oil level MAZDA 626 1987 Service Manual

TROUBLESHOOTING
7C

QUICK DIAGNOSIS CHART
How
to use
Quick Diagnosis Chart
1.
The
numbers indicate
the
order
of
inspection
for
troubleshooting.
2. Circled numbers indicate that
the
transaxle must
be
removed from
the
vehicle.
76G07C-013
Transaxle ON VEHICLE OFF VEHICLE
•

\ Inspection point
\
and
reference
\ page
Condition


7C-25
7C-26
7C-23
10—21
7C—23,24
Section

4A

7C-14
7C—20,22
10—lb
10-12 10—69
7C—5
Section

5

7C—58
7C-62
7C-70
7C-71
7C-55
7C-125
7C-54 7C-71
7C-66,

98

7C-68,

71
\ Inspection point
\
and
reference
\ page
Condition

ATF

level
and
condition

Selector

lever
Inhibitor
switch
and
wiring

^

Vacuum
diaphragm
and

piping

|

Kick-down
solenoid,
kick-down
switch
and
wiring
Engine

idle

speed

and

condition

Engine
stall

speed

Fluid

pressure

(Line

and
governor)
Control
valves

Governor

valve
Band
servo
Transaxle
air
check
Ignition
switch
and
starter
Front
clutch

Rear

clutch
Brake

band

Low

and
reverse
brake

Oil
pump Hydraulic
circuit

Torque

converter

One-way

clutch
Parking

linkage

Planetary
gear

I

Engine

starting
Engine does
not
start
in
N or P
range •
2 3
1

Engine

starting
Engine starts
in
ranges other than
N
and P
ranges •
1 2

Accelerating
Vehicle does
not
move
in
D
range (moves
in 1, 2 & R
ranges) •
• •
•
Accelerating
Vehicle does
not
move
in
forward ranges (moves
in R
range)
Ex-
tremely poor acceleration •
• 5
• •
© •
•
• ©
•
• •
•
Accelerating
Vehicle does
not
move
in R
range (moves
in
forward range) Extremely poor acceleration 1
2 •
•
• •
•
3 4
•
• 5
• ©
© •
©
• ©
•
• •
•
Accelerating
Vehicle does
not
move
in any
range 1
2 •
•
• •
•
3 4
•
• 5
• •
• •
•
© ©
•
• ©
•
Accelerating Slippage felt when accelerating 1
2 •
6
• •
•ST
CO
•
•
• 5
• •
• •
•
© ©
•
• •
• Accelerating
Vehicle moves
in
N
range
Accelerating
Excessive creep
Accelerating
No creep
at all
©
© •
•
© ©
•
• •
•
Accelerating
Low maximum speed
and
poor acceleration 1
2 •
•
• 7
3
4 6
•
5 •
• ©
© ©

No shifting

Does
not
shift from
1
st to 2nd
•
1 •
2
3 •
•
• 4
5
6 7
• •
© ©
•
• ©
•
• •
•

No shifting
Does
not
shift from
2nd to 3rd
•
1 •
2
3 •
•
• 4
5
6 7
•

No shifting

Does
not
shift from
3rd to 2nd
1
• •
2
• •
•
• 3
4
5 6
• ©
• ©
•
• ©
•
• •
•
76G07C-014
7C-9

7C TROUBLESHOOTING
ON VEHICLE OFF VEHICLE
-

\ Inspection point
\ and reference
\ page
Condition


LO
(O
CO CJ OJ CM I
I I
O
O
CJ
r-~
r—
7C-27
7C—23,24
Section

4A

7C—14
7C—20,22
7C-75

CO
O)
<o
in
I
I I
o
o o
r—
r—
Section

5
CO CO
o
WON I
I I
o
o o
1— 1—
m i-
in co
S
IO
i-
1
1 1
o
o o
—
I—
7C—54
7C-71
7C-66,

98

7C—68,

71
\ Inspection point
\ and reference
\ page
Condition

A.TF

level
and

condition

Selector
lever
Inhibitor
switch
and
wiring

Vacuum

diaphragm
and

piping

Kick-down

solenoid,

kick-down

switch
and

wiring

Engine

idle
speed
and
condition
Engine
stall
speed
Fluid
pressure
(Line
and
governor)

Control

valves

Governor

valve
Band
servo

Transaxle

air
check
Ignition
switch
and

starter

Front

clutch

Rear

clutch

Brake

band

Low

and
reverse
brake
Oil pump Hydraulic
circuit
Torque
converter

One-way

clutch

Parking

linkage
Planetary
gear

No
shifting

Does
not
shift from 2nd
to
1
st or from
3rd to
1
st 1
• •
2
• •
•
• 3
4
5 6
•
No
shifting

Does
not
kick-down when accelerator
is
depressed
in 3rd
within
the
kick-down range 1
• •
3
2*
•
• 4
5
• •
• •
• ©
•
• ©
•
• •
•
No
shifting
Excessive engine speed when accelerated
in 3rd
due
to
delayed kick-down 5
• 6
• ©
• •
•
• ©
•
• •
• No
shifting

Does
not
shift from
3rd to 2nd
on
D to
2
range shift 1
2 •
5
6 •
• ©
• ®
•
• ®
•
• •
•
No
shifting

Does
not
shift from
3rd to 2nd
on
D to 1
range shift 5
7 6
• ©
• ®
•
• ®
•
• •
•

Shift

shock

Excessive
N to
D
range shift shock •
• •
2
• 1
•
3 4
•
• •
• •
© •
•
• •
•
• •
•

Shift

shock

Excessive
1
st
to
2nd shift shock 1
• •
2
• •
3
• 4
•
5 6
• •
• ©
•
• •
•
• •
•

Shift

shock

Excissive 2nd
to 3rd
shift shock •
• •
1
• •
•
2 3
•
4 5
• ©
• ©

Shift

shock

Vehicle braked when shifted from
1
st
to 2nd

Shift

shock
Vehicle braked when shifted from 2nd
to 3rd
1
• •
•
• •
•
• 3
.
2 •
•

Shift

shock

Vehicle braked when shifted
to
R range 1
• •
•
• •
•
• •
•
3 2
• •
© ©
•
• •
•
• ©
•
Shift

shock

Shift shock felt when accelerator
is
released
and
deceleration occurs •
1 •
2
3*
•
4 5
6
• •
• •
• •
•
• ©
•
• *
•

Shift

shock

Excessively large 2nd
to 1st
shift shock
in 1
range 1
• •
2
• •
3
4 5
•
• •
•
Shift

point

Excessively high
1st to 2nd
and 2nd
to
3rd shift 1
• •
2
3 •
•
4 5
6
• •
•
Shift

point

Excessively high
3rd to 2nd
and
2nd to
1
st shift point •
1 •
2
3 •
•
4 5
6
• •
• •
• •
•
• ©
•
• •
•
Shift

point
Kick-down operates
or
engine overruns when depressing
ped-
al
in 3rd
beyond kick-down speed limit
1
2 •
3
• •
•
4 5
6
• 7
•

Shift
sequence

Shifts directly from 1st
to 3rd
1
• •
•
• •
•
• 2
3
• 4
• •
• ©
•
• ©
•
• •
•

Shift
sequence
Shifts from
2nd to 1st or
2nd
to
3rd
in
2
range •
1 •
•
• •
•
2 3
•
• •
•
7C-10

TROUBLESHOOTING
7C

ON VEHICLE -OFF VEHICLE
-

\ Inspection point
\
and
reference
\ page
Condition


in cd
ra
CM CM CM
I
I I
o
o o
I—
r~—
r—
7C—27
7C—23,24
Section
4A

7C—14
7C—20,22
7C-75

CM
0>
[—
CO
LO I
I I
O
O O
r^ r—
Section

5
CD CM
O
in (D
s
I
I I
o
o o
r—
r^

w <f>
CM
r-
m f-
I
I I
o
o o
r-— I—
r-—
7C—54
7C-71
7C—66,

98

7C-68,

71 \ Inspection point
\
and
reference
\ page
Condition

ATR

level
and
condition

Selector

lever

Inhibitor

switch
and
wiring

Vacuum

diaphragm
and
piping

Kick-down
solenoid,
kick-down
switch

and

wiring

Engine

idle

speed

and
condition
Engine
stall

speed

Fluid

pressure
(Line
and
governor)
Control
valves

Governor

valve
Band
servo

Transaxle

air
check
Ignition
switch
and

starter

Front
clutch

Rear

clutch

Brake

band

Low
and

reverse

brake
Oil
pump
Hydraulic
circuit

Torque

converter

One-way

clutch
Parking
linkage

Planetary

gear

Snift
sequence

Shifts from
1st to
2nd
or
2nd
to
3rd
in 1
range

Slipping

Practically
no
shift shock,
or
slip-page while 1st
to
2nd shifting 1
2 •
3
• •
•
4 5
•
7 6
• •
• ©
•
• ©
•
• •
•

Slipping

Pracatically
no
shift shock
or
slip-page while 2nd
to
3rd shifting 1
2 •
3
• •
•
4 5
•
7 6
•

Slipping

No shift shock
or
engine runaway
in 1 to 2
range shift 1
2 •
3
• 4
5
• 6
•
• 7
• •
• ©
•
© •
•
• •
•
Slipping

Engine runaway
or
slip when shifting
3rd to 2nd
1
• •
2
• •
•
3 4
•
5 6
• ®
• ©
•
• ®
•
• •
•

Slipping

Slippage evident when vehicle starts moving 1
2 •
5
• •
•
3 4
•
• 6
• •
• •
•
® ©
•
• •
•

Noise

Transaxle noisy
in P and N
range

Noise
Transaxle noisy
in D, 2, 1 and
R ranges •
(D •
•
© •
•
© •
©

Others

No engine brake
in 1
range •
1 •
•
• •
•
2 3
•
• 4
• •
• •
©
• ©
•
• •
•

Others

Vehicle moves
in P
range
or
parking gear
not
disengaged when
P
range disengaged
•

Others
Transaxle overheats 3
4 5
•
2 6
• ®
©
(D ©
© ©
©
• •
©
Others

White smoke from exhaust while running 1
• •
2
• •
3
4 5
•
• 6
• ®
© ©
©
© ©
©
• •
@

Others

Abnormal odor from
oil
level gauge pipe ©
® ©
©
© ®
©
• •
©
76G07C-016
Differential
Problem Probable Cause Remedy Page
Noise Insufficient fluid Add 7C—25
Low fluid quality Replace with specified
ATF
7C-25
Worn bearing Adjust
or
replace 7C-79
Contact surface
of
gears worn Replace 7C-79
Tooth surface
of
gears damaged Replace 7C-79
Contaminated
ATF
Repair
or
replace 7C-25
Differential gear damaged, excessive backlash Replace 7C-79
Excessive bearing preload Adjust 7C—94
76G07C-017
7C—11

7C TROUBLESHOOTING
STEP 1 (PRELIMINARY INSPECTION)
In this step, the main points related to the automatic transaxle are checked. These items must be kept
in the correct condition at all times in order to assure proper operation of the automatic transaxle.
1. Automatic Transaxle Fluid (ATF)
Check ATF level and condition. (Refer to page 7C—25.)
2. Selector Lever
Check selector lever position and adjust it if necessary. (Refer to page 7C—26.)
76G07C-018
3. Oil Leakage
Check for oil leakage.
(1) Warm up the ATF.
(2) Apply the parking brake and block the wheels
to prevent the vehicle from rolling.
(3) Shift the selector lever to R range.
(4) Check if oil leaks from the noted oil seals or
gaskets.
(5) If oil leaks, replace the seal or gasket.
76G07C-019
7C-12

7C TROUBLESHOOTING
STEP 2 (STALL TEST)
This step is performed to determine if there is slippage of the friction elements or malfunction of the
hydraulic components.
Preparation
Check the following items prior to testing:
1. Engine coolant, engine oil and ATF levels.
2. Warm the engine thoroughly to raise the ATF temperature to operating level (50—80°C, 122—176°F).
3. Set the parking brake and block the front and rear of the wheels.
Pull the parking brake Water temperature
ATF
7C—14
76G07C-024

ON-VEHICLE MAINTENANCE 7C
ON-VEHICLE MAINTENANCE
AUTOMATIC TRANSAXLE FLUID (ATF)
Inspection for Fluid Leaks
Check for fluid leaks; the following figure shows the locations where fluid leakage may possibly occur.
1. Kick-down solenoid
2. Vacuum diaphragm
3. Manual shaft
4. Speedometer driven gear
5. Oil level tube
6. Governor cover
7. Governor
8. Oil pan
9. Oil pump
10. Inhibitor switch
11. Transaxle case
12. Oil pump
13. Square head plugs
14. Bearing cover
15. Drive shaft
76G07C-041
©
i
©
[JdQ©
I
Inspection of Level
1. Apply the parking brake and block the wheels to
prevent the vehicle from rolling.
Note
Place the car on a flat, level surface.
2. Run the engine so that the automatic transaxle fluid
reaches operating temperature.
3. While the engine is idling, shift the select lever from
P to 1 and back again.
4. Let the engine idle.
5.Shift the select lever to P.
76G07C-042
7C-25

ON-VEHICLE MAINTENANCE 7C
9. Install the under cover and side cover.
10. Lower the vehicle.
11. Add ATF, and with the engine idling, check the fluid
level.
12. Verify that there is no fluid leakage from the trans-
axle. (Refer to page 7C—25.)
76G07C-052
REPLACEMENT OF SERVO PISTON RETURN
SPRING
1. Remove the control valve body. (Refer to replace-
ment of control valve.)
2. Loosen the anchor end-bolt and locknut.
3. Remove the band strut.
4. Compress the servo piston retainer with the SST.
5. Remove the snap ring with a screwdriver.
76G07C-053
76G07C-054
6. Remove the servo retainer, piston and spring by
gradually loosening the SST.
7. Replace the return spring. If the O-ring or the piston
seal is damaged, replace them.
8. Assemble the servo retainer, piston, and spring,
insert them into the case with the SST. Fit the snap
ring into the ring groove.
9. Install the band strut.
10. Tighten the anchor-end bolt to 12—15 N-m
(120—150 cm-kg, 104—130 in-lb), then back it
off two full turns. Tighten the locknut to 55—80
N m (5.6—8.2 m-kg, 41—59 ft-lb).
11. Install the control valve body, oil pan, etc. in the
reverse order of removal.
12. Adjust the fluid level, and check for fluid leaks.
(Refer to page 7C—25.)
76G07C-055
7C—29

DISASSEMBLY 7C
DISASSEMBLY
DISASSEMBLY - STEP 1
76G07C-072
1. Torque converter
2. Oil pump shaft
3. Turbine shaft
4. Inhibitor switch
5. Kick-down solenoid
6. Vacuum diaphragm and
rod
7. Oil level gauge and tube
8. Speedometer driven gear
9. Oil pan and gasket
10. Control valve body
11. Steel ball and spring
12. Oil pump
7C—35

7C DISASSEMBLY
9. Remove the kick-down solenoid and O-ring.
76G07C-078
76G07C-079
10. Remove the vacuum diaphragm. If the vacuum di-
aphragm is difficult to remove, use pliers to grasp
the flange.
Note
When the vacuum diaphragm is removed, take
care not to lose the diaphragm rod.
11. Remove the oil level gauge and filter tube.
76G07C-080
12. Remove the speedometer driven gear.
76G07C-081
7C—38

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