transaxle MAZDA 626 1987 Owners Manual

ASSEMBLY 7B
11. Install the one-way clutch.
(1) Hold the one-way clutch horizontally.
(2) Install it by turning the carrier hub assembly
counterclockwise.
(3) Install the snap ring.
86U07B-406
49 G019 028
12. Install the servo to the transaxle case.
(1) Install the servo spring and servo.
(2) Compress the servo with the SST.
(3) Install the snap ring.
(4) Remove the SST.
(5) Install the piston stem.
86U07B-407
13. Install the anchor strut.
86U07B-408
14. Install the 2-4 brake band in the transaxle case so
that it is expanded fully.
Note
Interlock the 2-4 brake band and anchor strut
as shown.
86U07B-409
7B-205

ASSEMBLY 7B
(2) Install the clutch assembly by rotating it.
86U07B-414
Note
Measure the height difference between the re-
verse and forward drum and transaxle case.
Standard height: 0.8 mm (0.032 in)
76G07B-185
17. Install the snap ring into the bottom ring groove
of the turbine shaft.
86U07B-416
7B—207

ASSEMBLY 7B
86U07B-418
86U07B-419
76G07B-223
Procedure
1. Use the following procedure to adjust the total end
play and select a suitable bearing race.
(1) Set the thrust bearing onto the clutch assembly.
(2) Remove the previous race and gasket.
(3) Set the thickest bearing race 2.2 mm (0.087
in) onto the oil pump.
(4) Set the oil pump onto the clutch assembly.
(5) Measure clearance between the transaxle case
and oil pump.
(6) Select a suitable bearing race from the chart
below.
Clearance mm (in) Select this bearing race mm (in)
0.91-1.10 (0.036—0.043) 1.2 (0.047)
0.71-0.90 (0.028-0.035) 1.4 (0.055)
0.51-0.70 (0.020—0.027) 1.6 (0.063)
0.31-0.50 (0.012-0.019) 1.8 (0.071)
0.11-0.30 (0.004-0.011) 2.0 (0.078)
0-0.10 (0-0.003) 2.2 (0.087)
(7) Remove the oil pump.
(8) Place the selected bearing race and a new gas-
ket onto the oil pump.
(9) Install the oil pump onto the clutch assembly.
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
86U07B-421
7B-209

7B ASSEMBLY
2. Adjust the 2-4 brake band.
(1) Loosen the locknut and tighten the piston stem
to the specified torque.
Tightening torque:
9—11
N
m (90—110 cm-kg, 78—95 in-lb)
86U07B-422
(2) Loosen the piston stem 2 turns.
(3) Tighten the locknut to the specified torque.
Tightening torque:
25—39 N-m (2.5—4.0 m-kg, 18—29 tt-lb)
86U07B-423
Install the oil strainer along with a new O-ring to
the transaxle.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
86U07B-424
4. Install the oil pan along with a new gasket.
Tightening torque:
8—11 N-m (85—110 cm-kg, 74—95 in-lb)
Note
Install the magnets in the positions shown in
the illustration.
86U07B-425
7B—210

ASSEMBLY 7B
5. Align the manual valve with the pin on the manual
plate, and install the control valve body into the
transaxle case.
Tightening torque:
11—15 Nm
(110—150 cm-kg, 95—130 in-lb)
86U07B-426
6. Install the solenoid connector and a new O-ring in
the transaxle case.
86U07B-427
7. Install a new O-ring on the bracket; then feed the
throttle cable through the transaxle case and con-
nect it to the throttle cam.
8. Install the throttle cable attaching bolts and bracket.
Tightening torque:
(§)8—11 Nm
(80—110 cm-kg, 69—95 in-lb)
(1)19—26
N
m
(1.9—2.6 m-kg, 14—19 ft-lb)
86U07B-428
9. Install the control valve body cover along with a
new gasket.
Tightening torque:
8—11
N
m (85—110 cm-kg, 74—95 in-lb)
86U07B-429
7 B—211

ASSEMBLY 7B
12. Install the pulse generator and fluid temperature
switch.
Tightening torque:
Pulse generator
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Fluid temperature switch
29—39 N-m (3.0—4.0 m-kg, 22—29 in-lb)
76G07B-190
76G07B-191
13. Install the inhibitor switch.
(1) Turn the manual shaft to the "N" position.
(2) Install the inhibitor switch and loosely tighten
the bolts.
(3) Remove the screw and move the inhibitor
switch so that the alignment hole is aligned with
the screw hole.
(4) Insert a 2.0 mm (0.079 in) diameter pin
through the holes.
(5) Install the screw; then tighten the bolts to the
specified torque.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
14. Install the harness with the remaining clip.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
15. Remove the transaxle from the SST.
76G07B-192
16. 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)
76G07B-193
7B-213

7B INSTALLATION
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.
86U07B-441
3. Mount the transaxle to the engine.
Tightening torque:
89—117
N m
(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.
86U07B-442
4. Install engine mount No. 4 and bracket.
Tightening torque:
Bolt
36—54 Nm (3.7—5.5 m-kg, 27—40 ft-lb)
Nut
64—89
N
m (6.5—9.1 m-kg, 47—66 ft-lb)
86U07B-443
5. Install engine mount No. 2.
Tightening torque:

(A)
85—117
N
m
(8.7—11.9 m-kg, 63—86 ft-lb)
(|)67—93 Nm
(6.8—9.5 m-kg, 49—69 ft-lb)
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7B—216

7B INSTALLATION
86U07B-449
Standard bolt Reamer bolt
86U07B-450
86U07B-451
14. Replace the clips at the end of the driveshaft and
joint shaft with new ones.
15. 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.
(3) Install and tighten the reamer bolts; then install
and tighten the standard bolts.
Tightening torque:
Reamer bolts 6.9—9.8 N-m
(70—100 cm-kg, 61—87 in-lb)
Standard bolts 42—62 N-m
(4.3—6.3 m-kg, 31.1—45.6 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 does not come.
16. 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 does not come
out.
17. Install the lower arm ball joints to the knuckles and
tighten the bolts and nuts.
Tightening torque:
43—54 N-m (4.4—5.5 m-kg, 32—40 ft-lb)
18. Install the undercover.
19. Install the stabilizer bar control link as follows:
(1) Install the stabilizer bar control link.
(2) Adjust protrusion 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)
86U07B-452
7B-218

INSTALLATION 7B
86U07B-453
86U07B-454
76G07B-198
20. Install the tie-rod ends and cotter pins.
Tightening torque:
29—44 N-m (3.0—4.5 m-kg, 22—33 ft-lb)
21. Install the oil cooler outlet and inlet hoses.
22. Install the splash shields.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
23. Install the front wheels.
Tightening torque:
88—118 N-m (9—12 m-kg, 65—87 ft-lb)
24. Connect the throttle cable.
Note
Adjust the throttle cable with the oil pressure
test. (Refer to page 7B—75, 76)
25. Connect the selector cable.
Tightening torque:
Nut
29—39 N-m (3.0—4.0 m-kg, 22—29 ft-lb)
Bolts
16—22 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
26. Connect the ground wires to the transaxle case.
Tightening torque:
8—11 N-m (80—115 cm-kg, 69—99 in-lb)
86U07B-456
7B—219

7B INSTALLATION
27. Connect the connectors as follows:
(1) Inhibitor switch
(2) Solenoid valve
(3) Pulse generator (G4A-EL)
(4) Fluid temperature switch (G4A-EL)
28. Connect the speedometer cable.
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76G07B-200
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29. Install the fresh air duct. (G4A-HL)
30. Install the air cleaner hose. (G4A-EL)
31. Install the air cleaner assembly; then connect the
air flow meter connector and inlet hose. (G4A-EL)
Tightening torque:
Bolt
31—40 N-m (3.2—4.1 m-kg, 23—30 in-lb)
Nut
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
32. Connect the distributor lead.
33. Install the main fuse block.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
34. Install the battery carrier and battery.
Tightening torque:
31—40 N-m (3.2—4.1 m-kg, 23—30 in-lb)
35. 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 7B—71)
(2) Check the manual linkage, and adjust if neces-
sary. (Refer to page 7B—72)
(3) Check the inhibitor switch operation. (Refer to
page 7B—65)
(4) Conduct a road test. (Refer to page 7B—34,
35)
(5) Check that there is no fluid leakage from the
transaxle. (Refer to page 7B—71)
76G07B-202
7B—220