transaxle MAZDA 626 1987 Manual Online

7B INSPECTION AND REPAIR
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn governor gear
2. Damaged or worn governor valve
3. Cracked or damaged governor carrier and sleeve
83U07B-267
Assembly
1. Insert the governor valve to the governor carrier
and sleeve.
2. Install the governor driven gear.
3. Install the roll pin.
83U07B-268
86U07B-260
LOW AND REVERSE BRAKE
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn drive and driven plates
Drive plate thickness
Standard: 1.6 mm (0.063 in)
Minimum: 1.4 mm (0.055 in)
2. Broken or worn snap ring
3. Deformed or detached spring and retainer as-
sembly
4. Broken or weakened spring
Free length of spring:
20.5 mm (0.807 in)
5. Damaged or worn piston
6. Damaged seal contact area of transaxle case
7B—134 expert22 fl/m http://rutracker.org

7B INSPECTION AND REPAIR
CONTROL VALVE BODY (G4A-EL)
Precaution
(1) Pay close attention when handling the control valve because it consists of the most precise and
delicate parts of the transaxle.
(2) Neatly arrange the removed parts in order to avoid mixing up similar parts.
(3) Disassemble the control valve assembly and thoroughly clean it when the clutch and/or brake bands
are burned, and/or when the automatic transaxle fluid is degenerated.
Components I
Front and premain control body
6—8 N-m (66—80 cm-kg, 57—69 in-lb)
1.1-2 Solenoid valve
2. 2-3 Solenoid valve
3. Bolts
4. Front control body
5. Front/premain front gasket
6. Premain separator
7. Front/premain rear gasket
8. Premain control body
9. Premain/main front gasket
10. Main separator
76G07B-141
7B—136

INSPECTION AND REPAIR 7B
CONTROL VALVE BODY (G4A-HL)
Precaution
(1) Pay close attention when handling the control valve because it consists df the most precise and
delicate parts of the transaxle.
(2) Neatly arrange the removed parts in order to avoid mixing up similar parts.
(3) Disassemble the control valve assembly and thoroughly clean it when the clutch and/or brake bands
are burned, and/or when the automatic transaxle fluid is degenerated.
Components I
Front and premain control body
6—8 Nm ® (66—80 cm-kg, 57—69 In-lb)
1. Lock-up solenoid valve
2. Front control body
3. Front/premain front gasket
4. Premain separator
5. Front/premain rear gasket
6. Premain control body
7. Premain/main front gasket
8. Main separator
76G07B-163
7B—155

7B INSPECTION AND REPAIR
BEARING HOUSING
Disassembly
Remove the bearing outer race with a pin punch and
hammer.
Note
Install the bearing outer race during reassem-
bly of transaxle to adjust the preload.
86U07B-350
Inspection
Check the following and replace any faulty parts.
1. Damaged bearing housing
2. Damaged bearing outer race
86U07B-351
7B—186

ASSEMBLY 7B
ASSEMBLY
PRECAUTION
(1) The automatic transaxle consists of high-precision-finished parts, necessitating careful inspection
before assembly because even a small nick could cause fluid leakage or affect performance.
(2) Clean out oil holes and oil passages with compressed air, and check that there are no obstructions.
(3) Before assembly, apply ATF to each O-ring, seal ring, rotating part, and friction part.
(4) If the brake band or drive plates are replaced with new ones, first soak them in ATF for at least
2 hours before installing.
(5) Each seal gasket and O-ring must be replaced with a new one.
(6) Be sure to install all thrust bearings and races in the correct direction and position.
ASSEMBLY—STEP 1
Torque Specifications
83U07B-365
11—14 N-m (110—140 cm-kg, 95—122 in-lb) 6-9 N-m (60—90 cm-kg, 52—78 in-lb)
8—11 N-m (80—110 cm-kg, 69—95 In-lb)
19—26 N m (1.9—2.6 m-kg, 14—19 ft-lb)
83U07B-366
7B—187

7B ASSEMBLY
76G07B-180
83U07B-382
(1) Remove the bearing outer race and adjust
shims from the transaxle case. (Refer to page
7B—106)
(2) Set the differential assembly into the convert-
er housing.
(3) Install the outer race removed in step (1) into
the SST; then set them on the differential as-
sembly.
Caution
Eliminate the gap by turning either A or B of
the selector.
(4) Set the six SST in the positions shown.
Note
Install the bolts in the positions shown in the
illustration above.
83U07B-383
(5) Set the transaxle case on the selectors.
(6) Tighten the SST (bolts) to the specified torque.
Tightening torque:
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
83U07B-384
7B-192

ASSEMBLY 7B
86U07B-371
86U07B-372
(7) Turn the SST (selector) to increase the clear-
ance indicated by the arrow with the SST
(bars), until it no longer turns.
Note
a) This is to seat the bearings.
b) To turn the SST (B), bend the bar as shown.
(8) Turn the selector in the opposite direction un-
til the preload is eliminated (gap is reduced).
(9) Insert the SST through the oil seal hole of the
transaxle case and attach it to the pinion shaft.
(10) Mount the SST and pull scale or torque
wrench.
(11) Widen the clearance between A and B to ob-
tain the specified preload/pull scale reading.
Preload:
0.5 N-m (5 cm-kg, 4.3 in-lb)
Reading on pull scale:
5 N (0.5 kg, 1.1 lb)
Note
Read the preload when the differential starts
to turn.
(12) Measure the clearance between A and B.
(13) Add 0.3 mm (0.0118 in) to the measured
clearance, and select the shim(s) closest in
valve to that measurement.
76G07B-224

Thickness
of
shim
0.10
mm
(0.004
in)
0.12
mm
(0.005
in)
0.14 mm (0.006
in)
0.16 mm (0.0063
in)
0.18 mm (0.007
in)

0.20 mm (0.008
in)
0.50 mm (0.020
in)
0.70 mm (0.028
in)
1.00 mm (0.039
in)
86U07B-374
Caution
a) Measure the clearance around the entire cir-
cumference, and select shims equivalent to
the maximum clearance.
b)The maximum allowable number of shims
is 3.
7B—193

7B ASSEMBLY
83U07B-389
83U07B-390
83U07B-391
(14) Remove the transaxle case and selector.
(15) Install the required shim(s) and tap the bear-
ing race into the transaxle case.
(16) Install the transaxle case.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
(17) Check that the preload is within specification.
If not within specification, return to step (2).
Preload: 2.9—3.9 N-m
(30—40 cm-kg, 26—35 in-lb)
Reading on pull scale: 29—39 N
(3.0—4.0 kg, 6.6—8.8 lb)
(18) Remove the transaxle case and differential as-
sembly.
3. Install the idle gear and output gear as an assem-
bly by tapping in with a plastic hammer.
4. Install the bearing housing.
(1) Install the bearing housing on the converter
housing.
Tightening torque:
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
(2) Align the groove on the idle shaft with the
matching mark on the bearing housing.
(3) Tap the roll pin in with a pin punch and
hammer.
83U07B-392
7B—194

ASSEMBLY 7B
86U07B-390
76G07B-182
86U07B-392
O-rings
Sealant
Output shell
(5) Install the SST in the case.
(6) Compress the spring and retainer assembly.
(7) Install the snap ring with snap ring pliers.
(8) Remove the SST.
6. Check the low and reverse brake piston operation.
(1) Pour in ATF so that the low and reverse brake
piston is fully submerged.
(2) Check that no bubbles come from between the
piston and seals when applying compressed
air through the fluid passage. (Refer to page
7B—204)
Caution
The compressed air must be under 392 kPa
(4.0 kg/cm2, 57 psi) and not applied for over
3 seconds.
7. Install the output shell to the output gear, and in-
stall the bearing race onto the output shell.
Bearing race outer diameter.
72.0 mm (2.83 in)
8. Apply a thin coat of silicon sealant to the contact
surfaces of the converter housing and transaxle
case.
9. Install the O-rings.
10. Install the transaxle case to the converter housing.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
86U07B-393
7B—201

7B ASSEMBLY
11. Install the SST to the differential side gear.
Caution
Failure to install the SST may allow the
differential side gears to become misposi-
tioned.
86U07B-394
ASSEMBLY-STEP 3
Procedure
1. Temporarily install the SST to hold the turbine shaft.
86U07B-395
w
2. Install the turbine shaft and 3-4 clutch assembly.
(1) Assemble the turbine shaft and 3-4 clutch as-
sembly.
86U07B-396
(2) Check that the thrust bearing and bearing race
are installed in the correct position.
(3) Install the turbine shaft and 3-4 clutch assem-
bly into the transaxle case.
86U07B-397
7B—202