transaxle MAZDA 626 1987 Workshop Manual

7C ASSEMBLY
7C-112
Procedure
1. Use the following procedure to adjust the total end
play and select a suitable bearing race.
(1) Remove the pump cover from the oil pump.
(2) Install the bearing into the rear clutch drum.
(3) Mount the bearing race to the pump cover; and
then install it into the front clutch drum.
Note
A front clutch drum end play adjust shim must
not be used between the pump cover and the
front clutch drum when checking total end
play.
(4) Position a straight edge on the transaxle case,
and measure the clearance between the
straight edge and either the pump cover or the
transaxle case.
a) If the pump cover surface is lower than the
transaxle case, measure the clearance be-
tween the straight edge and the pump
cover.
Specification:
0.10 mm (0.004 in) max.
Note
a) Make the measurement without the oil
pump gasket installed.
b) Measured clearance plus thickness of oil
pump gasket equals total end play.
b) If the pump cover surface is higher than the
transaxle case, measure the clearance be-
tween the straight edge and the transaxle
case.
Specification:
0.15 mm (0.006 in) max.
Caution
Do not position the straight edge on the bolt
holes for mounting the oil pump to the trans-
axle case.
Note
Thickness of oil pump gasket minus measured
clearance equals total end play.
2. If the end play is not within specification, adjust it
by selecting the proper bearing race.
Caution
Use only one bearing race.
Bearing race outer diameter: 41.0 mm (1.61 in)
Bearing race sizes mm (in)

1.2 (0.047) 1.4 CO.055) 1.6 (0.063)
1.8 (0.071) 2.0 (0.079) 2.2 (0.087)

3. Reinstall the oil pump cover.
Tightening torque: 11—14 N-m
(110—140 cm-kg, 95—122 in-lb)

ASSEMBLY 7C
4. Use the following procedure to adjust the front
clutch drum end play and select the adjust shim.
(1) Set the oil pump gasket onto the transaxle
case.
(2) Place the adjust shim onto the front clutch
drum.
(3) Install the oil pump and bearing race into the
transaxle; then tighten the oil pump mounting
bolts to the specified torque.
Tightening torque:
15—22 N m (1.5—2.2 m-kg, 11—16 ft-lb)
76G07C-300
76G07C-301
63U07B-220
(4) Position the transaxle with the oil pump facing
down ward position.
(5) While turning the connecting shell 2 complete
turns, push the front clutch drum toward the
oil pump with a screwdriver to seat the front
clutch drum.
(6) Measure the clearance between the front clutch
drum and the connecting shell. This clearance
is the front clutch drum end play.
End play: 0.5—0.8 mm (0.020—0.031 in)
(7) If the end play is not within specification, ad-
just it by selecting the proper adjust shim.
Shim sizes mm (in)

1.3 (0.051) 1.5 (0.059) 1.7 (0.067)
2.3 (0.091) 1.9 (0.075) 2.1 (0.083)
1.7 (0.067)
2.3 (0.091)
2.5 (0.098) 2.7 (0.106)

76G07C-302
7C-113

7C ASSEMBLY
76G07C-311
76G07C-312
76G07C-313
12. Install the speedometer driven gear.
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
13. Install the oil level gauge and tube along with a new
O-ring to the transaxle case.
Tightening torque:
7—10 N m (70—100 cm-kg, 61-87 in-lb)
14. Install a new O-ring on the vacuum diaphragm.
15. Select the proper diaphragm rod.
(1) Measure the N dimension with the SST and
a scale.
(2) Select the diaphragm rod in accordance with
the table below.

N dimension Applicable diaphragm
rod
length
Below 25.4 mm (1.000
in)
29.5
mm
(1.161
in)

25.4—25.9
mm
(1.000-1.020
in)
30.0
mm
(1.181
in)

25.9—26.4
mm
(1.020-1.039
in)
30.5
mm
(1.200
in)

26.4—26.9
mm
(1.039-1.059
in)
31.0
mm
(1.220
in)

26.9 mm (1,059 in)
or
over 31.5
mm
(1.240
in)
16. Install the vacuum diaphragm.
76G07C-314
7C—116

ASSEMBLY 7C
17. Install a new O-ring on the kick-down solenoid.
18. Install the kick-down solenoid.
76G07C-315
19. Apply sealant to the threads and seat face of the
switch; and install the inhibitor switch.
Tightening torque:
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
76G07C-316
20. Remove the transaxle from the transaxle hanger.
21. Install a new clip on the turbine shaft.
76G07C-317
22. Install the turbine shaft.
23. Install the oil pump shaft.
76G07C-318
7C-117

7C INSTALLATION
86U07B-441
86U07B-442
76G07C-322
1. Attach rope at 2 places on the transaxle. Place a
flat board on a jack and set the transaxle on it.
Caution
The transaxle is not well balanced; be care-
ful when positioning it on the jack.
2. Move the transaxle into place and attach the rope
to the SST.
3. Mount the transaxle to the engine.
Tightening torque:
89—117 Nm (9.1—11.9 m-kg, 66—86 ft-lb)
Note
a) Lift the transaxle with the jack while pull-
ing the rope.
b) Align the torque converter bolts and drive
plate holes.
4. Install engine mount No. 4 and bracket.
Tightening torque:
(A) 36—54 Nm
(3.7—5.5 m-kg, 27—40 ft-lb)
(g) 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
5. Install engine mount No. 2.
Tightening torque:
® 67—93 N-m
(6.8—9.5 m-kg, 49—69 ft-lb)
(f) 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
76G07C-323
7C—120

INSTALLATION 7C
B
i^sN |
-- f
®4 4-1;
6. Install the crossmember and the left side lower arm
as an assembly.
Tightening torque:

(A)
36—54 N m
(3.7—5.5 m-kg, 27—40 ft-lb)
(|) 75—93 N m
(7.6—9.5 m-kg, 55—69 ft-lb)
©78—117 N m
(18.0—11.9 m-kg, 58—86 ft-lb)
7. Remove the jack and the rope.
8. Remove the SST.
76G07C-324
76G07C-325
76G07C-326
9. Install the starter and harnesses.
Tightening torque:
® 10—12 N-m
(100—120 cm-kg, 87—104 in-lb)
(|)31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
10. Install the torque converter bolts.
Tightening torque:
34—49 Nm (3.5—5.0 m-kg, 25—36 ft-lb)
11. Install the end plate.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
12. Replace the clip at the ends of the driveshafts and
joint shaft with new ones.
13. Install the joint shaft and right driveshaft as follows:
(1) Remove the SST and insert the joint shaft into
the transaxle.
(2) Mount the joint shaft bracket onto the engine.
76G07C-327
7C—121

7C INSTALLATION
(3) Install and tighten the reamer bolts, then install
and tighten the standard bolts.
Tightening torque:
Reamer bolts 7—10 N-m
(70—100 cm-kg, 61—87 in-lb)
Standard bolts 42—62 N m
(4.3—6.3 m-kg, 31—46 ft-lb)
(4) Pull the front hub outward to connect the
driveshaft to the joint shaft.
(5) Push the joint from the differential side to se-
curely connect the driveshaft to the joint shaft.
Caution
a) Do not damage the oil seal.
b) After installation, pull the front hub outward
to verify that the driveshaft is secured.
Install the left driveshaft as follows:
(1) Pull the front hub outward to insert the
driveshaft into the transaxle.
(2) Push the joint from the differential side to con-
nect the driveshaft to the differential side gear.
Caution
a) Do not damage the oil seal.
b) After installation, pull the front hub outward
to verify that the driveshaft is secured.
Install the lower arm ball joints to the knuckles and
tighten the bolts and nuts.
Tightening torque:
36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb)
Install the under cover.
Install the stabilizer bar control link as follows:
(1) Install the stabilizer bar control link.
(2) Adjust length A to 20.1 mm (0.79 in).
(3) Tighten bolt B to the specified torque.
Tightening torque:
16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
Install the tie-rod ends and cotter pins.
Tightening torque:
29—44 N-m (3.0—4.5 m-kg, 22—33 ft-lb)
7C-122

INSTALLATION 7C
76G07C-332
19. Install the oil cooler outlet and inlet hoses.
Note
Align the mating mark as shown.
20. Install the splash shields.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
21. Install the front wheels.
Tightening torque:
88—118 N-m (9—12 m-kg, 65—87 ft-lb)
22. Connect the vacuum hose.
23. Connect the selector cable.
Tightening torque:
Nut
44—64 N-m (4.5—6.5 m-kg, 33—47 ft-lb)
Bolts
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
76G07C-333
24. Connect the ground wires
to
the transaxle case and
oil pump.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
76G07C-334
25. Connect the connectors.
(1) Inhibitor switch
(2) Kick-down switch
26. Connect the speedometer cable.
76G07C-335
7C—123

7C INSTALLATION
31.
Connect the distributor lead.
Connect the main fuse block.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Install the fresh air duct.
Install the battery carrier and battery.
Tghtening torque:
Bolts
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
Nut
5—7 N-m (50—70 cm-kg, 43—61 in-lb)
Pour in ATF and check the following:
(1) With the engine idling, check that the fluid lev-
el is between the F and L marks on the dip-
stick. (Refer to page 7C—25.)
(2) Check the manual linkage, and adjust if neces-
sary. (Refer to page 7C—26.)
(3) Check the inhibitor switch operation. (Refer to
page 7C—23.)
(4) Conduct a road test. (Refer to page 7C—18.)
(5) Check that there is no fluid leakage from the
transaxle. (Refer to page 7C—25.)
76G07C-337
7C-124

DRIVESHAFT 9
REMOVAL
Remove in the sequence shown in the figure referring to the removal note for the specially marked parts.
0
B6U09X-U53
6. Hub cap
7. Lock nut
8. Driveshaft
9. Joint shaft
10. Transaxle
Removal Note
Lock nut
Applying the brakes. Raise the lock nut tab and loos-
en it. Do not remove it.
1. Wheel
2. Tie-rod end
3. Stabilizer
4. Lower arm
5. Splash shield
86U09X-054
9-29