A/T - Fluid Leaks From Servo Cover

Bulletin No: 05-015/09

Last issued: 09/04/2009

Subject
ATF LEAK FROM A/T SERVO COVER

APPLICABLE MODEL(S)/VINS
2009 Mazda6 with 6AT (AW6A-EL)
2007-2009 CX-7 with 6AT (AW6A-EL/AW6AX-EL) built before JM3 ER **** 9* 232339 November 1, 2008
2007-2009 CX-9 with 6AT (AW6A-EL/AW6AX-EL) built before JM3 TB **** 9* 170029 November 1, 2008

DESCRIPTION





Some vehicles may leak ATF from a servo cover (A) on a 6 speed automatic transmission (AW6A-EL/AW6AXEL). This is caused by damage to the servo cover O-rings (B) during the production process. The production process has been changed to correct this concern.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Lift up the vehicle

3. Remove the under cover.





4. Remove the drain plug and drain ATF into a clean container (ATF will be re-used).

CAUTION:
When installing the drain plug, use a new gasket. Tightening torque is 39.2 Nm (28.9 lb/ft).





5. Use a stand lift to press the servo cover to prevent it from popping out due to spring force, and remove the snap ring using snap ring pliers.





NOTE:
It is easier to remove snap ring if it is positioned to the opposite direction of the engine side.





6. Place ATF recovery container under servo cover and remove the servo cover.





7. Slowly remove the brake piston from the servo cover.





8. Remove O-rings from the brake piston and the servo cover, apply ATF to the new O-rings, and assemble them into the servo cover and the brake piston. Install the piston spring.

^ Be careful not to damage new O-rings during the assembly.





9. Use a stand lift to press the servo cover, the brake piston and the spring into position.





^ Turn servo cover during installation to prevent O-ring damage.

^ Press in the servo cover 1mm above the snap ring groove.





10. Using snap ring pliers, install the snap ring and confirm proper fit.

11. Clean excess ATF from bottom of transmission.

12. Lower the vehicle.

13. Refill ATF with drained oil from step 4.





14. Start engine and shift from "P" to "D" range two times and allow engine to warm up.

15. Check oil level with ATF dip stick using a new nylon cloth to prevent contamination. If additional fluid is required, use ATF JWS3309 to top off.

16. Verify repair by inspecting A/T servo cover and drain plug after test drive.

17. Install the under cover.





PART(S) INFORMATION





WARRANTY INFORMATION

NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.

^ This repair will be covered under Mazda's New Vehicle Limited Warranty term for a powertrain component.

^ Additional diagnostic time cannot be claimed for this repair.