oil MAZDA MX-5 1994 Workshop Manual

J TRANSMISSION Extension Housing Parts Disassemble in the order shown in the figure. REPLACE 1. Steel ball, spring, and spring cap 8. Change bushing 2. Select-lock spindle, spring, and spring cap 9. Wave washer 3. Plug, spring, and pushpin 10. Change control case 4. Blind cover 11. Rod cover 5. Roll pin 12. Oil passage 6. Control rod 13. Oil seal 7. Control rod end Do not remove unless necessary Gartner Banana

J TRANSMISSION ASSEMBLY Precaution 1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit. 2. Before assembly, make sure all parts are completely clean. 4 3. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil. 35UOJX-053 (5TH) (REVERSE) (~RD, 4TH) (1 ST, 2ND) 45UOJX-029 Clutch hub For the synchronizer assemblies, align the synchronizer ring grooves and synchronizer keys. The synchronizer rings can be distinguished as shown in the figure. The inner diametes of the 2nd synchronizer ring is larger than the 1 st. When installing the gears and clutch hub assemblies in the following procedure, make sure that they are installed in the direction shown in the figure. Gartner Banana

TRANSMISSION J Extension Housing Parts Assemble in the order shown in the figure, referring to Assembly Note. 1. Oil seal 8. Control rod end Assembly Note .............. page 5-28 9. Roll pin 2. Oil passage Assembly Note .............. page J-28 3. Rod cover 10. Blind cover Assembly Note .............. page J-28 11. Plug, spring, and pushpin w 4. Change control case 12. Select-lock spindle, spring, and spring cap 5. Wave washer Assembly Note .............. page J-28 6. Change bushing 13. Steel ball, spring, and spring cap 7. Control rod Gartner Banana

J TRANSMISSION Assembly note Oil seal 1. Apply the specified oil to a new oil seal. 2. Install the new oil seal by using the SST. Rod cover 1. Apply transmission oil to the rubber bushings on the rod cover. 2. Install the rod cover with the mark facing forward. L I 35UOJX-058 Roll pin Install a new roll pin into the control rod end. The split in the roll pin must be facing in the direction shown in the figure. L I 45UOJX-031 Select-lock spindle, spring, and spring cap 1. Install the select-lock spindle, spring, and spring cap. Tightening torque: 7.9-10.7 Nm (80-11 0 kgfan, 70-95.4 in-lbf) 2. Push the select-lock spindle down by pushing on the control rod. This will ensure that the steel ball correctly engages the select-lock spindle. 45UOJX-032 Gartner Banana

TRANSMISSION J Mainshaft Parts Assemble in the order shown in the figure, referring to Assembly Note. WPPLY SPEwim OIL To IwiviDwL PmTs 45UOJX-034 Clutch hub Synchronizer key Clutch hub sleeve Synchronizer key springs Mainshaft 2nd gear Assembly Note .............. page J-32 2nd synchronizer ring Double cone Inner cone Synchronizer assembly (2nd) Clutch hub assembly (Istf2nd) Assembly Note .............. page J-32 3rd gear Assembly Note .............. page J-32 3rd synchronizer ring Clutch hub assembly (3rdl4th) Assembly Note .............. page J-32 Snap ring Assembly Note .............. page J-32 1 st synchronizer ring Bearing race Assembly Note .............. page J-32 Bearing Assembly Note .............. page J-32 1 st gear Assembly Note .............. page J-32 5-31 Gartner Banana

TRANSMISSION J 1. Oil seal Assembly Note .................. below 2. Snap ring u 3. Steel ball 4. Speedometer drive gear 5. Snap ring 6. Transmission case 7. Extension housing Assembly Note .................. below 8. Main drive gear bearing Assembly Note .................. below 9. Snap ring 10. Countershaft front bearing Assembly Note .............. page J-44 11. Snap ring 12. Adjustment shim Assembly Note .............. page J-44 13. Gasket 14. Front cover 15. Speedometer driven gear 16. Neutral switch 17. Back-up light switch 18. Boot 19. Clutch release fork Assembly Note .............. page J-44 20. Clutch release collar Assembly Note .............. page J-44 35UOJX-020 Assembly note Oil seal 1. Apply transmission oil to the outer periphery. 2. lnstall a new oil seal with the SST. Extension housing 1. Apply sealant to the contact surfaces of the bearing housing and transmission case. 2. Align the inner shift lever and shift rod end groove, and install the extension housing. 3. Apply sealant to the bolt threads, and install the bolts. Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, l4--19 ft4bf) Main drive gear bearing Install the main drive gear bearing by using the SST, and secure it with a new snap ring. Gartner Banana

TRANSMISSION J INSTALLATION 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Install in the order shown in the figure, referring to lnstallation Note. L 3. Add the specified amount of the specified transmission oil. (Refer to page J-8.) 4. Warm up the engine and transmission, and inspect for oil leakage and transmission problems. 1. Transmission 7. Exhaust pipe Installation Note ............. page J-46 8. Performance rod 2. Power plant frame (PPF) 9. Differential mounting pipe Installation Note ............. page J-46 10. Undercover 3. S~eedometer cable 11. Shift lever w 4. ~iarter Installation Note ............. page J-47 5. Clutch release cylinder 12. Rear console 6. Propeller shaft 13. Shift lever knob Service ...................... section L Gartner Banana

J TRANSMISSION -=DIFFERENTIAL MOUNTING SPACER 45UOJX-054 Installation note Transmission 1. Tilt the engine by pushing up on the front of the oil pan with a wooden block and a transmission jack. d 2. Support the transmission with a transmission jack. 3. Raise the transmission into place and install and tighten the installation bolts. Tightening torque: 64-89 N-m (6.5--9.1 kgf-m, 48-65 ft.lbf) Power plant frame (PPF) 1. Install the differential mounting spacer. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) 2. Support the transmission with a jack so that it is level. 3. Position the PPF and tighten the transmission-side bolts by hand. 4. Verify that the sleeve is installed into the block. 5. Install the spacer and reamer bolts in the forward hole, then hand tighten them. 6. Snugly install the power plant frame bracket. 7. Tighten the transmission-side bolts. Tightening torque: 104-123 N-m (10.S12.6 kgf.m, 76.7-91.1 ft.lbf) 8. Tighten the differential-side bolts. Tightening torque: 104-1 23 N-m (1 0.S12.6 kgf.m, 76.7-91.1 ft-lbf) Gartner Banana

TRANSMISSION J 9. Install the power plant frame bracket. Tightening torque @ : lO4--123 N.m (1 0.6-1 2.6 kgf.m, 76.7-91.1 ft-lbf) @: 37-43 N.m (3.7-5.5 kgf-m, 27-39 ftlbf) 10. Remove the jack, and connect the wire harness. 11. Measure distance A with a straightedge and vernier cali- pers. Distance A: 66.0 2 5mm (2.60 a 0.197 in) 12. If the distance is not within specification, reposition the PPF to the transmission. FRONT Shift lever 1. Pour the specified amount of oil into the change control case. The change control case must also be filled with the specified amount of oil whenever the extension housing has been removed or the transmission has been overhauled. Specified oil Grade: API service GL-4 or GL-5 All season: SAE 75W-90 Above 10°C (50°F): SAE 80W-90 Specified amount: 80-95 cc (4.9-5.8 cu in) 2. Apply oil to the shift lever as shown. 3. Apply sealant to the contact surfaces of the boot panel and the change control case. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . AUTOMATIC TRANSMISSION INDEX ................................ K- 2 OUTLINE ............................. K- 3 SPECIFICATIONS ................... K- 3 ........... CROSS-SECTIONAL VIEW K- 4 POWER FLOW DIAGRAM ............ K- 5 OPERATION OF COMPONENTS ...... K- 5 FLUID PASSAGE LOCATIONS ........ K- 6 TROUBLESHOOTING .................. K- 8 GENERAL NOTES ................... K- 8 .......... QUICK DIAGNOSIS CHART K- 9 ON-BOARD DIAGNOSIS SYSTEM ...... K- 11 DESCRIPTION ...................... K- 11 PREPARATION ...................... K- 11 ....... DIAGNOSTIC TROUBLE CODE K- 11 .......... MECHANICAL SYSTEM TEST K- 22 PREPARATION ...................... K- 22 STALL TEST ........................ K- 22 TIME LAG TEST ..................... K- 25 LINE PRESSURE TEST .............. K- 26 ROAD TEST .......................... K- 29 D-RANGE TEST ..................... K- 29 S-RANGE TEST ..................... K- 31 ..................... L-RANGE TEST K- 32 . P-RANGE TEST ..................... K- 33 AUTOMATIC TRANSMISSION FLUID (ATF) ................................ K- 35 ATF ................................ K- 35 REPLACEMENT ..................... K- 37 ELECTRICAL SYSTEM COMPONENTS . . K- 38 PREPARATION ...................... K- 38 HOLD SWITCH ...................... K- 38 PARWNEUTRAL SWITCH ............ K- 39 .............. ATF THERMOSENSOR K- 41 VEHICLE SPEED PULSE GENERATOR ...................... K- 41 1-2 SHIFT. 2-3 SHIFT. 3-4 SHIFT. ... 3-2 CONTROL SOLENOID VALVE K- 42 LOCKUP CONTROL SOLENOID ....... VALVE ............................ K- 42 POWERTRAIN CONTROL MODULE (TRANSMISSION) .................. K- 43 TRANSMISSION ....................... K- 46 TRANSMISSION UNIT (REMOVAL) .... K- 46 TRANSMISSION UNlT (DISASSEMBLY) ................... K- 50 TORQUE CONVERTER .............. K- 61 OILPUMP .......................... K- 62 FOURTH GEAR CONNECTING SHELL AND FOURTH GEAR PLANETARY GEAR UNIT (FOURTH GEAR SUN GEAR. FOURTH GEAR PLANETARY PINION CARRIER. FOURTH GEAR CLUTCH HUB) ...... K- 67 DIRECT CLUTCH .................... K- 70 FOURTH GEAR BAND SERVO ........ K- 76 DRUM SUPPORT. ACCUMULATOR. AND FOURTH GEAR CASE ......... K- 79 2ND BAND SERVO .................. K- 83 FRONT CLUTCH .................... K- 86 REAR CLUTCH ...................... K- 91 CONNECTING SHELL AND FRONT PLANETARY GEAR UNlT (REAR CLUTCH HUB. FRONT PLANETARY PINION CARRIER. REAR SUN GEAR) ................. K- 96 REAR PLANETARY GEAR UNlT (CONNECTING DRUM. REAR PLANETARY PINION CARRIER. ONE-WAY CLUTCH) K- 98 LOW AND REVERSE BRAKE K-102 ................ ......... EXTENSION HOUSING AND PARKING MECHANISM ............. K-107 OIL SEAL ........................... K-ill CONTROL VALVE BODY ............. K-112 UPPER VALVE BODY ................ K-116 LOWER VALVE BODY ............... K-120 CONTROL VALVE BODY ............. K-125 VACUUM DIAPHRAGM ............... K-130 TRANSMISSION UNIT (ASSEMBLY) ... K-132 TRANSMISSION UNIT (INSTALLATION) ................... K-147 OIL COOLER .......................... K-151 REMOVAL I INSPECTION I INSTALLATION ..................... K-151 DRIVE PLATE ......................... K-152 PREPARATION ...................... K-152 REMOVAL 1 INSPECTION I INSTALLATION ..................... K-152 SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) ......... K-154 SHIFT-LOCK SYSTEM COMPONENTS K-154 TROUBLESHOOTING ................ K-155 SHIFT-LOCK ........................ K-157 EMERGENCY OVERRIDE BUTTON ... K-157 KEY INTERLOCK .................... K-157 KEY INTERLOCK SOLENOID ......... K-157 KEY INTERLOCK UNIT ............... K-158 P RANGE SWITCH .................. K-159 SHIFT-LOCKACTUATOR ............. K-159 SELECTOR LEVER .................. K-161 HYDRAULIC CIRCUIT .................. K-168 P RANGE ........................... K-168 R RANGE ........................... K-169 N RANGE; BELOW 7 kmlh I4.34 mph) . K-170 N RANGE; ABOVE 9 kmlh (5.58 mph} . K-171 D RANGE; 1 ST GEAR ................ K-172 D RANGE; 2ND GEAR ............... K-173 D RANGE; THIRD GEAR ............. K-174 D RANGE; FOURTH GEAR. LOCKUP ON ....................... K-175 S RANGE; 1 ST GEAR ................ K-176 S RANGE; 2ND GEAR ............... K-177 S RANGE; THIRD GEAR ............. K-178 L RANGE; 1 ST GEAR ................ K-179 L RANGE; 2ND GEAR ................ K-180 Gartner Banana