MAZDA 626 1987 Workshop Manual

INSPECTION AND REPAIR 7B
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn valves
2. Damaged oil passage
3. Cracked or damaged valve body
4. Operation of each valve
5. Weakened spring
Spring

Spring name Outer dia.
mm
(in) Free length
mm
(in) Wire dia.
mm (in)
Spring color
1-2 shift control spring 5.5 (0.217) 46.0 (1.811) 0.5 (0.020) Light green
1-2 shift spring 5.0 (0.197) 24.9 (0.980) 0.5 (0.020) Gray
2-3 shift spring 6.1 (0.240) 39.7 (1.563) 0.65 (0.026) Pink
3-4 shift spring 6.4 (0.252) 37.0 (1.457) 0.6 (0.024)
—

Throttle backup spring 6.4 (0.252) 33.5 (1.319) 0.6 (0.024) Pink
Throttle modulator front spring 5.0 (0.197) 27.8 (1.094) 0.6 (0.024) Red
Throttle modulator rear spring 7.15 (0.281) 30.8 (1.213) 0.85 (0.033) Red
1 rang control spring 6.15 (0.242) 39.2 (1.543) 0.65 (0.026) White
2 rang control spring 3.95 (0.156) 32.1 (1.264) 0.45 (0.018)
—

Kick-down spring 5.4 (0.213) 38.1 (1.500) 0.8 (0.031)
—

Throttle assist spring 5.15 (0.203) 32.3 (1.272) 0,55 (0.022) Dark green
Throttle spring 5.4 (0.213) 48.3 (1.902) 0.8 (0.031)
—

Converter relief ball spring 6.9 (0.272) 24.1 (0.949) 0.9 (0.035) Maroon
Orifice check valve spring 5.0 (0.197) 12.5 (0.492) 0.23 (0.009)
-
76G07B-220
Assembly
1. Install the throttle adjust plug, throttle assist spring,
throttle valve, throttle spring, and throttle plug as-
sembly.
83U07B-296
Caution
Install the throttle plug assembly with the
groove aligned with the bolt hole.
83U07B-297
7B—165

7B INSPECTION AND REPAIR
2. Install the throttle return spring as shown.
3. Install the throttle cam assembly to the main con-
trol body.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
83U07B-298
Install the throttle modulator plug, throttle modula-
tor rear spring, throttle modulator sleeve C, throt-
tle modulator valve, throttle modulator sleeve B,
throttle modulator front spring, throttle modulator
sleeve A, and stopper pin.
Install the throttle backup valve, throttle backup
spring, and retainer.
83U07B-299
6. Install the 1-2 shift control sleeve, 1-2 shift control
spring, 1-2 shift control valve, stopper plug, and
stopper pin.
7. Install the 2-3 shift rear plug, 2-3 shift spring, 2-3
shift valve, 2-3 shift front plug, 2-3 shift sleeve, and
stopper pin.
83U07B-300
8. Install the 1 range control valve, 1 range control
spring, and retainer.
9. Install the 2 range control rear sleeve, 2 range con-
trol spring, 2 range control valve, 2 range control
plug, 2 range control front sleeve, and stopper pin.
10. Install the kick-down spring, kick-down valve, stop-
per plug, and stopper pin.
7B-166

INSPECTION AND REPAIR 7B
11. Install the 1-2 shift spring, 1-2 shift valve, 1-2 shift
plug, stopper plug, and stopper pin.
12. Install the 3-4 shift rear plug, 3-4 shift spring, 3-4
shift valve, 3-4 shift sleeve, 3-4 shift front plug, stop-
per plug, and stopper pin.
Note
Install the 3-4 shift sleeve with the identifica-
tion notches facing inward.
83U07B-302
7B—167

7B INSPECTION AND REPAIR
Rear Control Body
Disassembly
Disassemble in the sequence shown in the figure.
83U07B-303
1. Manual valve 11. Stopper plug
2. Stopper pin 12. Pressure regulator backup plug
3. Stopper plug 13. Pressure regulator plug sleeve
4. Lock-up control valve 14. Pressure regulator plug
5. Lock-up control spring 15. Pressure regulator spring seat
6. Stopper pin 16. Pressure regulator spring
7. Stopper plug 17. Pressure regulator valve
8. OD lock-up valve 18. Stopper pin
9. OD lock-up spring 19. Stopper plug
10. Stopper pin 20. Lock-up support valve
21. Lock-up support spring
7B-168

INSPECTION AND REPAIR 7B
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn valves
2. Damaged oil passage
3. Cracked or damaged valve body
4. Operation of each valve
5. Weakened spring
Spring

Spring name Outer dia.
mm (in)
Free length
mm
(in)
30.7 (1.209)
46
2
(1 819)
52
3
(2.059)
Wire dia.
mm (in)
Spring color
Blue
Yellow
Red"
Pressure regulator spring 9.5 (0.374)
Free length
mm
(in)
30.7 (1.209)
46
2
(1 819)
52
3
(2.059)
0.7 (0 028)
0
8
(0.031)
1.0 (0.039)
0.8 (0.031)
Spring color
Blue
Yellow
Red"
Lock-up control spring 7,3 (0 287)
Free length
mm
(in)
30.7 (1.209)
46
2
(1 819)
52
3
(2.059)
0.7 (0 028)
0
8
(0.031)
1.0 (0.039)
0.8 (0.031)
Spring color
Blue
Yellow
Red"
Lock-up support spring 7.0 (0.276)
Free length
mm
(in)
30.7 (1.209)
46
2
(1 819)
52
3
(2.059)
0.7 (0 028)
0
8
(0.031)
1.0 (0.039)
0.8 (0.031)
Spring color
Blue
Yellow
Red" OD lock-up spring 7.1 (0.280) 66.5 (2.618)
0.7 (0 028)
0
8
(0.031)
1.0 (0.039)
0.8 (0.031)
Spring color
Blue
Yellow
Red"

76G07B-166
Assembly
1. Install the lock-up support spring, lock-up support
valve, stopper plug, and stopper pin.
Note
Install the stopper plug large end first.
83U07B-305
2. Install the pressure regulator valve, pressure regu-
lator spring, pressure regulator spring seat, pres-
sure regulator plug, pressure regulator plug sleeve,
pressure regulator backup plug, stopper plug, and
stopper pin.
Note
Install the stopper plug large end first.
83U07B-306
7B—169

7B INSPECTION AND REPAIR
83U07B-307
3. Install the OD lock-up spring, OD lock-up valve,
stopper plug, and stopper pin.
Note
Install the stopper plug large end first.
4. Install the lock-up control spring, lock-up control
valve, stopper plug, and stopper pin.
83U07B-308
3. Install the manual valve.
83U07B-309
7B-170

INSPECTION AND REPAIR 7B
Assembly of Control Valve Body
Note
a) Do not mix-up the front and rear gaskets
during assembly.
b) Match the bolt head letter and the control
valve body letter.
83U07B-310
1. Install the orifice check valves (02.0 mm, 0.079 in;
01.6 mm, 0.063 in; 01.0 mm, 0.039 in) and
springs, converter relief ball and spring, and rub-
ber balls in the rear control body as shown.
83U07B-311
2. Install the gaskets on both sides of the rear sepa-
rator; then install it onto the rear control body.
83U07B-312
Note
The main/rear rear gasket and main/rear front
gasket are not interchangeable.
83U07B-313
7B-171

7B INSPECTION AND REPAIR
Oil strainer micuiici /^j in Orifice
5 mm (0.059 in)
Orifice 01.5 mm (0.059 in)
Rubber ball
3. Install the orifice check valves (01.5 mm, 0.059 in)
and springs, oil strainer, and rubber ball in the main
control body as shown.
76GQ7B-167
4. Install the rear control body to the main control
body.
83U07B-315
5. Loosely tighten the bolts.
Note
Match the bolt head letter as shown.
83U07B-316
Rubber ball
6. Turn the assembly over and install the rubber balls
in the main contrcl body as shown.
83U07B-317
7B-172

INSPECTION AND REPAIR 7B
00 8°mm 0rifice 0 mm (0 039 in)
(0.031 in) q
I^Throttle i relief
-T-o^^ball
y
Orifice 01.0 mm (0.039 in)
83U07B-318
83U07B-319
Premain/main
front gasket
Premain/main
rear gasket
83U07B-320
7. Install the orifice check valves (01.0 mm, 0.039 in;
00.8 mm; 0.031 in) and springs, and the throttle
relief ball and spring in the premain control body
as shown.
8. Install the gaskets on both sides of the main sepa-
rator; then install it onto the premain control body.
Note
The premain/main rear gasket and pre-
main/main front gasket are not inter-
changeable.
9. Set the premain control body onto the main con-
trol body.
83U07B-321
7B-173

7B INSPECTION AND REPAIR
10. Loosely tighten the bolts.
Note
Match the bolt head letter as shown.
83U07B-322
Rubber ball
11. Install the rubber balls, orifice check valve (01.7
mm, 0.067 in) in and spring in the premain con-
trol body as shown.
83U07B-323
83U07B-324
front gasket rear gasket
Note
The front/premain front gasket and
front/premain rear gasket are not inter-
changeable.
83U07B-325
7B—174