Mazda 2: Manual Transaxle

MANUAL TRANSAXLE LOCATION INDEX

Mazda 2. 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.

Mazda 2. NEUTRAL SWITCH REMOVAL/INSTALLATION

4. Remove the neutral switch.

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

Tightening torque

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.

Mazda 2. BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION

4. Remove the back-up light switch.

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

Tightening torque

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.

Mazda 2. TRANSAXLE OIL INSPECTION

Manual transaxle oil grade

Manual transaxle oil viscosity

5. Install the hole cover.

Mazda 2. TRANSAXLE OIL INSPECTION

Tightening torque

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

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

Mazda 2. TRANSAXLE OIL REPLACEMENT

Manual transaxle oil grade

Manual transaxle oil viscosity

Manual transaxle oil capacity (approx. quantity)

7. Install the hole cover.

Mazda 2. TRANSAXLE OIL REPLACEMENT

Tightening torque

OIL SEAL (DIFFERENTIAL) REPLACEMENT

CAUTION:

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.

Mazda 2. OIL SEAL (DIFFERENTIAL) REPLACEMENT

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

Mazda 2. OIL SEAL (DIFFERENTIAL) REPLACEMENT

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).

Mazda 2. MANUAL TRANSAXLE REMOVAL/INSTALLATION

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

Mazda 2. MANUAL TRANSAXLE REMOVAL/INSTALLATION

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:

Mazda 2. MANUAL TRANSAXLE REMOVAL/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.

Mazda 2. MANUAL TRANSAXLE REMOVAL/INSTALLATION

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.

Mazda 2. MANUAL TRANSAXLE REMOVAL/INSTALLATION

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.

Mazda 2. MANUAL TRANSAXLE REMOVAL/INSTALLATION

2. Using the bolts part number 99794 1025 or M10

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