Mazda GTHTTCF7AR Reference manual

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CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2011 Mazda Motor of America, Inc.
Subject:
AUTOMATIC TRANSMISSION/TRANSAXLE COOLER AND LINES FLUSHING
PROCEDURE
Bulletin No: 05-008/11
Last Issued: 09/21/2011
Service Bulletin Mazda North American Operations
Irvine, CA 92618-2922
MULTI-MODEL - AUTOMATIC TRANSMISSION/TRANSAXLE COOLER AND LINES FLUSHING
PROCEDURE
BULLETIN NOTE
• This bulletin supersedes the previous bulletins 05-012/10 issued 09/30/10, 05-014/06 issued on 12/12/06
and K-005/98 issued on 04/22/98. The APPLICABLE MODELS, DESCRIPTION and WARRANTY INFOR-
MATION have been revised.
• Changes are noted below in Red beside the change bar.
APPLICABLE MODEL(S)/VINS
DESCRIPTION
Automatic Transaxle/Transmission (A/T) oil cooler and lines must be power flushed completely before an over-
hauled or replacement A/T is installed (except SKYACTIV-DRIVE). The most common cause of repeat A/T fail-
ures is lack of lubrication to the front and rear planetary gears. This is usually caused by an accumulation of
metal particles and debris (from a previous A/T failure) on the internal mesh type baffle of the oil cooler. Power
flushing will remove the restriction by back flushing, followed by forward flushing to dislodge a restriction, then
back flushing again. This will in turn ensure full ATF flow for the transmission when it is operating.
NOTE: Repeat repairs caused by improper or lack of cooler line flushing will not be covered under warranty,
and are subject to review and debit by Mazda.
NOTE: For SKYACTIV-DRIVE, flushing is not recommended as part of service maintenance. There are no oil
cooler lines and the replacement SKYACTIV-DRIVE will come with a new oil cooler, which is mounted
directly to the case.
1995-2009 B-Series 1997-2006 MPV 2004-2012 Mazda3 (except SKYACTIV)
1997-2003 Protege 2001-2011 Tribute 2006-2012 MX-5
1997-2005 Miata 2003-2012 Mazda6 2007-2012 CX-7
1997-2002 626 2004-2011 RX-8 2007-2012 CX-9
1997-2002 Millenia 2006-2012 Mazda5 2011-2012 Mazda2

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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Mazda Required Tool (MRT) Power Flushing Equipment
Part Number Description
GTHTTCF7AR G-Tech A/T Cooler Line Flusher
(Supreme Heated Cooler Line Flusher)

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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REPAIR PROCEDURE
Before power flushing, inspect the hoses/lines and clamps on the vehicle. Repair or replace as necessary.
Power flushing must begin with back flushing, followed by forward flushing to dislodge a restriction, then back
flushing again. If back flushing is not performed before forward flushing, the restriction could further reduce the
automatic transmission fluid (ATF) flow through the internal mesh type baffle (C) of the cooler and flushing will
not be effective or possible.
If the cooler is not properly flushed, oil flow from the cooler to the transmission will not be enough to lubricate
the transmission. The most common cause of repeat transmission failure is lack of lubrication to the front and
rear planetary gears.
Inspecting Oil Lines & Clamps
Be sure to inspect the vehicle transmission lines (hoses/pipes) for cuts, crimps (pinched), cracks or any other
damage before reusing them. If any problem exists or the hose comes off when applying oil pressure, replace it.
CAUTION: Always use new clamps when replacing hoses.
A Oil in
B Oil out
C Mesh Type Baffle
D Location of internal metal particles and debris accumulation

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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FLUSHING PROCEDURE
CAUTION: The G-Tech flushing unit uses hot fluid under pressure. Inspect all flushing unit hoses and connec-
tions before operation. Always wear safety glasses, gloves, and protective clothing. If ATF acci-
dentally gets in your eyes or skin, rinse with water immediately.
WARNING: Improper use of this flushing unit can result in burns and other serious injuries. Always wear eye
protection and protective clothing and follow all instructions in the manufacturers booklet.
NOTE: • For best results, perform a back flush, forward flush, and back flush as outlined.
• Be sure to follow these instructions carefully when performing the flushing procedure.
• Depending on the production date, some flushing units may not come equipped with certain
options. If not, please disregard that step.
• Refer to Appendix for flushing unit illustration and component names where “callout” numbers are
indicated.
(STEP A - SETUP)
1. Plug both power lines (if equipped), of the flushing unit directly into a 110V (15 amp) grounded electrical out-
let.
ATTENTION - Make sure the following:
• NEVER plug the heater and motor cords into a wall outlet that has anything else plugged into it.
• NEVER plug the heater and/or motor cord into an extension cord.
• ALWAYS place the fluid purge hose in an EPA-approved oil waste container before operating the
flusher to prevent fluid spills.
• Before starting or engaging the motor for flushing and purging, be certain that the ATF in the tank
has reached about 120F.
• NEVER raise the shop air psi higher than 125 as this will cause damage to the motor, pump, and/or
the vehicle’s cooling system.
• Do NOT use mineral spirits, solvents, or any volatile liquid in the flusher!
2. Add 8 gallons of ATF to the flushing unit tank.
3. Always turn the heater switch (callout 3) to the On position first. The green light will come on. If the red light
is lit, then the tank is low on fluid and there will be NO power to the heater. The ATF recommended maxi-
mum amount is eight (8) gallons. Do NOT overfill the tank. Allow approximately 15 minutes for the flushing
unit to reach operating temperature of above 120 Fahrenheit using the unit’s thermometer (callout #15).
CAUTION: On previous flushing units, the heater may be adjustable. However, doing so is solely at the
risk and responsibility of the operator. On current flushing units, the heater is NOT adjustable.
Factory setting of the heater is 150-160 Fahrenheit.

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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4. Install the appropriate quick disconnect line adaptors to the ATF cooler inlet and outlet lines using any of the
three methods in Figure below (radiator (A), hose (B), or banjo bolt (C)). Connect the red pressure hose to
the cooler inlet line (E). Connect the blue return hose to the cooler outlet line (D) (the line coming from the
vehicle’s cooler tank going to the transmission).
Three ways to attach the flusher to the vehicle:
A To radiator
B To hose
C To banjo bolt
D Return out hose (blue line)
E Pressure in hose (red line)
F Air purge hose

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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5. Connect a shop air hose (C) (less than 125 psi) to the air purge valve (D) (callout #20) as shown.
NOTE: The quick connect fitting on the air purge valve has a one-way check valve to keep ATF from enter-
ing your shop’s air system. Do NOT remove or replace this fitting. Attach the coupler provided with
the flushing unit to your air shop line if your coupler is not compatible.
6. Secure the end of the fluid purge hose (blue short hose with open end) into an EPA-approved waste con-
tainer. ATTENTION – The pressure is very high and purging takes only a few seconds. Be sure to ade-
quately secure the short hose into a container to prevent spills.
7. Turn the fluid purge valve handle (callout #6) so that the needle points toward the fluid purge hose (the
“purge” position). Turn the motor switch ON (callout #3) and purge the dirty fluid. Allow the fluid to flow until
fluid turns clear. Then turn the motor switch off. The amount of purge will vary based on each vehicle and
when the fluid turns clear. This amount will average between one pint and one quart. Always turn the fluid
purge handle (callout #6) to the flush position (the needle faces toward the filters) after each purge.
A Return out hose (blue line)
B Pressure in hose (red line)
C Shop air line
D Air purge hose

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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8. Replenish ATF to the flushing unit’s tank, if the low fluid indicator (red) light (callout #3) comes On after purg-
ing.
(STEP B - BACK FLUSH)
9. The best method for flushing is to back-flush the cooler first. If possible to back-flush the cooler (see note),
set the reverse lever (callout #21) to the “2” position. If not possible, set the lever to the “1” position for for-
ward-flush.
NOTE:
• Some coolers cannot be back-flushed due to a directional check valve that makes back-flushing
impossible. In some circumstances, it is possible to temporarily remove the check valve which will
allow back-flushing of the system. Be sure to re-install the check valve.
• If there is a one way check valve in the line, the flow forward on a clear system will be above 4 gpm
and in the back-flushing position zero (0) gpm. The pressure release valve will open and all fluid will
go from the pump back into the tank. The flow meter will read zero (0) gpm.
• When the reverse lever is set to position “1”, the fluid flows from the red hose into the cooler. The
red hose is the “pressure” line and the blue hose is the “return” line.
• When the reverse lever is set to position “2”, the fluid reverses and flows from the blue hose into the
cooler. The blue hose is the “pressure” line and the red hose is the “return” line.
10.Turn the motor switch ON. Let the flushing unit back flush for 15 minutes. Regulate the air supply to 90-100
psi. Also verify the flow meter (callout #9) reads a minimum 3-4 gallons per minute (gpm) for proper flow.
A Cooler-in line
B Flushing fluid out
C Flushing fluid in
D Cooler-out line

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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11. While the flushing unit is running, open the air purge valve (callout #20) for 10-15 seconds to cause agitation
and improve the flushing process. Then close the air purge valve for 5 minutes. Repeat the opening and
closing three (3) times.
12.Turn the motor switch OFF.
(STEP C - FORWARD FLUSH)
13.To change flow of the cleaning process for forward flushing, turn the reverse lever (callout #21) to the oppo-
site setting, ie: position “1”. Turn the motor switch ON and let the flushing unit forward flush for 5 minutes.
Regulate the air supply to 90-100 psi. Also verify the flow meter (callout #9) reads a minimum 3-4 gpm for
proper flow. While the flushing unit is running, open the air purge valve (callout #20) for 10-15 seconds to
cause agitation and improve the flushing process. Then close the air purge valve.
14.Turn the motor switch OFF, leaving the air purge valve open for at least 15 seconds to purge the lines of
residual ATF. Close the air purge valve.
(STEP D - BACK FLUSH)
15.To change flow of the cleaning process for back flushing, turn the reverse lever (callout #21) to the opposite
setting, ie: position “2”. Turn the motor switch ON and let the flushing unit back flush for 15 minutes. Regu-
late the air supply to 90-100 psi. Also verify the flow meter (callout #9) reads a minimum 3-4 gpm for proper
flow. While the flushing unit is running, open the air purge valve (callout #20) for 10-15 seconds to cause
agitation and improve the flushing process. Then close the air purge valve for 5 minutes. Repeat the open-
ing and closing three (3) times.
16.Turn the motor switch OFF, leaving the air purge valve open for at least 15 seconds to purge the lines of
residual ATF. Close the air purge valve.
(STEP E - VERIFY FLUSH)
17.Remove the bypass (left side) spin-on filter and install a filter screen on top of the filter. Reinstall the bypass
filter back onto the flushing unit. Turn the motor switch ON and back-flush for 5 minutes. Turn the motor
switch OFF.
18.Turn the air purge valve to the purge position to purge the lines and filters of ATF.
19.Remove the bypass spin-on filter and visually check the filter screen.
a. If debris is present in the filter screen, remove filter screen and flush vehicle again by repeating Steps B –
D.
b. If no debris is present, remove filter screen and re-install the bypass filter. Turn the heater switch OFF.
NOTE: If the vehicle was flushed completely and properly but debris is still present in the filter screens,
check these areas:
• Non-bypass (NBP) spin-on filter for damage or pollution.
• Severe contamination of the holding tank and/or flushing unit hoses.
20.Turn the motor and heater toggle switches OFF and disconnect the pressure and return hoses from the
vehicle cooler lines.
• Never leave the heater on overnight.
21.Install the test coupling (provided with your adaptor kit) to connect the pressure and return hoses to each
other for storage.
22. Unplug the flushing unit from the wall outlet.
23. Flushing is now complete.

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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MAINTENANCE
The most important maintenance you can do on your Heated Cooler Line Flusher is changing the filters*.
Changing the filters is integral to the flusher’s effectiveness.
Changing the filters every 100 flushes.
* Please refer to the Filter Cross Reference Guide if you intend to use a bypass filter and no bypass filter other
than those available through G-TEC. It is essential that you do NOT use two bypass filters, which are common
auto filters. They will allow 20% of the flow to bypass the filter, which will contaminate the holding tank with
debris. In addition, when a bypass filter reaches its capacity, it will allow 100% of the flow to bypass the filter and
recontaminate the cooler. The bypass filter must always be on the left side of the filter mount (standing at the
handle end of the flusher).
Daily Check ATF level daily by removing the fill cap/gray tower and making sure the ATF stays 3-4
inches from the top of the fill neck. Do not overfill. Clean any ATF from the top of the electrical
box to prevent seepage.
Quarterly Change the ATF in the flusher unit tank every three months or when fluid becomes dirty/dark.
ATF must be cold at the time of fluid change. Snap the testcoupling into the quick-disconnect
end of the pressure hose, and secure this end into an EPA-approved waste disposal
container. Then turn on the motor of the flusher and let it pump empty.
Clean out any sludge in the bottom of the tank by using the flusher’s drain plug. After cleaning,
refill the tank with 8 gallons of clean ATF.
Yearly
(Fragile) Unplug the heater from the electrical box and remove the heater from the tank. Clean the
heater’s coils and replace/replug the heater.
Unplug the float switch and very carefully remove it from the tank.
ATTENTION: The float switch is very delicate! Check for any metal shavings or damage to the
magnet end and/or the float tip. Carefully replace/replug the float switch making sure the
arrow point up. Do not overtighten!

Bulletin No: 05-008/11
© 2011 Mazda Motor of America, Inc. Last Issued: 09/21/2011
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TROUBLESHOOTING
CAUTION: Always unplug the flushing unit before any troubleshooting.
Problem 1 No heat and red light is On
Solution 1. Make sure fluid level is above the float switch (callout #18) or 3-4 inches from the top of the
fill neck
2. Check wall outlet is working properly
3. Check continuity at the float switch
Problem 2 Pump/motor not working or overheating
Solution 1. Make sure flushing unit is plugged intoa 110V (15 amp) outlet with NOTHING else plugged
in.
2. Make sure flushing unit is NOT plugged into a drop light, extension cord, etc.
3. Check if heater is at 150-160 F before engaging motor (otherwise ATF is too thick).
4. Check motor voltage with a voltmeter (Specification = 110 Volts).
Problem 3 No or low fluid coming from pressure line
Solution 1. Using two wrenches, unscrew the quick-disconnect coupling from the end of the pressure
line hose.
2. Carefully remove washer and spring and clean out the hose and related parts.
3. Reinstall parts in reverse order and tighten the connections
Problem 4 ATF leak around connections and fittings
Solution 1. Re-tighten or replace worn clamps
2. Check hoses for pin holes or punctures
Problem 5 Flushing unit does not appear to be cleaning
Solution 1. Change both spin-on filters
2. If ATF in the holding tank is black, replace fluid
3. Check for restrictions by connecting the pressure and return hoses with the provided
coupling so that fluid circulates through the flushing unit only
Problem 6 Shop’s circuit breaker tripping or Thermal switch on motor is tripping
Solution 1. Clear entire flushing system of debris.
2. Check for restrictions from motor to hoses to connectors
3. Make sure flushing unit is plugged into a 110V (15 amp) outlet with NOTHING plugged in.
4. Heater must be at 150-160 F before engaging motor (otherwise ATF is too thick)
5. Check motor voltage with a voltmeter (Specification = 110 Volts).
6. Reset thermal switch on back of motor