Part 2
Assembly Procedure Con't50. 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.
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.
54. Install the oil pump component to the transaxle case.
Tightening torque:
19.6 - 29.4 N-m (2.0 - 2.9 kgf-m, 14.5 - 21.6 ft-lbf)
Bolt length (measured from below the head)
A: 22 mm (0.866 in)
B: 35 mm (1.378 in)
55. Verify that the input shaft turns smoothly.
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)
57. Put a mark on the piston rod at the point where it intersects with the case.
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 appropriate piston rod.
Piston rod size
Caution: Do not damage the differential gear lube apply tube.
59. Install the differential gear lube apply tube to the converter housing.
60. Install the magnets to the oil reservoir lock plate.
Caution: Do not damage the oil reservoir lock plate.
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.
63. Install the gaskets to the transaxle case as shown in the figure.
64. Apply ATF to the new transaxle case gaskets.
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.
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.
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.
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.
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)
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.
76. Install a new O-ring to the coupler component.
Caution:
^ Do not apply too much force to the coupler component.
^ Do not damage the coupler component.
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.
79. Connect the manual valve link and install the control valve body component.
80. Temporarily install the control valve body component with the bolts.
Bolt length (measured from below the head)
A: 31 mm (1.220 in)
B: 17 mm (0.669 in)
C: 21 mm (0.827 in)
Note: Aligning the bolt holes, temporarily tighten the bolts by hand.
81. Temporarily install the suction cover and a new gasket with the bolts.
82. Tighten the bolts in the order shown in the figure.
Tightening torque:
8 - 12 N-m (82 - 122 kgf-cm, 72 - 105 in-lbf)
83. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.
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.
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.
87. Connect the coupler component to the clamps.
Note: Completely remove sealant and oil with white gasoline or similar.
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.
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.
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)
92. Inspect the condition of connector pin of the coupler component (foreign material, bent/broken pins) and O-ring.
93. Align the transaxle case and the coupler component connector.
94. Be sure to match the position of the TCM marking.
Caution: Do not turn more than 60� from the marking.
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.
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.
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 in)
Inner diameter: 52 mm (2.05 in) or more
Plate thickness: 2 mm (0.08 in) or more
Converter Housing Side
Substitution SST
^ 49 F027 009
Outer diameter: 76.8 mm (3.02 in)
Plate thickness: 2 mm (0.08 in) or more
^ 49 L033 101
Outer diameter: 73 - 76.3 mm (2.88 - 3.00 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
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.
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.
102. To ensure that the torque converter is installed accurately, measure distance A between the end 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.
104. Add the ATF.