Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. 2. 3. 4. 5. Install the spring retainers to the synchronizer hub. Align the scribe marks previously made on the synchronizer hub and the synchronizer sleeve. Install the synchronizer hub to the synchronizer sleeve with the three struts. Install the main drive synchronizer stop ring to the synchronizer sleeve. Install the drive sprocket to the mainshaft. 6. Install the synchronizer assembly to the mainshaft. 7. Install the synchronizer snap ring to the mainshaft. 8. Use a soft faced hammer in order to install the following components into the annulus gear: • The input gear • The planetary assembly 9. Install the snap ring to the input bearing. 10. Apply RTV GM P/N 12345739 or equivalent to the input shaft bearing retainer mating surfaces. 11. Apply threadlocker GM P/N 12345382 or equivalent to the input shaft bearing retainer bolts. 12. Install the input shaft bearing retainer and the input bearing retainer bolts to the front case half. Tighten Tighten the input bearing retainer bolts to 19 N·m (14 lb ft). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 13. Install the three bolts that secure the encoder motor to the front case. Tighten Tighten the input bearing retainer bolts to 18 N·m (13 lb ft). 14. Install the range shift hub into the front case half. 15. Install the front output shaft to the front case half. 16. Install the driven sprocket to the chain. Important: The following components are installed into the front case half as an assembly: • The mainshaft assembly • The driven sprocket • The drive chain 17. 18. 19. 20. Install the drive chain onto the drive sprocket located on the mainshaft. Install the driven gear snap ring to the front output shaft. Install the mode shift fork onto the shift rail. Install the mode shift fork assembly through the range shift fork, onto the synchronizer sleeve, and into the front case half. 21. Install the mode fork shift spring to the shift rail. 22. Install the following components into the rear case half: • The oil pump pickup tube. • The oil tube connector • The pump pickup screen

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WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK. For disassembly, relocate the transmission to the top of a flat work bench. WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF OIL. 1. Remove torque converter (7902) . 2. Remove input shaft (7017) . The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly. NOTE: For transfer case disassembly and assembly see Section 07-07A, Section 07-07B and Section 07-07C. 3. If the vehicle has a transfer case (7A195) , use a 13mm socket to remove five bolts holding the transfer case to the extension housing (7A039) . Remove transfer case and set aside for reassembly. NOTE: The case oil pressure plug is a press fit into the extension housing and is not serviced separately. CAUTION: The parking pawl (7A441) , parking pawl return spring (7D070) , and parking pawl shaft (7D071) could fall out during removal of the extension housing . 4. Remove the extension housing seal using Front Seal Remover T74P-77248-A. NOTE: Remove extension housing bushing (7A034) only if service is required by inspection. 5. Remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-E. 6. Use 17mm socket to remove four M10 x 30mm screws (E800152-S72) and two studs (E800137-S72) holding the extension housing to the transmission case (7005) . 7. Remove the parking pawl , parking pawl return spring , and parking pawl shaft . 8. Use a 10mm socket to remove two M6 x 20mm screws holding governor to collector body. Remove the governor body, governor primary valve (7C054) , governor valve spring (7A302) , and governor weight (7D324) . The governor body counter weight (7F124) need not be removed.

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1. Raise the vehicle on a hoist. For additional information, refer to Section 100-02 . 2. Remove the front wheel and tire assemblies. For additional information, refer to Section 204-04 . 3. Disconnect the tie-rod ends. 1. Remove and discard the cotter pins. 2. Remove the castle nuts. 3. NOTE: Remove the adapter from the ball end of the tool and apply a small amount of grease to the tie-rod stud and to the ball of the tool. Use care not to damage the tie-rod dust boots when installing the tool. Disconnect the tie-rod ends from the front wheel spindles, using Tie-Rod End Remove TOOL-3290-D or equivalent. 4. Remove the left tie-rod end. 5. If equipped, remove the lower engine splash shield. 6. Remove the stabilizer bar. For additional information, refer to Section 204-01A . 7. Remove the nuts retaining the power steering cooler to the steering gear and position the cooler out of the way. 8. CAUTION: Clean any loose dirt from the valve portion of steering gear housing to prevent contamination of the power steering system. NOTE: Plug the ends of the fluid lines and ports to prevent entry of dirt. Disconnect and plug the power steering lines at the steering gear. 1. Disconnect the pressure line. 2. Disconnect the return line. 9. NOTE: Do not rotate the steering column while the intermediate shaft is disconnected or damage to the steering column clock spring will result. Remove the bolt retaining the lower steering column shaft to the steering gear input shaft. Disconnect the lower steering column shaft.

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1. CAUTION: Do not remove steering wheel (3600) and driver side air bag module (043B13) as an assembly unless the column is locked or the steering column shaft is secured to keep it from turning. This will avoid damage to the air bag sliding contact (14A664) assembly. Disconnect battery ground cable (14301) . Wait one minute for air bag diagnostic monitor to deplete its stored energy. 2. Remove steering wheel as outlined. 3. Remove the bolt retaining steering column gear input shaft coupling (3A525) to steering column. 4. Remove ignition switch lock cylinder (11582) as outlined. 5. Remove steering column opening cover and reinforcement. 6. Remove instrument panel cross brace. 7. Remove the lower steering column shroud (3530) and upper steering column shroud , fastened by self-tapping screws. 8. Disconnect all electrical connections (quick-couplers) from the ignition switch (11572) and key warning buzzer connecting wire. 9. Remove screws retaining multi-function switch (13K359) and position out of the way. 10. Remove the two nuts retaining steering shaft tube boot to the dash panel (01610) . 11. Remove four nuts retaining steering column to instrument panel (04320) . Lower steering column to clear the four mounting bolts, remove ignition/shifter interlock cable (3F719) (automatic transmission only) and remove steering column.

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Customer Concern: Tests/Procedures: Potential Causes: Check engine light is on for a code transmission P0715 (Input/Turbine Speed Sensor). 1. Scope the signal at the Powertrain Control Module (PCM) and watch for glitches while maneuvering the wire harness near the PCM connector. Wiring Reported Fix Details 2004 Mazda 3, 2.3L, USA/Canada * Input Speed Sensor – Car had a code p0715 and the a/t warning light was on. The transmission was downshifting on the freeway by itself. Replaced the input shaft speed sensor. Car is driving normally now, no trouble codes.