Mazda 2: Manual Transaxle

MANUAL TRANSAXLE LOCATION INDEX

1. Manual transaxle
   • (See MANUAL TRANSAXLE REMOVAL/INSTALLATION)
2. Back-up light switch
   • (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION)
3. Neutral switch
   • (See NEUTRAL SWITCH REMOVAL/INSTALLATION)
4. Transaxle oil
   • (See TRANSAXLE OIL INSPECTION)
   • (See TRANSAXLE OIL REPLACEMENT)
5. Oil seal (differential)
   • (See OIL SEAL (DIFFERENTIAL) REPLACEMENT)

NEUTRAL SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

2. Drain the transaxle oil. (See TRANSAXLE OIL REPLACEMENT).

3. Disconnect the neutral switch connector.

4. Remove the neutral switch.

5. Install the neutral switch (with a new gasket) to the transaxle case.

Tightening torque

• 20-29 N*m {2.1-2.9 kgf*m, 15-21 ft*lbf}

6. Connect the neutral switch connector.

7. Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT).

8. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

2. Drain the transaxle oil. (See TRANSAXLE OIL REPLACEMENT).

3. Disconnect the back-up light switch connector.

4. Remove the back-up light switch.

5. Install the back-up light switch (with a new gasket) to the transaxle case.

Tightening torque

• 20-29 N*m {2.1-2.9 kgf*m, 15-21 ft*lbf}

6. Add the specified amount and type of oil. (See TRANSAXLE OIL REPLACEMENT).

7. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

TRANSAXLE OIL INSPECTION

1. Park the vehicle on level ground.

2. Stop the engine and allow approx. 3 min before continuing.

3. Remove the hole cover.

4. Verify that the oil level is as shown in the figure.

• If the oil level is lower than the low level, add the specified amount and type of oil through the hole cover installation hole.

Manual transaxle oil grade

• API service GL-4

Manual transaxle oil viscosity

• SAE 75W-80

5. Install the hole cover.

Tightening torque

• 8-11 N*m {82-112 kgf*cm, 71-97 in*lbf}

TRANSAXLE OIL REPLACEMENT

1. Park the vehicle on level ground.

2. Remove the hole cover.

3. Remove the drain plug with the washer.

4. Drain the transaxle oil.

5. Install a new washer and the drain plug.

Tightening torque

• 39-59 N*m {4.0-6.0 kgf*m, 29-43 ft*lbf}

6. Add the specified amount and type of oil through the hole cover installation hole until the level reaches as shown in the figure.

Manual transaxle oil grade

• API service GL-4

Manual transaxle oil viscosity

• SAE 75W-80

Manual transaxle oil capacity (approx. quantity)

• 2.91 L {3.07 US qt, 2.56 Imp qt}

7. Install the hole cover.

Tightening torque

• 8-11 N*m {82-112 kgf*cm, 71-97 in*lbf}

OIL SEAL (DIFFERENTIAL) REPLACEMENT

CAUTION:

• Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake.

  Before performing the following procedures, remove the ABS wheel-speed sensor and fix it to an appropriate place where the harness will not be pulled by mistake while servicing the vehicle.

1. Drain the transaxle oil. (See TRANSAXLE OIL REPLACEMENT).

2. Disconnect the drive shaft (LH) from the transaxle. (See DRIVE SHAFT REMOVAL/INSTALLATION).

3. Disconnect the drive shaft (RH) from the joint shaft. (See DRIVE SHAFT REMOVAL/INSTALLATION).

4. Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION).

5. Remove the oil seals using a screwdriver.

6. Using the SSTs and a hammer, tap each new oil seal in evenly until the SSTs contacts the transaxle case.

7. Coat the lip of each oil seal with transaxle oil.

8. Install the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION).

9. Install the drive shaft (RH) to the joint shaft. (See DRIVE SHAFT REMOVAL/INSTALLATION).

10. Install the drive shaft (LH) to the transaxle. (See DRIVE SHAFT REMOVAL/INSTALLATION).

11. Add the specified amount and type of oil. (See TRANSAXLE OIL REPLACEMENT).

MANUAL TRANSAXLE REMOVAL/INSTALLATION

1. Remove the battery and battery tray and battery bracket. (See BATTERY REMOVAL/INSTALLATION).

2. Remove the wheels and tires. (See GENERAL PROCEDURES (FRONT AND REAR AXLES) ).

3. Remove the fresh-air duct and air cleaner component as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).

4. Remove the EGR pipe installation bolt (intake manifold side). (See EGR PIPE REMOVAL/INSTALLATION).

5. Suspend the EGR pipe (intake manifold side) with a cable in place out of the way.

6. Drain the transaxle oil. (See TRANSAXLE OIL REPLACEMENT).

7. Remove in the order indicated in the table.

8. Install in the reverse order of removal.

9. Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT).

NOTE:

• If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION).

1. Battery tray bracket
2. Neutral switch connector
3. Back-up light switch connector
4. Ground
5. Shift cable
6. Select cable
7. Cable bracket
8. Clutch release cylinder
9. Starter
10. Transaxle mounting bolt (upper side)
11. Wiring harness bracket
12. Stabilizer control link
13. Tie-rod end ball joint
14. Lower arm ball joint
15. Drive shaft (LH)
16. Drive shaft (RH)
17. Joint shaft
18. No.1 engine mount
19. No.4 engine mount rubber
20. No.4 engine mount bracket
21. Transaxle mounting bolt (lower side)
22. Manual transaxle

Shift Cable and Select Cable Removal Note

1. Remove the both shift cable end and select cable end using a fastener remover.

No.1 Engine Mount Removal Note

1. Remove the bolt A, B.

2. Loosen the bolt C and slide engine mount No.1 as shown in the figure.

No.4 Engine Mount Removal Note

1. Set the bracket and vacuum pipe out of the way to prevent interference with the SST as shown in the figure.

2. Using the bolts part number 99794 1025 or M10

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