maintenance MAZDA 626 1987 Owners Manual

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
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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.
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7C-25

7C ON-VEHICLE MAINTENANCE
76G07C-349
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Button must be depressed
76G07C-043
6. Ensure that the ATF level is between the F and L
marks. Add ATF to specification, if necessary.
ATF type: Dexron II or M II!
Inspection of Condition
1. Check the ATF for discoloration.
2. Check the ATF for any unusual smell.
Note
Determine whether or not the automatic trans-
mission should be disassembled by observ-
ing the condition of fluid carefully.
If the fluid is muddy and varnished, it indicates
burned drive plates.
SELECTOR LEVER
Inspection
1. Check that the selector lever can be shifted as
shown in the figure.
2. Make sure there is a click at each range when shift-
ed from P <-• 1 range.
3. Check that the positions of the selector lever and
the indicator are exact.
4. Check that the button returns smoothly when used
to shift the selector.
Adjustment
1. Shift the selector lever to the P range.
2. Loosen locknuts A, B, and C.
3. Shift the transaxle to P range by moving the man-
ual shaft of the transaxle.
4. Tighten locknut C to the specified torque.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
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7C-26

ON-VEHICLE MAINTENANCE 7C
76G07C-045
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5. Turn locknut A by hand until it just touches the
spacer.
6. Tighten locknut B to the specified torque.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
7. Verify that there is a click at each range when shift-
ed from P «-» 1 range.
8. Check that the positions of the selector lever and
the indicator are exact.
9. Check that the button returns smoothly when used
to shift the selector.
10. If necessary, check the spring.
VACUUM DIAPHRAGM
Inspection
1. Remove the vacuum hose from the vacuum di-
aphragm. Check for ATF leakage. Replace if any
is found.
2. Remove the vacuum diaphragm.
3. Verify that the diaphragm rod moves when vacu-
um is applied.
Caution
When removing the diaphragm, do not drop
the rod into the oil pan.
76G07C-046
Vacuum diaphragm
Adjustment
Note
a) Excessive shift shocks and improper shift-
ing often indicate a vacuum diaphragm mal-
function.
b) Remove approximately 1.0 liter (1.1 US qt,
0.9 Imp qt) of ATF before removing the
vacuum diaphragm.
1. Remove the vacuum diaphragm, rod, and O-ring
from the transaxle case.
2. Measure the N dimension indicated in the figure
with the SST and a scale.
3. Select the diaphragm rod in accordance with the
table.
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)
76G07C-048
10,-21

7C ON-VEHICLE MAINTENANCE
REPLACEMENT OF CONTROL VALVE
1. Disconnect the negative battery cable.
2. Jack up the vehicle and support it with safety
stands.
3. Drain the ATF.
4. Remove the under cover and side cover.
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5. Remove the oil pan from the transaxle case.
Caution
Be careful because some ATF will be in the
oil pan.
6. Remove the control valve body.
Caution
Be careful not to lose the ball and spring for
the torque converter relief valve or the vacu-
um diaphragm rod.
7. Install the control valve body as follows:
(1) Install the vacuum diaphragm rod.
(2) Insert the ball and spring into the hole in the
transaxle case.
Note
a) The ball is inserted first, then the spring.
b) Use petroleum jelly to prevent them from
falling out.
(3) Install the control valve, mating the groove of
the manual valve with the driving pin of the con-
trol rod.
(4) Tighten the control valve mounting bolts to the
specified torque.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
8. Install the oil pan and tighten the bolts to the speci-
fied torque.
Tightening torque:
5—8 N-m (50—80 cm-kg, 43—69 in-lb)
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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.)
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7C—29

9
FRONT AND REAR AXLES
OUTLINE 9—2
STRUCTURAL VIEW 9— 2
SPECIFICATIONS 9— 6
TROUBLESHOOTING GUIDE 9— 7
FRONT AXLE 9— 8
ON-VEHICLE MAINTENANCE 9— 8
REMOVAL 9— 9
DISASSEMBLY 9—11
INSPECTION 9—12
ASSEMBLY 9—13
INSTALLATION 9—14
REAR AXLE 9—16
ON-VEHICLE MAINTENANCE 9—16
[Drum Brake] 9—17
REMOVAL 9—17
DISASSEMBLY 9—18
INSPECTION 9—19
ASSEMBLY 9—19
INSTALLATION 9—20
[Disc Brake] 9—21
REMOVAL (2WS) 9—21
REMOVAL (4WS) 9—22
DISASSEMBLY 9—23
INSPECTION 9—24
ASSEMBLY 9—25
INSTALLATION (2WS) 9—26
INSTALLATION (4WS) 9—27
DRIVESHAFT 9—28
ON-VEHICLE MAINTENANCE 9—28
REMOVAL 9—29
DISASSEMBLY (MTX) 9—31
INSPECTION (MTX) 9—32
ASSEMBLY (MTX) 9—33
DISASSEMBLY (ATX) 9—35
INSPECTION (ATX) 9—36
ASSEMBLY (ATX) 9—36
INSTALLATION 9—37
JOINT SHAFT 9—39 86U09X-001

9 FRONT AXLE
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FRONT AXLE
ON-VEHICLE MAINTENANCE
Wheel Bearing Play
1. Jack up the vehicle and support it with safety
stands.
2. Check that there is no abnormal noise and that the
tire rotates smoothly when rotated by hand.
3. Remove the wheel.
4. Remove the caliper assembly and suspend it us-
ing a rope.
5. Position a dial indicator against the hub cap, then
push and pull the front wheel hub by hand in the
axial direction and measure the end play of the
wheel bearing.
If the end play exceeds specification, replace the
wheel bearing.
End play: 0.2 mm (0.0079 in) max
6. Install the caliper assembly.
Tightening torque: 78—98
N
m
(8.0—10.0 m-kg, 58—72 ft-lb)
7. Install the wheel.
Tightening torque: 88—118
N
m
(9.0—12.0 m-kg, 65—87 ft-lb)
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9—8

9 REAR AXLE
86U09X-027
69G09X-012
76G09X-003
REAR AXLE
ON-VEHICLE MAINTENANCE
Wheel Bearing Play
1.Jack up the vehicle and support it with safety
stands.
2. Check that there is no abnormal noise and that the
tire rotates smoothly when rotated by hand.
3. Remove the wheel.
4. Remove the caliper assembly and suspend it us-
ing a rope.
5. Position a dial indicator against the hub cap, then
push and pull the front wheel hub or brake drum
by hand in the axial direction and measure the end
play of the wheel bearing.
If the end play exceeds specification, replace the
wheel bearing.
End play: 0.2 mm (0.0079 in) max.
6. Install the caliper assembly. (Disc)
Tightening torque: 45—67 N-m
(4.6—6.8 m-kg, 33—49 ft-lb)
7. Install the wheel.
Tightening torque: 88—118 N-m
(9.0—12.0 m-kg, 65—87 ft-lb)
86U09X-029
9—16

9 DRIVESHAFT
86U09X-088
DRIVESHAFT
ON-VEHICLE MAINTENANCE
Boot
Check the boots on the driveshaft for cracks, dam-
age, grease leakage or loose boot bands. Replace
if necessary.
Spline Looseness
Turn the driveshaft by hand and check that the spline
and joint are not excessively loose.
Replace if necessary.
86U09X-089
Twisted or Cracked
Check that the driveshaft is not twisted or cracked.
Replace if necessary.
86U09X-090
9-28

10
STEERING SYSTEM
OUTLINE 10— 2
STRUCTURAL VIEW 10— 2 SPECIFICATIONS 10— 6
TROUBLESHOOTING GUIDE 10— 7
MANUAL STEERING 10— 7
POWER STEERING 10— 8
4WS 10— 9
ON-VEHICLE MAINTENANCE 10— 10
STEERING WHEEL PLAY 10— 10
LOOSENESS OR PLAY OF THE
STEERING WHEEL 10— 10
STEERING WHEEL EFFORT 10— 10
POWER STEERING FLUID LEVEL 1 fl-11
LOOSE OR DAMAGED
OIL PUMP BELT IC— 12
REAR STEERING GEAR OIL 10— 12 LEAKAGE OF POWER STEERING
FLUID 10— 13
INSPECTION AND ADJUSTMENT. 10— 15
BLEEDING OF POWER STEERING
SYSTEM 10— 15
POWER STEERING PRESSURE ... 10— 16
TIE-ROD END BOOTS 10— 18
REMOVAL AND INSTALLATION .. 10— 18
STEERING WHEEL AND COLUMN 10— 21
STRUCTURAL VIEW 10— 21
REMOVAL 10— 22
DISASSEMBLY AND ASSEMBLY.. 10— 24
INSPECTION 10— 25
INSTALLATION 1 fl-27
STEERING GEAR AND LINKAGE .. IC— 28
STRUCTURAL VIEW 10— 28
REMOVAL 10— 29
INSTALLATION 10— 30
4-WHEEL STEERING GEAR AND
LINKAGE 10— 31
STRUCTURAL VIEW 10— 31 4WS PERFORMANCE INSPECTION 10— 32
ADJUSTMENT OF STEERING
ANGLE TRASFER SHAFT 10— 35
REMOVAL AND INSTALLATION .. 10— 37
INSPECTION 10— 44
MANUAL STEERING 10— 48
DISASSEMBLY 10— 48
INSPECTION 10— 51
ASSEMBLY 10— 52
ENGINE SPEED SENSING POWER
STEERING 10— 58
DISASSEMBLY 10— 58
INSPECTION 10— 62
ASSEMBLY 10— 64
ELECTRONICALLY-CONTROLLED
POWER STEERING 10— 75
DISASSEMBLY 10— 75
INSPECTION 10— 78
ASSEMBLY 10— 79
OIL PUMP 10— 83
REMOVAL AND INSTALLATION .. 10— 83
ELECTRICAL COMPONENTS OF
ELECTRONICALLY-CONTROLLED
POWER STEERING 10— 87
CIRCUIT DIAGRAM 10— 87
TROUBLESHOOTING GUIDE 10— 87
TROUBLESHOOTING 10— 87
ELECTRICAL COMPONENTS OF
4 WHEEL STEERING 10— 94
CIRCUIT DIAGRAM 10— 94
TROUBLESHOOTING GUIDE 10— 95
TROUBLESHOOTING 10— 95
4WS WARNING LIGHT 10—102
SPEED SENSOR (IN METER) 10—103
SPEED SENSOR (AT TRANSAXLE) 10—103
REAR-TO-FRONT STEERING
RATIO SENSOR 10—103
OIL LEVEL SWITCH
(IN P/S RESERVOIR) 10—103
RELAY AND TIMER 10—104 76G10X-001