
• Do not damage the oil reservoir lock
plate.

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29. Remove the tube clamp and the oil reservoir lock
plate.

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30. Remove the magnets from the oil reservoir lock

plate.

Caution
• Do not damage the differential gear lube
apply tube.

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31. Using a flathead screwdriver, remove the oil pipe.

Caution
• Do not damage the converter housing.
• If using a screwdriver, use a wooden
block or equivalent to avoid damaging
the fitting surface of the converter
housing.

32. Remove the oil seal lip using a razor.

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05-17–16
SERVICE_1874-1U-06B(05-17).fm 17 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
33. Using a tape-wrapped flathead screwdriver,
remove the oil seal (converter housing side).

05-17
bawuua00000312

34. Remove the oil pump component.

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35. Remove the oil seal and the oil strainer from the
oil pump component.

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36. Remove the C3 clutch component, input shaft and

the front planetary gear component.

Note
• In some cases, the input shaft may be
detached with the thrust roller bearing
attached.

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37. Remove the C3 clutch component from the input

shaft and the front planetary gear component.

Note
• In some cases, the C3 clutch component
may be detached with the thrust washer
attached.

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05-17–17
SERVICE_1874-1U-06B(05-17).fm 18 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
38. Remove the brake band anchor bolt.

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39. Remove B1 the brake band.

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40. Inspect the lining of the brake band.

• If the lining is flaking or has changed color, or
if it is worn or the print mark is wearing away,
replace with a new brake band and C3 clutch.
When replacing, inspect the contact surfaces
between the C3 clutch drum and B1 brake
band. If they are scratched or have changed
color, replace with new parts. PRINT

Note
• Before replacing with a new B1 brake band,
soak it at least 2 h in ATF.
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41. Remove the snap ring using snap ring pliers.

Caution
• The brake piston cover will fly off due to
the force of the piston return spring.
• Do not drop the brake piston cover.
• Do not drop the B1 brake piston.

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42. Remove the brake piston cover, B1 brake piston

and the piston return spring.

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05-17–18
SERVICE_1874-1U-06B(05-17).fm 19 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
43. Remove the thrust bearing, bearing race and the
C1 clutch component.

Note
• In some cases, the C1 clutch component
may be detached with the thrust bearing
attached.

05-17
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44. Remove the thrust bearing, bearing race and the

sun gear input drum.

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45. Remove the detent spring cover and detent

spring.

Caution
• Be careful not to apply too much force to
the pawl return spring.

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46. Remove the pawl return spring and the parking

pawl shaft.

Caution
• Be careful not to apply too much force to
the torsion spring.

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47. Remove the torsion spring and the spring guide

sleeve.

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05-17–19
SERVICE_1874-1U-06B(05-17).fm 20 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
48. Remove the parking pawl and the parking pawl
bracket.

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49. Disconnect the parking rod from the manual valve

lever.

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50. Remove the manual valve lever from the transaxle

case.

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51. Remove the parking rod from the transaxle case.

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05-17–20
SERVICE_1874-1U-06B(05-17).fm 21 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
52. Remove the parking pin from the transaxle case.

Note
• Inspect the direction of the parking pin.

05-17
bawuua00000331

53. Remove the counter gear component.

Note
• For easy removal, tilt the counter gear
component slightly.

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54. Remove the differential component.

Caution
• Do not damage the VSS wiring harness.
• Do not pull hard on the VSS wiring
harness.

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55. Disconnect the VSS wiring harness from the tube

wiring clamp.

Caution
• Do not damage the oil cooler outlet tube.

bawuua00000334

05-17–21
SERVICE_1874-1U-06B(05-17).fm 22 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
56. Remove the pipe clamp, transaxle case No.1
plate, wiring harness clip and the oil cooler outlet
tube.
57. Remove the O-rings from the oil cooler outlet
tube.

bawuua00000335

58. Using a flathead screwdriver and a hammer, pry

back the crimp on the lockwashers.

Caution
• If the lockwasher crimp is not completely
pried back, the tool cannot fit over the
bolt properly and the bolt cannot be
loosened.

bawuua00000336

59. Remove the lockwashers, washers and the

counter drive gear.

Caution
• Do not damage the VSS wiring harness.
• Do not pull hard on the VSS wiring
harness.
• Do not damage the VSS.

bawuua00000337

60. Remove the VSS and spacer from the counter

drive gear.

bawuua00000338

05-17–22
SERVICE_1874-1U-06B(05-17).fm 23 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
61. Using a flathead screwdriver, remove the snap
ring.

Caution
• Do not drop the sun gear.

05-17
bawuua00000339

62. Remove the rear planetary gear component and

the one-way clutch.

Note
• In some cases, the sun gear may be
detached with the bearing race attached.

Note
• Remove the sun gear in the center while
holding it.
• The thrust washer of the rear planetary gear
on the rear side might remain on the
bawuua00000340
transaxle case side when removing the rear
planetary gear component.

63. Remove the thrust bearing and the bearing races.

bawuua00000341

64. Using a flathead screwdriver, remove the snap

ring.

bawuua00000342

05-17–23
SERVICE_1874-1U-06B(05-17).fm 24 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
65. Remove the retaining plates, drive and driven
plates.

Note
• Inspect the number of drive plates and
driven plates.

bawuua00000343

66. Inspect the lining of all drive plates.

PRINT
• If the lining is flaking or has changed color, or
if it is worn or the print mark is wearing away,
replace with a new drive plate. When
replacing, inspect the contact surfaces
between the retaining plate, driven plate and
drive plate. If they are scratched or have
changed color, replace with new parts.

Note
• Before replacing with new drive plates, soak
them at least 2 h in ATF.
bawuua00000344

67. Remove the C2 clutch component and the thrust

bearing.

bawuua00000345

68. Remove the seal rings from the transaxle case.

bawuua00000346

69. Remove the transaxle case plate No.2.

bawuua00000347

05-17–24
SERVICE_1874-1U-06B(05-17).fm 25 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
70. Remove the transaxle case plate No.3.

Caution
• Do not damage the transaxle case.
• If using a screwdriver, use a wooden
block or equivalent to avoid damaging
the fitting surface of the transaxle case.

71. Remove the oil seal lip using a razor.

05-17
bawuua00000348

72. Using a tape-wrapped flathead screwdriver,

remove the oil seal (transaxle case side).

Caution
• Do not damage the transaxle case.
• If using a screwdriver, use a wooden
block or equivalent to avoid damaging
the fitting surface of the transaxle case.

bawuua00000349

73. Using a tape-wrapped flathead screwdriver,

remove the oil seal (manual shaft).
End Of Sie
AT: OIL PUMP

bawuua00000350

05-17–25
SERVICE_1874-1U-06B(05-17).fm 26 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
OIL PUMP DISASSEMBLY/ASSEMBLY
id051700500100
Components

GREASE

4 R
SST

1 R ATF

3 ATF
GREASE

:NON SUPPLY PART

bawuua00000001
.

1 O-ring 3 Seal ring

2 Thrust washer 4 Oil seal

05-17–26
SERVICE_1874-1U-06B(05-17).fm 27 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly Procedure
1. Remove the O-ring from the oil pump.

05-17

bawuua00000002

2. Remove the thrust washer from the oil pump.

bawuua00000003

3. Remove the seal rings from the oil pump.

Caution
• Do not damage the bushing on the oil
pump body.

bawuua00000004

4. Using a tape-wrapped flathead screwdriver,

remove the oil seal from the oil pump body.

bawuua00000005

05-17–27
SERVICE_1874-1U-06B(05-17).fm 28 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Assembly Procedure

Caution
• Do not damage the oil seal.

1. Using the SST and a hammer, install the new oil

seal to the oil pump body.
Substitution SST
• 49 U027 003
Outer diameter: 67 mm {2.64 in} or more 49 U027 003
Inner diameter: 54— 61 mm {2.13— 2.40 in}
Plate thickness: 2 mm {0.08 in} or more
2. Apply grease to the oil seal lip.
-0.2—0.2 mm
3. Apply ATF to the new seal rings and sliding {-0.00788—0.00788 in}
surface of the oil pump component.

Caution
• Do not expand the seal rings too much.
bawuua00000006

• Be careful not to shorten the seal rings

too much, when installing the seal rings.

4. Compress the seal rings as shown in the figure.

5 mm {0.197 in}
Then install the seal rings to the oil pump
component.

Note
• Verify that oil seal rings rotate smoothly after
installing them.

5. Apply grease to the thrust washer.

Caution
• Apply grease to the mounting surface of
bawuua00000007
the thrust washer so that it does not drop
when installed.

6. Install the thrust washer to the oil pump

component.
7. Apply ATF to a new O-ring.

bawuua00000003

8. Install the O-ring to the oil pump component.

Caution
• Do not damage the oil seal lip.

bawuua00000002

05-17–28
SERVICE_1874-1U-06B(05-17).fm 29 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
9. Turn the drive gear with flathead screwdrivers and
verify it rotates smoothly.
End Of Sie
AT: AUTOMATIC TRANSAXLE CLUTCH COMPONENT

05-17
bawuua00000008

B1 BRAKE PISTON DISASSEMBLY/ASSEMBLY

id051700500200
Components

1 R ATF

ATF R 2

bawuua00000351
.

1 O-ring 2 O-ring

05-17–29
SERVICE_1874-1U-06B(05-17).fm 30 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly Procedure
1. Remove the O-ring from the B1 brake piston.

bawuua00000352

2. Remove the O-rings from the brake piston cover.

bawuua00000353

Assembly Procedure
1. Apply ATF to the new O-rings.
2. Install the O-rings to the brake piston cover.
Number of O-ring
• AJ: 3
• L3 with TC: 2
3. Apply ATF to a new O-ring.

bawuua00000353

4. Install the O-ring to the B1 brake piston.

End Of Sie

bawuua00000352

05-17–30
SERVICE_1874-1U-06B(05-17).fm 31 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
C3 CLUTCH COMPONENT DISASSEMBLY
id051700500300
Components

5 SST
6
8 7

05-17
12
R 11 R 10

2 SELECTIVE

3
bawuua00000354
.

1 Snap ring 7 Piston return spring

2 Retaining plate 8 Spring retainer
3 Drive plate 9 C3 clutch piston
4 Driven plate 10 O-ring
5 Snap ring 11 O-ring
6 C3 clutch balancer 12 C3 clutch drum

05-17–31
SERVICE_1874-1U-06B(05-17).fm 32 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly Procedure
1. Using a flathead screwdriver, remove the snap
ring from the C3 clutch drum.

bawuua00000355

2. Remove the retaining plate, drive and driven

plates from the C3 clutch drum.

Note
• Inspect the number of drive and driven
plates.

bawuua00000356

3. Place the SST on the clutch balancer and

compress the return spring with a press.
49 G025 001
Caution
• Be careful not to expand the snap ring
too much.

4. Remove the snap ring using snap ring pliers.

Caution
• Do not damage the seal on the clutch
balancer.
bawuua00000357

5. Remove the clutch balancer, return spring and the

retainer from the C3 clutch drum.

bawuua00000358

05-17–32
SERVICE_1874-1U-06B(05-17).fm 33 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
6. While pushing the C3 clutch piston by hand, apply
compressed air into the oil passage as shown in
the figure and remove the C3 clutch piston from
the C3 clutch drum.

Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}

Note
• When applying compressed air, shut the 3
oil passages of the C3 clutch drum as shown 05-17
in the figure. bawuua00000359

7. Remove the O-rings from the C3 clutch drum.

End Of Sie

bawuua00000360

C3 CLUTCH INSPECTION
id051700500400
1. Inspect the lining of all drive plates.
• If the lining is flaking or has changed color, or PRINT
if it is worn or the print mark is wearing away,
replace with a new drive plate. When
replacing, inspect the contact surfaces
between the retaining plate, driven plate and
drive plate. If they are scratched or have
changed color, replace with new parts.

Note
• Before replacing with new drive plates, soak
them at least 2 h in ATF.
bawuua00000495

2. Using vernier calipers, measure the free length of

the piston return spring.

C3 clutch return spring free length

Standard: 12.91 mm {0.5083 in}

• If it is less than the specification, replace the

piston return spring with a new one.
End Of Sie

bawuua00000496

05-17–33
SERVICE_1874-1U-06B(05-17).fm 34 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
C3 CLUTCH COMPONENT ASSEMBLY
id051700500500
Components

8 SST
7 ATF

5 6

4 ATF

ATF ATF

1
R 2 R 3

12

11 SELECTIVE

10
bawuua00000361
.

1 C3 clutch drum 7 C3 clutch balancer

2 O-ring 8 Snap ring
3 O-ring 9 Driven plate
4 C3 clutch piston 10 Drive plate
5 Spring retainer 11 Retaining plate
6 Piston return spring 12 Snap ring

05-17–34
SERVICE_1874-1U-06B(05-17).fm 35 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Assembly Procedure
1. Apply ATF to the new O-rings and the C3 clutch drum.
2. Install the O-rings to the C3 clutch drum.
3. Apply ATF to the sliding surface of the C3 clutch
piston.

Caution
• Do not damage the seal on the piston and
O-rings.

05-17

bawuua00000362

4. Install the C3 clutch piston to the C3 clutch drum.

5. Apply ATF to the seal on the clutch balancer.

Caution
• Do not damage the seal on the clutch
balancer.

bawuua00000363

6. Install the retainer, return spring and the clutch

balancer to the C3 clutch drum.

bawuua00000364

7. Place the SST on the clutch balancer and

compress the piston return spring with a press.
49 G025 001
Caution
• When installing the snap ring, set the end
gap of the snap ring as shown in the
figure.
• Do not expand the snap ring too much.

8. Install the snap ring in the groove using snap ring

pliers.
bawuua00000365

05-17–35
SERVICE_1874-1U-06B(05-17).fm 36 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
9. Install the driven plates, drive plates and the
retaining plate in the following order to the C3
clutch drum as shown in the figure.
• Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Retaining

bawuua00000366

Caution
• Inspect the number and order of the RETAINING PLATE
retaining plate, drive and driven plates.
DRIVE PLATE
DRIVEN PLATE

bawuua00000367

10. Using a flathead screwdriver, install the snap ring

in the groove.

Caution
• When installing the snap ring, set the end
gap of the snap ring as shown in the
figure.

bawuua00000368

11. Install the C3 clutch component to the oil pump

and set a dial indicator as shown in the figure.
12. Apply compressed air as shown in the figure and
measure the C3 clutch piston stroke.

Air pressure
200 kPa {2.0 kgf/cm2, 29 psi}

C3 clutch piston stroke

0.6 — 0.8 mm {0.024 — 0.031 in}

• If not within the specification, select an bawuua00000369

appropriate retaining plate.

05-17–36
SERVICE_1874-1U-06B(05-17).fm 37 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Retaining plate size
Identification mark Thickness (mm {in})
1 2.8 {0.110}
A 2.85 {0.112}
2 2.9 {0.114}
B 2.95 {0.116}
3 3.0 {0.118}
C 3.05 {0.120}
4 3.1 {0.122}
05-17
5 3.2 {0.126}
6 3.3 {0.130}
7 3.4 {0.134}
8 3.5 {0.138}
End Of Sie

FRONT PLANETARY GEAR COMPONENT INPUT SHAFT DISASSEMBLY/ASSEMBLY

id051700500600
Components

3
2

8 R ATF

ATF
9

7 R
6 ATF

5 ATF

4
bawuua00000497
.

1 Thrust washer 6 Bearing race

2 Front planetary gear component 7 Seal ring
3 Thrust washer 8 Seal ring
4 Front planetary sun gear 9 Input shaft
5 Thrust bearing

05-17–37
SERVICE_1874-1U-06B(05-17).fm 38 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly Procedure
1. Remove the thrust washer from the front
planetary gear component.

bawuua00000498

2. Remove the front planetary gear component from

the input shaft.

bawuua00000499

3. Remove the thrust washer from the front

planetary gear component.

Note
• In some cases, the thrust washer may be
detached with the input shaft attached.

bawuua00000500

4. Remove the front planetary sun gear, thrust

bearing and the bearing race from the input shaft.

Note
• If it is difficult to remove the bearing race, pry
it off gently using a flathead screwdriver.

bawuua00000501

05-17–38
SERVICE_1874-1U-06B(05-17).fm 39 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
5. Remove the seal rings from the input shaft.

05-17
bawuua00000502

6. Remove the seal rings from the input shaft.

bawuua00000503

Assembly Procedure
1. Apply ATF to the new seal rings and sliding surface of the input shaft.

Caution
• Do not expand the seal ring too much.
• Be careful not to shorten the seal rings too much, when installing the seal rings.

2. Compress the seal rings as shown in the figure.

Then install the seal rings to the input shaft. 5 mm {0.197 in}

Note
• Verity that seal rings rotate smoothly after
installing them.

3. Apply ATF to the bearing race.

bawuua00000504

4. Install the bearing race to the input shaft.

Caution
• Apply grease to the mounting surface of
the thrust washer so that it does not drop
when the front planetary gear component
is installed.
• Do not apply grease to the oil holes of the
thrust washer.
• Do not drop the thrust washer.

5. Apply grease to the thrust washer.

bawuua00000505

05-17–39
SERVICE_1874-1U-06B(05-17).fm 40 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
6. Install the thrust washer to the front planetary
gear component.

bawuua00000500

7. Install the front planetary gear component to the

input shaft.
8. Apply ATF to the thrust bearing.

bawuua00000506

9. Install the thrust bearing to the input shaft as

shown in the figure.

bawuua00000507

10. Install the front planetary sun gear to the input

shaft as shown in the figure.
11. Apply ATF to the new seal rings and sliding
surface of the input shaft.

Caution
• Do not expand the oil seal rings too
much.
• Be careful not to shorten the seal rings
too much, when installing the seal rings.

bawuua00000508

05-17–40
SERVICE_1874-1U-06B(05-17).fm 41 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
12. Compress the seal rings as shown in the figure.
Then install the seal rings to the input shaft. 5 mm {0.197 in}

Note
• Verify that seal rings rotate smoothly after
installing them.

Caution
• Apply grease to the mounting surface of
the thrust washer so that it does not drop
when the front planetary gear component 05-17
is installed.
• Do not coat grease to the oil holes of the
bawuua00000509

thrust washer.

13. Apply grease to the thrust washer.

14. Install the thrust washer to the front planetary
gear component.
End Of Sie

bawuua00000510

05-17–41
SERVICE_1874-1U-06B(05-17).fm 42 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
C1 CLUTCH COMPONENT DISASSEMBLY
id051700500700
Components

SELECTIVE 2

11
10 R

9
8

7
6
5 SST
bawuua00000370
.

1 Snap ring 7 Piston return spring

2 Retaining plate 8 Spring retainer
3 Drive plate 9 C1 clutch piston
4 Driven plate 10 O-ring
5 Snap ring 11 C1 clutch drum
6 C1 clutch balancer

05-17–42
SERVICE_1874-1U-06B(05-17).fm 43 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly Procedure
1. Using a flathead screwdriver, remove the snap
ring from the C1 clutch drum.

05-17

bawuua00000371

2. Remove the retaining plate, drive and driven

plates from the C1 clutch drum.

Note
• Inspect the number of drive and driven
plates.

bawuua00000372

3. Place the SST on the clutch balancer and

compress the return spring with a press.
49 G025 001
Caution
• Do not expand the snap ring too much.

4. Remove the snap ring using snap ring pliers.

Caution
• Do not damage the seal on the clutch
balancer.
bawuua00000373

5. Remove the clutch balancer, return spring and the

retainer from the C1 clutch drum.

bawuua00000374

05-17–43
SERVICE_1874-1U-06B(05-17).fm 44 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
6. While pushing the C1 clutch piston by hand, apply
compressed air into the oil passage as shown in
the figure and remove the forward clutch piston
from the C1 clutch drum.

Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}

Note
• When applying compressed air, block the
one oil passage of the C1 clutch drum as
shown in the figure. bawuua00000375

7. Remove the O-rings from the C1 clutch drum.

End Of Sie

bawuua00000376

C1 CLUTCH INSPECTION
id051700500800
1. Inspect the lining of all drive plates.
• If the lining is flaking or has changed color, or PRINT
if it is worn or the print mark is wearing away,
replace with a new drive plate. When
replacing, inspect the contact surfaces
between the retaining plate, driven plate and
drive plate. If they are scratched or have
changed color, replace with new parts.

Note
• Before replacing with new drive plates, soak
them at least 2 h in ATF.
bawuua00000511

2. Using vernier calipers, measure the free length of

the piston return spring.

C1 clutch return spring free length

Standard: 17.01 mm {0.6697 in}

• If it is less than the specification, replace the

piston return spring with a new one.
End Of Sie

bawuua00000512

05-17–44
SERVICE_1874-1U-06B(05-17).fm 45 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
C1 CLUTCH COMPONENT ASSEMBLY
id051700500900
Components

SELECTIVE 10 05-17

11

1
2 R

ATF
3 ATF

5
6 ATF
7 SST
bawuua00000377
.

1 C1 clutch drum 7 Snap ring

2 O-ring 8 Driven plate
3 C1 clutch piston 9 Drive plate
4 Spring retainer 10 Retaining plate
5 Piston return spring 11 Snap ring
6 C1 clutch balancer

05-17–45
SERVICE_1874-1U-06B(05-17).fm 46 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Assembly Procedure
1. Apply ATF to the new O-rings and the C1 clutch drum.
2. Install the O-rings to the C1 clutch drum.
3. Apply ATF to the sliding surface of the forward
clutch piston.

Caution
• Do not damage the seal on the piston and
O-ring.

bawuua00000378

4. Install the C1 clutch piston to the C1 clutch drum.

5. Apply ATF to the seal on the clutch balancer.

Caution
• Do not damage the seal on the clutch
balancer.

bawuua00000379

6. Install the retainer, return spring and the clutch

balancer to the C1 clutch drum.

bawuua00000380

7. Place the SST on the clutch balancer and

compress the return spring component with a
press. 49 G025 001

Caution
• When installing the snap ring, set the end
gap of the snap ring as shown in the
figure.
• Do not expand the snap ring too much.

8. Install the snap ring in the groove using snap ring

pliers.
bawuua00000381

05-17–46
SERVICE_1874-1U-06B(05-17).fm 47 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
9. Install the driven plates, drive plates and the
retaining plate in the following order to the C1
clutch drum as shown in the figure.
Six drive plates type
• Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Driven— Drive—
Driven— Drive— Retaining
Seven drive plates type
• Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Driven— Drive—
Driven— Drive— Driven— Drive— Retaining 05-17
bawuua00000382

Caution
• Inspect the number and order of the RETAINING PLATE
retaining plate, drive and driven plates.
DRIVE PLATE DRIVEN PLATE

bawuua00000383

10. Using a flathead screwdriver, install the snap ring

in the groove.

Caution
• When installing the snap ring, set the end
gap of the snap ring as shown in the
figure.

bawuua00000384

11. Install the C1 clutch component on the input shaft

and set a dial indicator as shown in the figure.
12. Apply compressed air as shown in the figure and
measure the C1 clutch piston stroke.

Air pressure
200 kPa {2.0 kgf/cm2, 29 psi}

C1 clutch piston stroke

1.2 — 1.4 mm {0.047 — 0.055 in}

• If not within the specification, select an bawuua00000385

appropriate retaining plate.

05-17–47
SERVICE_1874-1U-06B(05-17).fm 48 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Retaining plate size
Identification mark Thickness (mm {in})
1 2.8 {0.110}
2 2.9 {0.114}
3 3.0 {0.118}
4 3.1 {0.122}
A 3.15 {0.124}
5 3.2 {0.126}
B 3.25 {0.128}
6 3.3 {0.130}
C 3.35 {0.132}
7 3.4 {0.134}
8 3.5 {0.138}

End Of Sie

05-17–48
SERVICE_1874-1U-06B(05-17).fm 49 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
COUNTER DRIVE GEAR DISASSEMBLY/ASSEMBLY
id051700501000
Components

9 R
SST
11

8 SST

10 R 05-17
13 SST

12

4 SST
5
SST
7 R
bawuua00000386
.

1 Rear planetary ring gear 8 Counter drive gear

2 Snap ring 9 Bearing race
3 Rear planetary ring gear flange 10 Bearing race
4 Nut 11 Snap ring
5 Washer 12 Center support
6 Snap ring 13 Tapered roller bearing
7 Tapered roller bearing

05-17–49
SERVICE_1874-1U-06B(05-17).fm 50 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly Procedure
1. Using the snap ring pliers, loosen the snap ring
and remove the rear planetary ring gear.

bawuua00000387

2. Using a flathead screwdriver, remove the snap

ring from the rear planetary ring gear.
3. Remove the ring gear flange from the rear
planetary ring gear.

bawuua00000388

4. Using a flathead screwdriver and hammer, pry

back the crimps locking the washer.

Caution
• If the lockwasher crimps are not
completely pried back, the tool cannot fit
over the bolt properly and the bolt cannot
be loosened.

bawuua00000389

5. Using the SST, remove the nut and the washer.

49 G019 040

bawuua00000390

05-17–50
SERVICE_1874-1U-06B(05-17).fm 51 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
6. Using a flathead screwdriver, remove the snap
ring from the counter drive gear.

Caution
• Do not drop the tapered roller bearing.

05-17
bawuua00000391

7. Using the SST, remove the counter drive gear

and tapered roller bearing. 49 G019 026
49 B032 317

bawuua00000392

8. Using a flathead screwdriver and hammer,

remove the bearing race inner from the counter
drive gear.

bawuua00000393

9. Using a flathead screwdriver and hammer,

remove the bearing race outer from the counter
drive gear.

bawuua00000394

05-17–51
SERVICE_1874-1U-06B(05-17).fm 52 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
10. Using a flathead screwdriver, remove the snap
ring from the counter drive gear.

bawuua00000395

Note
• The tapered roller bearing cannot be
removed from the center support.
• The tapered roller bearing and center
support must be replaced as a set.

bawuua00000396

Assembly Procedure

Note
• The tapered roller bearing and bearing race outer must be replaced as a set.

1. Using the SST and a press, install the tapered

roller bearing to the center support.
Substitution SST STEEL PLATE
• 49 L033 101
Outer diameter: 70— 76 mm {2.76— 2.99 in}
Inner diameter: 68.2 mm {2.69 in} or more
Plate thickness: 1 mm {0.04 in} or more

49 L033 101

bawuua00000397

2. Using a flathead screwdriver, install the hole snap

ring to the counter drive gear.

bawuua00000395

05-17–52
SERVICE_1874-1U-06B(05-17).fm 53 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
3. Using the old bearing race and the steel plate as
shown in the figure, install the new bearing race
outer to the counter drive gear.

STEEL PLATE
05-17

OLD BEARING
RACE

NEW BEARING
RACE

bawuua00000398

4. Using the old bearing race and the steel plate as

shown in the figure, install the new bearing race
inner to the counter drive gear.

Caution
• Do not press fit the bearing too deeply.
• Verify that the bearing is press fit to allow
the installation of the nut.
STEEL PLATE

OLD BEARING
RACE

NEW BEARING
RACE

bawuua00000399

5. Using the SST and a press, install the counter

drive gear with the tapered roller bearing.
Substitution SST 49 W027 001
• 49 W027 001
Outer diameter: 70— 81 mm {2.76— 3.18 in}
Plate thickness: 1 mm {0.04 in} or more

Note
• Verify that the claw of the washer is fit into
the groove on the center support.
• Verify that the nut is installed in the correct
bawuua00000400
direction.

6. Install the washer and nut.

7. Using the SST, tighten the nut.

NUT

WASHER

bawuua00000401

05-17–53
SERVICE_1874-1U-06B(05-17).fm 54 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
8. Using a spring balance, measure the starting and
rotating torque of the counter drive gear.
49 G019 040

bawuua00000402

Counter drive gear starting and rotating torque

N·m {kgf·cm, in·lbf}
Bearing Starting torque Rotating torque
New 0.40 — 0.50 {4.08 — 5.09, 3.55 — 4.41} 0.40 — 0.48 {4.08 — 4.89, 3.55 — 4.24}
Reused 0.20 — 0.25 {2.04 — 2.54, 1.77 — 2.20} 0.20 — 0.24 {2.04 — 2.44, 1.77 — 2.11}

• Adjust the starting and rotating torque by tightening the nut.

• If the starting and rotating torque does not fall within the specification, loosen the nut and retighten the nut
to adjust torque.
9. Using a flathead screwdriver and hammer, crimp
down the washer.

bawuua00000403

10. Using a flathead screwdriver, install the hole snap

ring to the counter drive gear.
11. Install the rear planetary ring gear flange to the
rear planetary ring gear.

bawuua00000391

12. Using a flathead screwdriver, install the snap ring

in the groove.
13. Install the rear planetary ring gear to the counter
drive gear.

bawuua00000388

05-17–54
SERVICE_1874-1U-06B(05-17).fm 55 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
14. Using the snap ring pliers, while loosening the
snap ring, install the rear planetary ring gear.
End Of Sie

05-17
bawuua00000387

ONE-WAY CLUTCH COMPONENT INSPECTION

id051700501100
1. Hold the one-way clutch component in place.
Verify that the rear planetary gear rotates when
turned clockwise and does not rotate when turned
counterclockwise.
LOCK FREE
End Of Sie

bawuua00000513

05-17–55
SERVICE_1874-1U-06B(05-17).fm 56 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
REAR PLANETARY GEAR COMPONENT AND ONE-WAY CLUTCH COMPONENT DISASSEMBLY
id051700501200
Components

3
9
2

4
5
6
7

8
bawuua00000514
.

1 One-way clutch component 6 Bearing race

2 Thrust washer 7 Planetary sun gear
3 Thrust washer 8 Bearing race
4 Bearing race 9 Rear planetary gear component
5 Thrust bearing

Disassembly Procedure
1. Remove the one-way clutch component from the
rear planetary gear component.

bawuua00000515

05-17–56
SERVICE_1874-1U-06B(05-17).fm 57 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
2. Remove the thrust washer from the rear planetary
gear component.

05-17
bawuua00000516

3. Remove the thrust washer from the rear planetary

gear component.

bawuua00000517

4. Remove the planetary sun gear and bearing

races from the rear planetary gear component.

Note
• If it is difficult to remove the bearing race,
remove it gently using a flathead
screwdriver.

End Of Sie

bawuua00000518

REAR PLANETARY GEAR INSPECTION

id051700501300

Note
• Measure at different places and take an average.

1. Using a dial indicator, measure the inner diameter

of the rear planetary gear bushings.

Rear planetary gear bushing inner diameter

Front side: 33.26 — 33.286 mm {1.3095 —
1.3104 in}
Rear side: 33.26 — 33.286 mm {1.3095 —
1.3104 in}

• If it exceeds the specification, replace the rear

planetary gear component with a new one.
• When the rear planetary gear component is
bawuua00000519
replaced, inspect the contact surface opposed
to the planetary sun gear.
• If the surface of it is scratched or has changed color, replace the planetary sun gear with a new one.

05-17–57
SERVICE_1874-1U-06B(05-17).fm 58 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
2. Using a dial indicator, measure the inner diameter
of the planetary sun gear bushings.

Rear planetary sun gear bushing inner

diameter
Front side: 24.2 — 24.226 mm {0.9528 —
0.9537 in}
Rear side: 24.2 — 24.226 mm {0.9528 —
0.9537 in}

• If it exceeds the specification, replace the

planetary sun gear component with a new
bawuua00000520
one.
• When the planetary sun gear component is
replaced, inspect the contact surface opposed to the intermediate shaft.
• If the surface of it is scratched or has changed color, replace the intermediate shaft with a new one.
End Of Sie
REAR PLANETARY GEAR COMPONENT AND ONE-WAY CLUTCH COMPONENT ASSEMBLY
id051700501400
Components

GREASE
1
GREASE

7 ATF

6 ATF

5 ATF

4 ATF

bawuua00000521
.

1 Rear planetary gear component 5 Bearing race

2 Thrust washer 6 Thrust bearing
3 Thrust washer 7 Bearing race
4 Bearing race 8 Planetary sun gear

05-17–58
SERVICE_1874-1U-06B(05-17).fm 59 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Assembly Procedure

Caution
• Apply grease to the mounting surface of the thrust washer so that it will not drop when the rear
planetary gear component is installed.
• Do not apply grease to the oil holes of the thrust washer.

1. Apply grease to the thrust washer.

2. Install the thrust washer to the rear planetary gear
component.
05-17
Caution
• Apply grease to the mounting surface of
the thrust washer so that it will not drop
when the rear planetary gear component
is installed.
• Do not apply grease to the oil holes of the
thrust washer.

3. Apply grease to the thrust washer.

bawuua00000522

4. Install the thrust washer to the rear planetary gear

component.

Caution
• Apply grease to the mounting surface of
the thrust washer so that it will not drop
when the rear planetary gear component
is installed.
• Do not apply grease to the oil holes of the
thrust washer.

5. Apply ATF to the bearing races and the thrust

bawuua00000523
bearing.
6. Install the bearing races to the planetary sun gear
as shown in the figure.
7. Install the planetary sun gear to the rear planetary
gear component.
End Of Sie

bawuua00000524

05-17–59
SERVICE_1874-1U-06B(05-17).fm 60 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
C2 CLUTCH COMPONENT DISASSEMBLY
id051700501500
Components

3 SELECTIVE

7
6 SST

12 R
11 R 13

10
bawuua00000045
.

1 Thrust bearing 4 Drive plate

2 Snap ring 5 Driven plate
3 Retaining plate 6 Snap ring

05-17–60
SERVICE_1874-1U-06B(05-17).fm 61 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
7 C2 clutch balancer 11 O-ring
8 Piston return spring 12 O-ring
9 Spring retainer 13 Intermediate shaft
10 C2 clutch piston

Disassembly Procedure
1. Remove the thrust bearing from the intermediate
shaft.
05-17
Note
• If the bearing is difficult to remove, blow air
between the bearing and the intermediate
shaft.

bawuua00000046

2. Using a flathead screwdriver, remove the snap

ring from the intermediate shaft.

bawuua00000047

3. Remove the retaining plate, drive and driven

plates from the intermediate shaft.

Note
• Inspect the number of drive and driven
plates.

bawuua00000048

4. Place the SST on the clutch balancer and

compress the return spring with a press.
49 G025 001
Caution
• Do not contract the return spring too
much.
• Do not expand the snap ring too much.

5. Remove the snap ring using snap ring pliers.

Caution
• Do not damage the seal on the clutch
bawuua00000049
balancer.

05-17–61
SERVICE_1874-1U-06B(05-17).fm 62 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
6. Remove the clutch balancer, return spring and the
spring retainer from the intermediate shaft.

Caution
• Do not damage the seal on the piston.

bawuua00000050

7. While pushing the C2 clutch piston by hand, apply

compressed air into the oil passage as shown in
the figure and remove the C2 clutch piston from
the intermediate shaft.

Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}

Note
• When applying compressed air, block the
three oil passages of the intermediate shaft
as shown in the figure. bawuua00000051

8. Remove the O-rings from the intermediate shaft.

End Of Sie

bawuua00000052

05-17–62
SERVICE_1874-1U-06B(05-17).fm 63 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
C2 CLUTCH INSPECTION
id051700501600
1. Inspect the lining of all drive plates.
• If the lining is flaking or has changed color, or PRINT
if it is worn or the print mark is wearing away,
replace with a new drive plate. When
replacing, inspect the contact surfaces
between the retaining plate, driven plate and
drive plate. If they are scratched or have
changed color, replace with new parts.
05-17
Note
• Before replacing with new drive plates, soak
them at least 2 h in ATF.
bawuua00000525

2. Using vernier calipers, measure the free length of

the piston return spring.

C2 clutch return spring free length

Standard: 14.02 mm {0.5520 in}

• If it is less than the specification, replace the

piston return spring with a new one.
End Of Sie

bawuua00000526

05-17–63
SERVICE_1874-1U-06B(05-17).fm 64 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
C2 CLUTCH COMPONENT ASSEMBLY
id051700501700
Components

10

12

11 SELECTIVE

7 ATF

8 SST

13

2 R
3 R 1
ATF

ATF

4 ATF

bawuua00000086
.

1 Intermediate shaft 4 C2 clutch piston

2 O-ring 5 Spring retainer
3 O-ring 6 Piston return spring

05-17–64
SERVICE_1874-1U-06B(05-17).fm 65 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
7 C2 clutch balancer 11 Retaining plate
8 Snap ring 12 Snap ring
9 Driven plate 13 Thrust bearing
10 Drive plate

Assembly Procedure
1. Apply ATF to the new O-rings and the intermediate shaft.
2. Install the O-rings to the intermediate shaft.
05-17

bawuua00000087

O-ring size
mm {in}
Inner diameter Thickness
Upper 51.90 {2.043} 1.60 {0.0630}
Lower 50.40 {1.984} 2.62 {0.1031}

3. Apply ATF to the sliding surface of the C2 clutch piston.

Caution
• Do not damage the seal on the piston and O-ring.

4. Install the C2 clutch piston to the intermediate

shaft.
5. Apply ATF to the seal on the clutch balancer and
sliding surface.

Caution
• Do not damage the seal on the clutch
balancer.
• Do not damage the O-ring.

bawuua00000088

6. Install the spring retainer, return spring and the

clutch balancer to the intermediate shaft.

Caution
• Be careful not to shorten the spring too
much. If it is too short, it will bite into the
O-ring.

bawuua00000089

05-17–65
SERVICE_1874-1U-06B(05-17).fm 66 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
7. Place the SST on the clutch balancer and
compress the return spring with a press.
49 G025 001
Caution
• Do not expand the snap ring too much.

8. Install the snap ring into the groove using snap

ring pliers.

bawuua00000090

9. Install the driven plates, drive plates and the

retaining plate in the following order to the
intermediate shaft as shown in the figure.
Three drive plates type
• Driven— Drive— Driven— Drive— Driven—
Drive— Retaining
Four drive plates type
• Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Retaining

bawuua00000091

RETAINING PLATE
Caution
• Inspect the number and order of the
DRIVE PLATE
retaining plate, drive and driven plates. DRIVEN PLATE

bawuua00000092

10. Using a flathead screwdriver, install the snap ring

into the groove.
11. Apply ATF to the thrust bearing.

Note
• Install the bearing in the correct direction as
shown in the figure.

bawuua00000093

12. Install the thrust bearing to the intermediate shaft.

bawuua00000094

05-17–66
SERVICE_1874-1U-06B(05-17).fm 67 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
13. Install the intermediate shaft on the transaxle
case and set a dial indicator as shown in the
figure.
14. Apply compressed air as shown in the figure and
measure the C2 clutch piston stroke.

Air pressure
400 kPa {4.1 kgfcm2, 58 psi}

C2 clutch piston stroke

0.45 — 0.65 mm {0.0178 — 0.0255 in} 05-17

• If not within the specification, select an

appropriate retaining plate.

bawuua00000095

Retaining plate size

Identification mark Thickness (mm {in})
1 2.5 {0.0984}
2 2.6 {0.102}
3 2.7 {0.106}
4 2.8 {0.110}
A 2.85 {0.112}
5 2.9 {0.114}
B 2.95 {0.116}
6 3.0 {0.118}
C 3.05 {0.120}
7 3.1 {0.122}
8 3.2 {0.126}

End Of Sie

05-17–67
SERVICE_1874-1U-06B(05-17).fm 68 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
TRANSAXLE CASE AND B2 BRAKE DISASSEMBLY/ASSEMBLY
id051700501800
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

3
2
1 SST

5 R
4 R
ATF
ATF

bawuua00000404

1 Snap ring 3 Low and reverse brake piston

2 Low and reverse brake return spring (See 05-17-69 Low and Reverse Brake Piston
(See 05-17-70 Low and Reverse Brake Return Disassembly Note.)
Spring Assembly Note.) (See 05-17-70 Low and Reverse Brake Piston
Assembly Note.)
4 O-ring
5 O-ring

05-17–68
SERVICE_1874-1U-06B(05-17).fm 69 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Low and Reverse Brake Piston Disassembly Note
1. Using a flathead screwdriver, remove the snap
ring from the transaxle case.

05-17

bawuua00000405

2. Remove the low and reverse brake return spring

from the transaxle case.

Caution
• Do not damage the seal on the piston.

bawuua00000406

3. While pushing the low and reverse brake piston

by hand, apply compressed air into the oil
passage of the transaxle case as shown in the
figure and remove the low and reverse brake
piston.

Air pressure
392 kPa {4.0 kgf/cm2, 57 psi}

bawuua00000407

4. Remove the O-rings from the low and reverse

brake piston.

bawuua00000408

05-17–69
SERVICE_1874-1U-06B(05-17).fm 70 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Low and Reverse Brake Piston Assembly Note
1. Apply ATF to the new O-rings.
2. Install the O-ring to the low and reverse brake
piston.
3. Apply ATF to the sliding surface of the transaxle
case.

Caution
• Do not damage the seal on the piston and
O-ring.

bawuua00000408

4. Install the low and reverse brake piston to the

transaxle case.

bawuua00000409

Low and Reverse Brake Return Spring Assembly Note

1. Install the low and reverse brake return spring to
the transaxle case.

bawuua00000406

2. Using the SST, press the return spring into the

49 G019 0A9
position where the snap ring groove is visible.

bawuua00000410

05-17–70
SERVICE_1874-1U-06B(05-17).fm 71 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
3. Using a flathead screwdriver, install the snap ring
in the groove.

Caution
• When installing the snap ring, set the end
gap of the snap ring as shown in the
figure.

End Of Sie
05-17
bawuua00000411

TRANSAXLE CASE AND B2 BRAKE INSPECTION

id051700501900

Note
• Measure at different places and take an average.

1. Using a dial indicator, inspect the transaxle case

bushing.

Transaxle case bushing inner diameter

Standard: 21.932 — 21.953 mm {0.86347 —
0.86429 in}

• If it exceeds the specification, replace the

transaxle case with a new one.
• When the transaxle case is replaced, inspect
the contact surface of the intermediate shaft
bushing.
• If the surface is scratched or has changed
bawuua00000527

color, replace the intermediate shaft with a

new one.
2. Inspect the lining of all drive plates.
PRINT
• If the lining is flaking or has changed color, or
if it is worn or the print mark is wearing away,
replace with a new drive plate. When
replacing, inspect the contact surfaces
between the retaining plate, driven plate and
drive plate. If they are scratched or have
changed color, replace with new parts.

Note
• Before replacing with new drive plates, soak
them at least 2 h in ATF.
bawuua00000528

3. Using vernier calipers, measure the free length of

the piston return spring.

B2 brake return spring free length

Standard: 19.01 mm {0.7485 in}

• If it is less than the specification, replace the

piston return spring with a new one.
End Of Sie
AT: CONTROL VALVE BODY

bawuua00000529

05-17–71
SERVICE_1874-1U-06B(05-17).fm 72 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY
id051700502000
Components

1 ATF

3
bawuua00000530
.

1 Manual valve 4 Shift solenoid A

2 E-ring 5 Shift solenoid B
3 Manual valve connecting rod

05-17–72
SERVICE_1874-1U-06B(05-17).fm 73 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Disassembly Procedure

Caution
• Do not pull the manual valve strongly.

1. Remove the manual valve from the control valve

body.

05-17

bawuua00000531

2. Using a flathead screwdriver, remove the E-ring.

3. Remove the manual valve connecting rod from
the manual valve.

Caution
• Do not damage the solenoid.

bawuua00000532

4. Remove the solenoids from the control valve

body.

bawuua00000533

05-17–73
SERVICE_1874-1U-06B(05-17).fm 74 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Assembly Procedure

Caution
• Do not damage the solenoid.

1. Install the solenoids to the front control valve

body.

Tightening torque
8.0 — 12.0 N·m {81.6 — 122.3 kgf·cm, 70.9
— 106.1 in·lbf}

2. Install the manual valve connecting rod to the

manual valve.

bawuua00000533

3. Install the E-ring.

4. Apply ATF to the manual valve.

Caution
• Do not damage the manual valve.

bawuua00000534

5. Install the manual valve to the control valve body.

End Of Sie
AT: AUTOMATIC TRANSAXLE

bawuua00000531

05-17–74
SERVICE_1874-1U-06B(05-17).fm 75 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE ASSEMBLY
id051700502200
Assembly
Bearing and race locations

C2 CLUTCH COMPONENT
PLANETARY SUN GEAR

REAR PLANETARY
GEAR COMPONENT 05-17
6
ONE-WAY CLUTCH
COMPONENT 11

10

9
8
7

SUN GEAR INPUT DRUM

4 C1 CLUTCH COMPONENT
3
INPUT SHAFT

FRONT PLANETARY SUN GEAR

FRONT PLANETARY GEAR COMPONENT

C3 CLUTCH COMPONENT

OIL PUMP COMPONENT

bawuua00000412

05-17–75
SERVICE_1874-1U-06B(05-17).fm 76 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
1 2 3 4 5 6 7 8 9 10 11
64.0 101.0 85.0 79.8 104.2
Outer — — — — — —
{2.52} {3.98} {3.35} {3.14} {4.10}
Thrust washer (mm {in})
51.0 75.3 72.7 68.3 69.0
Inner — — — — — —
{2.01} {2.96} {2.86} {2.69} {2.72}
43.7
Outer — — — — — — — — — —
{1.72}
Bearing race (front) (mm {in})
25.6
Inner — — — — — — — — — —
{1.01}
61.3 52.6 45.6 48.7 43.8 75.0
Outer — — — — —
{2.41} {2.07} {1.80} {1.92} {1.72} {2.95}
Bearing (mm {in})
43.7 39.2 33.2 35.0 24.25 50.5
Inner — — — — —
{1.72} {1.54} {1.31} {1.38} {0.9547} {1.99}
68.8 48.5 47.0 45.6 41.7
Outer — — — — — —
{2.71} {1.91} {1.85} {1.80} {1.64}
Bearing race (rear) (mm {in})
46.9 38.1 35.2 33.2 24.2
Inner — — — — — —
{1.85} {1.50} {1.39} {1.31} {0.953}

05-17–76
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AUTOMATIC TRANSAXLE
Components

05-17

17
20 R
16

12

9 11

13
14
15
1
10

19
2
18
R 4
3 ATF

4 R

6
5

bawuua00000413
.

05-17–77
SERVICE_1874-1U-06B(05-17).fm 78 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
1 Transaxle case plate No.3 11 Manual valve lever
2 Transaxle case plate No.2 12 Parking pawl
3 Seal ring 13 Parking pawl bracket
4 O-ring 14 Torsion spring
5 Oil cooler outlet tube 15 Spring guide sleeve
6 Wiring harness clip 16 Pawl return spring
7 Transaxle case No.1 plate 17 Parking pawl shaft
8 Pipe clamp 18 Detent spring
9 Parking pin 19 Detent spring cover
10 Parking rod 20 Stud bolt

05-17–78
SERVICE_1874-1U-06B(05-17).fm 79 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE

4
3

05-17

bawuua00000414

1 Oil pipe 3 Oil reservoir lock plate

2 Magnet 4 Tube clamp

05-17–79
SERVICE_1874-1U-06B(05-17).fm 80 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE

ATF
39 37
18 ATF

R 38
30
35 ATF

17 ATF

25

34
26

36 ATF 27

SST
28
ATF
3
ATF 5

2 ATF

11
33 ATF
4 ATF

6
16 R ATF

7
R 1
8 ATF

9 ATF
10 ATF
19
ATF
ATF

ATF 20
ATF

12 21
ATF
13 15 ATF 23
24
14
29

22

31
32 ATF

bawuua00000415

1 Thrust bearing 3 Retaining plate

2 C2 clutch component 4 Driven plate

05-17–80
SERVICE_1874-1U-06B(05-17).fm 81 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
5 Drive plate 22 C1 clutch component
6 Retaining plate 23 Bearing race
7 Snap ring 24 Thrust bearing
8 Bearing race 25 Piston return spring
9 Thrust bearing 26 B1 brake piston
10 Bearing race 27 Brake piston cover
11 Rear planetary gear component and one-way clutch 28 Snap ring
component 29 B1 brake band
12 Snap Ring 30 Brake band anchor bolt 05-17
13 Spacer 31 Front planetary gear component and input shaft
14 Vehicle speed sensor (VSS) 32 C3 clutch component
15 Counter drive gear 33 Oil strainer
16 Lock washer 34 Oil Pump component
17 Differential component 35 Gasket
18 Counter gear component 36 Gasket
19 Sun gear input drum 37 Transaxle case gasket
20 Bearing race 38 O-ring
21 Thrust bearing 39 Breather pipe

05-17–81
SERVICE_1874-1U-06B(05-17).fm 82 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE

18
8 R
R 16
3
SST SST
ATF R 2 R 17 R 1
10 R
R
5 SST 9
7 R

ATF

11

4 R
SEALANT

ATF

14

R 19 R 12
13

15 R
20

6
*1

22

21
bawuua00000416

1 Oil seal (manual shaft) 8 O-ring

2 O-ring (transaxle case side) 9 Coupler component
3 Oil seal (transaxle case side) 10 Coupler component lock plate
4 O-ring (converter housing side) (2WD) 11 Control valve body component
5 Oil seal (converter housing side) 12 Gasket
6 Input/turbine speed sensor 13 Suction cover
7 Gasket 14 Lock plate

05-17–82
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AUTOMATIC TRANSAXLE
15 Control valve body cover 19 Gasket
16 TCM 20 Drain plug
17 O-ring 21 Torque converter
18 Filler plug 22 Oil pipe and O-ring

*1
: The figure shows Mazda6 specification.

Assembly Procedure
05-17
Caution
• Do not damage the oil seal.

1. Using the SST and a hammer, install a new oil

seal to the transaxle case.
Substitution SST 49 G030 797
• 49 F026 102
Outer diameter: 27 mm {1.07 in} or more -0.3—0.4 mm
Inner diameter: 15— 18 mm {0.60— 0.70 in} {-0.0118—0.0157 in}
2. Apply ATF to the new seal rings and sliding
surface of the transaxle case. 49 F026 102

bawuua00000417

3. Compress the seal rings as shown in the figure.

Then install the seal rings in the transaxle case. 5 mm {0.197 in}

Caution
• Do not expand the seal rings too much.
• Be careful not to shorten the seal rings
too much, when installing the seal rings.

Note
• Inspect that seal rings rotate smoothly after
installing them.
bawuua00000418

4. Install the transaxle case plate No.3.

Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}

bawuua00000419

05-17–83
SERVICE_1874-1U-06B(05-17).fm 84 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
5. Install the transaxle case plate No.2.

Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}

bawuua00000420

6. Apply ATF or grease to the thrust bearing and

install it to the C2 clutch component.
7. Apply ATF to the seal ring and rubbing surface of
the C2 clutch component where the bushing is fit.

Caution
• Do not damage the seal ring.

bawuua00000421

8. Install the C2 clutch component to the transaxle

case.
9. Apply ATF to the driven plates, drive plates and
retaining plates.

Note
• Replace with new drive plates after soaking
them at least 2 h in ATF.

bawuua00000422

10. Install driven plates, drive plates and the retaining

plate in the following order to the transaxle case
as shown in the figure.
Six drive plates type
• Retaining— Drive— Driven— Drive—
Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Retaining
Seven drive plates type
• Retaining— Drive— Driven— Drive—
Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Driven— Drive—
Retaining
bawuua00000423

RETAINING PLATE
Caution
• Inspect the number and order of the
retaining plates, drive and driven plates. DRIVE PLATE DRIVEN PLATE

RETAINING PLATE

bawuua00000424

05-17–84
SERVICE_1874-1U-06B(05-17).fm 85 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
11. Using a flathead screwdriver, install the snap ring
in the groove.

Caution
• Align the opening of the snap ring with
the position as shown in the figure.

05-17
bawuua00000425

12. Apply ATF to the thrust bearing and the bearing

races and install them to the transaxle case.

Note
• Align the spline of the C2 clutch drive plates
and B2 brake drive plates before installing
the rear planetary gear component.

bawuua00000426

13. Apply ATF to each gear and the bushing, and

then install the rear planetary gear component to
the transaxle case.
14. Apply ATF to the sliding surface of the one-way
clutch.

Note
• For easy installation, while turning the rear
planetary gear component, install it.

bawuua00000427

15. Install the one-way clutch to the transaxle case.

bawuua00000428

16. Using a flathead screwdriver, install the snap ring

in the groove.

Caution
• Align the opening of the snap ring with
the position shown in the figure.

bawuua00000429

05-17–85
SERVICE_1874-1U-06B(05-17).fm 86 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
17. While holding the one-way clutch component,
inspect that the planetary gear turns to right LOCK FREE
(clockwise) but does not turn to left
(counterclockwise).

Caution
• Do not damage the VSS.

bawuua00000430

18. Install the VSS and spacer to the counter drive

gear.

Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}
SPACER

19. Apply ATF to the spline on the counter drive gear

and spline on the ring gear.

Caution
• Do not damage the VSS wiring harness.
• Do not pull hard on the VSS wiring
bawuua00000431

harness.

20. Install the counter drive gear to the transaxle case.

Note
• Verify that the claws of the lockwashers are facing upward.

21. Install the new lockwashers and washers with

new bolts.

Tightening torque B B
82.7 — 93.6 N·m {8.5 — 9.5 kgf·cm, 61.0 —
69.0 ft·lbf}

Bolt length (measured from below the head)

A: 28 mm {1.102 in}
B: 35 mm {1.378 in}
A
B

B B

bawuua00000432

05-17–86
SERVICE_1874-1U-06B(05-17).fm 87 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
22. Using a flathead screwdriver and a hammer, pry
back the crimp locking the lockwashers.
23. Apply ATF to the new O-rings.
24. Install the O-rings to the oil cooler outlet tube.

05-17
bawuua00000433

25. Install the oil cooler outlet tube, pipe clamp,

transaxle case No.1 plate and the wiring harness
clip to the converter housing.

Caution
• Do not damage the VSS wiring harness.
• Do not pull hard on the VSS wiring
harness.

Tightening torque
7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}

bawuua00000434

26. Connect the VSS wiring harness to the wiring

harness clip.
27. Apply ATF to the bearing and gear of the
differential component.

bawuua00000435

28. Install the differential component to the transaxle

case.
29. Apply ATF to the bearing and gear of the counter
gear component.

bawuua00000436

05-17–87
SERVICE_1874-1U-06B(05-17).fm 88 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
30. Install the counter gear component to the
transaxle case.

Note
• If it is difficult to install the counter driven
gear, remove the differential component and
then install the counter driven gear. Install
the differential component again.
• For easy installation, tilt the counter gear
slightly.

bawuua00000437

31. Install the parking pin to the transaxle case.

Caution
• Verify to install the parking pin as shown
in the figure.

bawuua00000438

32. Insert the parking rod to the transaxle case.

bawuua00000439

33. Install the manual valve lever to the transaxle

case.

bawuua00000440

34. Connect the parking rod to the manual valve

lever.

bawuua00000441

05-17–88
SERVICE_1874-1U-06B(05-17).fm 89 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
35. Install the parking pawl, parking pawl bracket and
the parking rod to the transaxle case.

Caution
• Do not apply too much force to the
torsion spring.

Tightening torque
7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
05-17

bawuua00000442

36. Install the spring guide sleeve and the torsion

spring.

Tightening torque
7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}

Note
• Install the torsion spring to the position of the
parking lock pawl and parking lock pawl
bracket shown in the figure together with the
spring guide sleeve and torsion spring
bawuua00000443
installed.

Caution
• Do not apply too much force to the pawl return spring.

37. Install the pawl return spring to the parking pawl shaft.
38. Install the pawl return spring and the parking pawl
shaft to the transaxle case.

Caution
• Do not apply too much force to the detent
spring.

Note
• When installing the pawl return spring to
transaxle case, install the parking pawl side
of the spring, then install the parking pawl
shaft.
bawuua00000444

05-17–89
SERVICE_1874-1U-06B(05-17).fm 90 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
39. Install the detent spring cover and detent spring
to the transaxle case.

Tightening torque
7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}

bawuua00000445

Note
• When installing, ensure that the center of the
detent spring’s roller fits the center of the
manual valve lever.

bawuua00000446

40. Install the sun gear input drum to the transaxle

case.
41. Apply ATF to the bearing race and the thrust
bearing, and then install them to the transaxle
case.

bawuua00000447

42. Install the C1 clutch component to the transaxle

case.
43. Apply ATF to the bearing race and the thrust
bearing, and then install them to the transaxle
case.
Caution
• If the input shaft is not hold during
installation, the thrust washer might be
come off.
Note
• Align the spline of the C1 clutch drive plates
bawuua00000448
before installing the input shaft and front
planetary gear.
• Hold the C1 clutch component and install the front planetary gear while holding the input shaft.

05-17–90
SERVICE_1874-1U-06B(05-17).fm 91 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
44. Install the input shaft and the front planetary gear
to the transaxle case.
45. Apply ATF to the bushing of the C3 clutch
component.

Note
• Before installing the C3 clutch component,
align the spline of the C3 clutch drive plates
and the spline of the B1 brake drive plates.

05-17
bawuua00000449
46. Install the C3 clutch component to the transaxle
case.

bawuua00000450

Note
• Install the C3 clutch component so that it C3 CLUTCH COMPONENT
engages with the sun gear drum as shown in
the figure.

SUN GEAR
INPUT DRUM

bawuua00000451

47. Install the B1 brake band to the transaxle case.

bawuua00000452

48. Install the brake band anchor bolt to the transaxle

case.

Tightening torque
133.3 — 199.9 N·m {13.6 — 20.3 kgf·m, 98.3
— 147.4 ft·lbf}

bawuua00000453

05-17–91
SERVICE_1874-1U-06B(05-17).fm 92 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
49. Install the piston return spring, B1 brake piston
and the brake piston cover to the transaxle case.

bawuua00000454

50. Using the SST, press the brake piston cover into
the position where the snap ring groove is visible.
51. Apply ATF to the oil seal.

BRAKE PISTON COVER

49 T019 0A1

bawuua00000455

52. Install the oil strainer and the oil seal to the oil
pump component.
53. Apply ATF to each rubbing surface of the oil pump
component.

Caution
• Do not drop the thrust washer.
• Do not damage the oil seal.

bawuua00000456

54. Install the oil pump component to the transaxle

case. B
A
A
Tightening torque
19.6 — 29.4 N·m {2.0 — 2.9 kgf·m, 14.5 —
21.6 ft·lbf}
A
Bolt length (measured from below the head)
A: 22 mm {0.866 in} B A
B: 35 mm {1.378 in} A

bawuua00000457

05-17–92
SERVICE_1874-1U-06B(05-17).fm 93 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
55. Verify that the input shaft turns smoothly.

05-17
bawuua00000458

56. Using a dial indicator, measure the input shaft

end play.

Input shaft end play

0.349 — 1.081 mm {0.01374 — 0.04255 in}

bawuua00000459

57. Put a mark on the piston rod at the point where it MARK
intersects with the case.

bawuua00000460

58. Measure the stroke between the transaxle case

and the mark on the piston rod when applying
compressed air into the oil hole as shown in the
figure.

Air pressure
400 kPa {4.1 kgf/cm2, 58 psi}

B1 brake piston stroke

5.50 — 6.00 mm {0.217 — 0.236 in}

• If not within the specification, select an bawuua00000461

appropriate piston rod.

05-17–93
SERVICE_1874-1U-06B(05-17).fm 94 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
Piston rod size
Identification mark Length (mm {in})
— 102.80 {4.0473}
1 103.05 {4.0571}
2 103.30 {4.0669}
3 103.55 {4.0768}
4 103.80 {4.0866}
5 104.05 {4.0965}
6 104.30 {4.1063}
7 104.55 {4.1161}
8 104.80 {4.1260}
9 105.05 {4.1358}
10 105.30 {4.1457}

Caution
• Do not damage the differential gear lube
apply tube.

MARK

bawuua00000462

59. Install the differential gear lube apply tube to the

converter housing.

bawuua00000463

60. Install the magnets to the oil reservoir lock plate.

Caution
• Do not damage the oil reservoir lock
plate.

bawuua00000464

05-17–94
SERVICE_1874-1U-06B(05-17).fm 95 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
61. Install the oil reservoir lock plate and the tube
clamp to the converter housing.

Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}

62. Apply ATF to the new gaskets.

05-17
bawuua00000465

63. Install the gaskets to the transaxle case as shown

in the figure.
64. Apply ATF to the new transaxle case gaskets.

bawuua00000466

65. Install the transaxle case gaskets to the transaxle

case as shown in the figure.

Caution
• Verify to install the transaxle case gasket
as shown in the figure.

66. Remove any packing material and be careful not

to get oil on the contact surface of the transaxle
case and the converter housing.
67. Clean the contact surface of the transaxle case
and the converter housing and the bolt holes.
bawuua00000467

Note
• Completely remove sealant and oil with white gasoline or equivalent.

68. Apply ATF to a O-ring of the oil pump.

69. Apply sealant to the converter housing as shown
in the figure.

Note
• Spread sealant over the contact surface.
• Do not apply sealant to the transaxle case.

Caution
• Do not damage the O-ring on the oil
pump component.
• Do not damage the housing oil seal.
bawuua00000468

05-17–95
SERVICE_1874-1U-06B(05-17).fm 96 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
70. Install the converter housing to the transaxle
case.

Note
• Tap all around the contact surface with a
plastic hammer during installation.

71. Temporarily tighten the bolts by hand as shown in

the figure.

bawuua00000469

D
E
A

B
B
B B
A
B C A

B C
B

B
B A
B A
B B

bawuua00000470

Bolt number Bolt size Length (measured from below the head) (mm {in})
A M8 × 1.25 30 {1.18}
B M8 × 1.25 35 {1.38}
C M8 × 1.25 39 {1.54}
D M10 × 1.25 25 {0.984}
E M10 × 1.25 40 {1.57}

72. Tighten the bolts.

Tightening torque
A, B, C: 23.5 — 35.3 N·m {2.4 — 3.5 kgf·m, 17.4 — 26.0 ft·lbf}
D, E: 29.4 — 41.2 N·m {3.0 — 4.2 kgf·m, 21.7 — 30.3 ft·lbf}

Caution
• Do not damage the input/turbine speed sensor.

05-17–96
SERVICE_1874-1U-06B(05-17).fm 97 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
73. Install the input/turbine speed sensor to the
transaxle case.

Tightening torque
3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60
in·lbf}

05-17
bawuua00000471

74. Apply ATF to a new gasket as shown in the figure.

75. Install the gasket to the coupler component.

Caution
• Do not apply ATF to the O-ring. O-RING

76. Install a new O-ring to the coupler component.

GASKET
Caution
• Do not apply too much force to the
coupler component.
• Do not damage the coupler component.
bawuua00000472

77. Install the coupler component to the transaxle

case.

Note
• Install the coupler component to the transaxle case by engaging its claw.

78. Install a new coupler component lock plate.

Caution
• When installing the control valve body
component, do not put the coupler
component in the open space of the
separate plate in the control valve body
component.
• Do not pinch the coupler component
between the separate plate and the
control valve body component.
bawuua00000473

79. Connect the manual valve link and install the

SEPARATE PLATE
control valve body component.

bawuua00000474

05-17–97
SERVICE_1874-1U-06B(05-17).fm 98 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
80. Temporarily install the control valve body
component with the bolts.

Bolt length (measured from below the head) A

A: 31 mm {1.220 in}
B: 17 mm {0.669 in}
C: 21 mm {0.827 in} B
B
B
Note
• Aligning the bolt holes, temporarily tighten
the bolts by hand. C C

bawuua00000475

81. Temporarily install the suction cover and a new

gasket with the bolts.

bawuua00000476

82. Tighten the bolts in the order shown in the figure.

Tightening torque
5
8 — 12 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}
4
1
2

3 6

7
8
bawuua00000477

05-17–98
SERVICE_1874-1U-06B(05-17).fm 99 ページ ２００６年３月１３日 月曜日 午後９時４４分

AUTOMATIC TRANSAXLE
83. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.

05-17

VSS CONNECTOR INPUT/TURBINE SPEED SENSOR

CONNECTOR

bawuua00000478

Caution
• If the control valve body cover is installed with the wiring harnesses overlapped, the wiring
harnesses may be pinched between the cover and valve body causing the wiring harnesses to be
damaged. Therefore, verify that the wiring harnesses are not overlapped when installing the
control valve body cover.

NO GOOD GOOD

bawuua00000479

84. Apply ATF to a new O-ring and install it on the TFT sensor.
85. Install the TFT sensor with the lock plate and a
bolt to the control valve body component as
shown in the figure.

Tightening torque
8 — 12 N·m {82 — 122 kgf·cm, 72 — 105
in·lbf}

86. Connect the solenoid connectors, VSS connector

and the input/turbine speed sensor connector.

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AUTOMATIC TRANSAXLE
87. Connect the coupler component to the clamps.
CLAMP
Note
• Completely remove sealant and oil with CLAMP
white gasoline or similar.

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88. Clean sealant and oil off the contact surface of

the transaxle case with the control valve body
cover and the bolt holes.

Note
• Completely remove oil with white gasoline or
similar.

89. Clean oil off the contact surface of the new control
valve body cover with the transaxle case.

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90. Apply sealant to the new control valve body cover

as shown in the figure.

Caution
• Be careful that the coupler component
will not become caught between the
control valve body cover and transaxle
case.

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AUTOMATIC TRANSAXLE
91. Install the new control valve body cover with new
seal bolts.

Tightening torque
9.8 — 15.7 N·m {100 — 160 kgf·cm, 87 —
138 in·lbf}

05-17

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92. Inspect the condition of connector pin of the

coupler component (foreign material, bent/broken
pins) and O-ring.

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93. Align the transaxle case and the coupler

component connector.

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94. Be sure to match the position of the TCM

marking.

Caution
• Do not turn more than 60° from the
marking.

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AUTOMATIC TRANSAXLE
95. Verify the correct positioning of the TCM and
coupler component.
96. Install the TCM to the transaxle case.

Tightening torque
19.6 — 29.4 N·m {2.0 — 2.9 kgf·m, 14.5 —
21.6 ft·lbf}

Caution
• Do not repair the threads using a tap or
other tools.
• Do not damage the transaxle case.
• Do not overtighten the stud bolts. (The
stud bolts should remain protruded from
the end of the transaxle case more than
47 mm {1.85 in}.)
• If any of the stud bolts is overtightened,
the transaxle case may be damaged
(holes in the case may result).
• If the transaxle case is damaged, the
transaxle must be replaced.

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97. Install the double nutted stud bolts to the

transaxle case.
98. Remove the double nutted from the stud bolt.

Caution
• Do not damage the oil seal.

47—51 mm
{1.85—2.00 in}

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99. Using the SST and a hammer, tap a new oil seal so that the specified oil seal position is obtained.
Transaxle Case Side
Substitution SST
• 49 H028 202
Outer diameter: 54.5— 61 mm {2.15— 2.40 49 H028 202
in} 3—4 mm
Inner diameter: 52 mm {2.05 in} or more {0.118—0.157 in}
Plate thickness: 2 mm {0.08 in} or more

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05-17–102
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AUTOMATIC TRANSAXLE
Converter Housing Side
Substitution SST AW6A-EL
• 49 F027 009
Outer diameter: 76.8 mm {3.02 in}
49 F027 009
Plate thickness: 2 mm {0.08 in} or more
• 49 L033 101
Outer diameter: 73— 76.3 mm {2.88— 3.00 2.3—3.3 mm
{0.091—0.130 in}
in}
Inner diameter: 69 mm {2.72 in} or more
Length: 20 mm {0.79 in} or more
Plate thickness: 2 mm {0.08 in} or more 05-17

AW6AX-EL
49 L033 101

7.4—8.4 mm
{0.292—0.330 in}

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100.Install a new gasket and the drain plug.

Tightening torque
23.5 — 54.9 N·m {2.4 — 5.5 kgf·m, 17.4 —
40.4 ft·lbf}

Caution
• Do not damage the oil seal.
• Do not drop the torque converter.
• Be careful that fingers do not get caught.

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101.Using a flathead screwdriver, position the drive

gear on the oil pump component in the center.
Then install the torque converter component to
the transaxle.

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05-17–103
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AUTOMATIC TRANSAXLE
102.To ensure that the torque converter is installed
A
accurately, measure distance A between the end
TORQUE CONVERTER
of the torque converter and the end of the
converter housing.

Distance A (between the end of the torque

converter and the end of the converter
housing)
Mazda6: 18 mm {0.709 in}
CX-7: 31.4 mm {1.24 in}

103.Install the O-rings and oil pipes. (Refer to the

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Workshop Manual.)
104.Add the ATF.
End Of Sie
AUTOMATIC TRANSAXLE INSPECTION
id051700502300
B2 Brake Inspection
1. Apply ATF to the driven plates, drive plates and retaining plates.

Note
• Replace with new drive plates after soaking them at least 2 h in ATF.

2. Install driven plates, drive plates and the retaining

plate in the following order to the transaxle case
as shown in the figure.
Six drive plates type
• Retaining— Drive— Driven— Drive—
Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Retaining
Seven drive plates type
• Retaining— Drive— Driven— Drive—
Driven— Drive— Driven— Drive— Driven—
Drive— Driven— Drive— Driven— Drive—
Retaining
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RETAINING PLATE
Caution
• Inspect the number and order of the
retaining plates, drive and driven plates. DRIVE PLATE DRIVEN PLATE

RETAINING PLATE

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3. Using a flathead screwdriver, install the snap ring

into the groove.

Caution
• Align the opening of the snap ring with
the position shown in the figure.

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AUTOMATIC TRANSAXLE
4. Set a dial indicator as shown in the figure.
5. While applying compressed air into the oil
passage as shown in the figure, measure the B2
brake clearance and inspect the piston moves
smoothly.

Air pressure
200 kPa {2.0 kgf/cm2, 29 psi}

B2 brake clearance
1.20 — 1.40 mm {0.047 — 0.055 in} 05-17

• If not within the specification, select another

retaining plate.

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Retaining plate size

Identification mark Thickness (mm {in})
47 4.7 {0.185}
48 4.8 {0.189}
49 4.9 {0.193}
50 5.0 {0.197}
51 5.1 {0.201}
52 5.2 {0.205}
53 5.3 {0.209}

6. Using a flathead screwdriver, remove the snap

ring.

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7. Remove the retaining plates, drive and driven

plates.

Note
• Inspect the number of drive and driven
plates.

End Of Sie

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05-17–105
SERVICE_1874-1U-06B(05-50).fm 1 ページ ２００６年３月１３日 月曜日 午後９時５３分

TECHNICAL DATA
05-50 TECHNICAL DATA
TRANSMISSION/TRANSAXLE
TECHNICAL DATA . . . . . . . . . . . . . . . . 05-50–1

End of Toc
TRANSMISSION/TRANSAXLE TECHNICAL DATA
WM: TRANSMISSION/TRANSAXLE

id055000800100

Item Specification
C3 clutch return spring free length Standard: 12.91 mm {0.5083 in} 05-50
C3 clutch piston stroke 0.6 — 0.8 mm {0.024 — 0.031 in}
C1 clutch return spring free length Standard: 17.01 mm {0.6697 in}
C1 clutch piston stroke 1.2 — 1.4 mm {0.047 — 0.055 in}
Front side: 33.26 — 33.286 mm {1.3095 — 1.3104 in}
Rear planetary gear bushing inner diameter
Rear side: 33.26 — 33.286 mm {1.3095 — 1.3104 in}
Front side: 24.2 — 24.226 mm {0.9528 — 0.9537 in}
Rear planetary sun gear bushing inner diameter
Rear side: 24.2 — 24.226 mm {0.9528 — 0.9537 in}
C2 clutch return spring free length Standard: 14.02 mm {0.5520 in}
C2 clutch piston stroke 0.45 — 0.65 mm {0.0178 — 0.0255 in}
Transaxle case bushing inner diameter Standard: 21.932 — 21.953 mm {0.86347 — 0.86429 in}
B2 brake return spring free length Standard: 19.01 mm {0.7485 in}
Input shaft end play 0.349 — 1.081 mm {0.01374 — 0.04255 in}
B1 brake piston stroke 5.50 — 6.00 mm {0.217 — 0.236 in}
Distance A (between the end of the torque converter Mazda6: 18 mm {0.709 in}
and the end of the converter housing) CX-7: 31.4 mm {1.24 in}
B2 brake clearance 1.20 — 1.40 mm {0.047 — 0.055 in}

Counter drive gear starting and rotating torque

N·m {kgf·cm, in·lbf}
Bearing Starting torque Rotating torque
New 0.40 — 0.50 {4.08 — 5.09, 3.55 — 4.41} 0.40 — 0.48 {4.08 — 4.89, 3.55 — 4.24}
Reused 0.20 — 0.25 {2.04 — 2.54, 1.77 — 2.20} 0.20 — 0.24 {2.04 — 2.44, 1.77 — 2.11}

End Of Sie

05-50–1
SERVICE_1874-1U-06B(05-60).fm 1 ページ ２００６年３月１３日 月曜日 午後９時５３分

SERVICE TOOLS
05-60 SERVICE TOOLS
TRANSMISSION/TRANSAXLE SST. . . . 05-60–1

End of Toc
TRANSMISSION/TRANSAXLE SST
AT: TRANSMISSION/TRANSAXLE

id056000500100

49 0107 680A 49 L010 1A0 49 U027 003

Engine stand Engine hanger Oil seal installer 05-60

set

49 G025 001 49 G019 040 49 G019 026

Sensor rotor Wrench Plate

installer

49 B032 317 49 F027 009 49 L033 101

Bearing & oil Attachment for Oil seal installer

seal remover 68 & 77

49 W027 001 49 G019 0A9 49 G030 797

Body Compressor Handle

49 F026 102 49 T019 0A1 49 H028 202

Bearing installer Servo piston Block L

lifter set

End Of Sie

05-60–1