Brake MAZDA 626 1987 Workshop Manual

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

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
(4) Install the detent ball, spring, washer and plug;
then tighten the plug.
Tightening torque:
12—18
N
m (1.2—1.8 m-kg, 8.7—13 ft-lb)
86U07B-386
Install the low and reverse brake piston.
(1) Apply ATF to the inner and outer seals, and
install them to the low and reverse brake piston.
(2) Face the outer seal lip toward the inside by
gently rolling it down around the circumference
for easier installation into the case.
(3) Install the low and reverse brake piston by
pushing evenly around the circumference, be-
ing careful not to damage the outer seal.
86U07B-388
(4) Install the spring and retainer assembly.
86U07B-389
7B-200

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
6. Install the drive and driven plates.
Note
Installation order:
G4A-EL
Driven-Drive-Driven-Drive-Driven-Drive
G4A-HL
Driven-Drive-Driven-Drive-Driven-Drive-
D riven-Drive
76G07B-183
7. Install the retaining plate.
8. Install the snap ring.
86U07B-403
7B—204
. Check the low and reverse brake clearance.
(1) Measure the clearance between the snap ring
and the low and reverse brake retaining plate.
(2) If the clearance is not within specification, ad-
just it by selecting a proper retaining plate.
Low and reverse brake clearance:
2.1—2.4 mm (0.083—0.094 in)
Retaining plate sizes mm (in)
G4A-EL
10.0 (0.394) 10.2 (0.402) 10.4 (0.410)
10.6 (0.417) 10.8 (0.425)
G4A-HL
6.8 (0.268) 7.0 (0.276) 7.2 (0.283)
7.4 (0.291) 7.6 (0.299) 7.8 (0.307)
Check the low and reverse brake operation by ap-
plying compressed air through the fluid passage
as shown in the figure.
Air pressure:
392 kPa (4.0 kg/cm2, 57 psi)

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

7B ASSEMBLY
86U07B-410
86U07B-411
86U07B-412
15. Install the small sun gear and one-way clutch.
(1) Check that the thrust bearing and bearing race
are installed in the correct position.
(2) Install the small sun gear and one-way clutch
by rotating it.
16. Install the piston stem in the position while pulling
out the 2-4 brake band with a pliers; then loosely
tighten the piston stem by hand.
17. Install the clutch assembly.
(1) Check that the thrust bearing is installed in the
correct position.
86U07B-413
7B-206

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

OD
IV) K>
2-4 brake band
—Coasting clutch pressure brake pressure
To oil cooler
N-R accumulator 12-3 accumulator
2-3 Timingr valve 18 Coasting bypass valve Bypass valve Servo control y valve (Blocked)
Pressure modifier valve (Blocked)
3-4 shift valve
Low reducing valve
Pressure regulator valve 3-2 timing valve 3-2 Icapacity valve
Manual valve
Throttle valve
Oil pump
• Throttle pressure
1 Throttle modulated pressure
• Line pressure
I Torque converter pressure Forward clutch pressure\^
Reverse clutch pressure—_____
1-2 accumulator
Throttle back-up valve (Blocked)
-j Throttle J modulator I valve
Apply side 9
Lock-up control valve
-< O
u >
o
o
J3 o
Q >
• m
-< o
3D >
C n
O
O
J3 o
a •C* > • m
-si
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