transaxle MAZDA 626 1987 Workshop Manual

7C
AUTOMATIC TRANSAXLE
(3-Speed)
OUTLINE 7C— 2
SPECIFICATIONS 7C— 2
CROSS-SECTIONAL VIEW 7C— 3
OPERATION OF COMPONENTS . 7C— 4
FLUID PASSAGE LOCATION 7C— 5
TROUBLESHOOTING 7C— 8
GENERAL NOTE 7C— 8
QUICK DIAGNOSIS CHART 7C— 9
STEP 1
(PRELIMINARY INSPECTION).... 7C— 12
STEP 2 (STALL TEST) 7C— 14
STEP 3 (TIME LAG TEST) 7C— 17
STEP 4 (ROAD TEST) 7C— 18
STEP 5 (OIL PRESSURE TEST)... 7C— 20
ELECTRIC COMPONENTS 7C— 23
INHIBITOR SWITCH 7C— 23
KICK-DOWN SWITCH 7C— 23
KICK-DOWN SOLENOID 7C— 24
ON-VEHICLE MAINTENANCE 7C- 25
AUTOMATIC TRANSAXLE FLUID
(ATF) 7C— 25
SELECTOR LEVER 7C— 26
VACUUM DIAPHRAGM 7C— 27
REPLACEMENT OF CONTROL
VALVE 7C— 28
REPLACEMENT OF SERVO
PISTON RETURN SPRING 7C— 29
REMOVAL 7C— 30
PREPARATION 7C— 30
DISASSEMBLY 7C— 35
DISASSEMBLY-STEP 1 7C— 35
DISASSEMBLY-STEP 2 7C— 41
DISASSEMBLY-STEP 3 7C— 45
DISASSEMBLY-STEP 4 7C— 51
INSPECTION AND REPAIR 7C- 54
PRECAUTION 7C— 54
TORQUE CONVERTER 7C— 54
OIL PUMP 7C— 55
FRONT CLUTCH 7C— 58
REAR CLUTCH 7C— 62
REAR CLUTCH HUB 7C— 65
DRUM HUB 7C— 66
ONE-WAY CLUTCH INNER RACE 7C— 68
BAND SERVO 7C— 69
BRAKE BAND 7C— 70
PLANETARY CARRIER (FRONT).. 7C— 71
ONE-WAY CLUTCH 7C— 71
LOW AND REVERSE BRAKE 7C— 71
GOVERNOR 7C— 72
CONTROL VALVE BODY 7C— 75
DIFFERENTIAL 7C— 79
OUTPUT GEAR 7C— 82
IDLE GEAR 7C— 83
BEARING COVER ASSEMBLY .... 7C— 86
BEARING HOUSING 7C— 87
SIDE BEARING HOUSING 7C— 88
ASSEMBLY 7C— 89
PRECAUTION 7C— 89
ASSEMBLY-STEP 1 7C— 89
ASSEMBLY-STEP 2 7C— 98
ASSEMBLY-STEP 3 7C—106
ASSEMBLY-STEP 4 7C—111
INSTALLATION 7C—119
TORQUE SPECIFICATIONS 7C—119
HYDRAULIC CIRCUIT 7C—125
OUTLINE 7C—125
P RANGE 7C—126
R RANGE 7C—127
N RANGE 7C—128
D RANGE (1ST GEAR) 7C—129
D RANGE (2ND GEAR) 7C—130
D RANGE (3RD GEAR) 7C—131
D RANGE (KICK-DOWN; SHIFT
VALVES IN 2ND POSITION) 7C—132
2 RANGE (2ND GEAR) 7C—133
1 RANGE (1ST GEAR) 7C—134
1 RANGE (2ND GEAR) 7C—135
76G07C-001

7C OUTLINE
OUTLINE
SPECIFICATIONS
Model F3A Model FE engine F6 engine
Torque converter stall torque ratio 1.800-2.100 : 1
Gear ratio
First 2.841
Gear ratio Second 1.541 Gear ratio
Third 1.000
Gear ratio
Reverse 2.400
Final gear ratio 3.450 : 1 3.631 : 1
Number of drive plates/ driven plates
Front clutch 3/3
Number of drive plates/ driven plates Rear clutch 4/4 Number of drive plates/ driven plates
Low and reverse brake 4/4
Servo diameter (Piston outer dia./retainer inner dia.) mm (in) 64/36 (2.52/1.42) 64/44 (2.52/1.73)
Speedometer gear ratio (Driven/Drive gear) 0.80 (20/25) 0.84 (21/25)
Automatic transaxle fluid
Type Dexron-II or M-III
Automatic transaxle fluid Capacity liters
(US qt, Imp qt) 6.2 (6.6, 5.5)
76G07C-002
7C—2

OUTLINE 7C
CROSS-SECTIONAL VIEW
76G07C-003
1. Transaxle case
2. Front clutch
3. Rear clutch
4. Connecting shell
5. Rear clutch hub
6. Planetary carrier (front)
7. Sun gear
8. Low and reverse brake
9. One-way clutch
10. One-way clutch inner race
11. Planetary carrier (rear)
12. Drum hub assembly
13. Bearing housing
14. Output gear
15. Turbine shaft
16. Oil pump shaft
17. Bearing cover
18. Oil seal
19. Torque converter
20. Converter housing
21. Oil seal
22. Speedometer drive gear
63U07B-003
23. Side gear
24. Pinion gear
25. Pinion shaft
26. Differential gear case
27. Ring gear
28. Oil seal
29. Side bearing housing
30. Control valve body
31. Oil pan
32. Oil pump
7C-3

7C OUTLINE
Transaxle Case
Outlet to governor valve
Inlet to governor valve'
Governor pressure
check port
To low and reverse brake
Band servo (Apply side)
Band servo (Release side)
Inlet to governor valve Inlet to oil pump
Outlet to front clutch
Outlet to rear clutch
Outlet to governor valve j Outlet to torque converter
Line pressure check port Outlet to oil pump
Outlet to oil pump Inlet to oil pump
Outlet to front clutch
Outlet to rear clutch
Outlet to torque converter
Band servo (Apply side)
Band servo (Release side)
Outlet to governor valve—
Inlet to governor valve
reverse brake
76G07C-008
7C—6

7C TROUBLESHOOTING
TROUBLESHOOTING
GENERAL NOTE
In the event of a problem with the automatic transaxle, the cause may be in the engine, powertrain,
hydraulic control system, or electrical control system. When troubleshooting, it is recommended to
begin from those points that can be judged quickly and easily. The recommended troubleshooting
sequence is described below.
STEP 1: PRELIMINARY INSPECTION Check preliminary items • ATF level and condition
• Oil leakage • Selector lever position
• Vacuum leakage
• Idle speed and ignition timing
• Tire inflation pressure • Inhibitor switch
This step checks conditions surrounding the automatic
transaxle.
STEP 2: STALL TEST Check engine stall speed This step checks the powertrain.
• Friction element slipping
• Torque converter capacity
STEP 3: TIME LAG TEST Check time lag of oil pressure supply This step checks operation of the hydraulic control system. • Friction elements slipping
• Regulating valves
STEP 4: ROAD TEST Check items on road test
• Shift point • Shift schedule
• Kick-down • Shift shock
This step checks functions of the electrical control system
and hydraulic control system.
STEP 5: OIL PRESSURE TEST Check line pressures and governor pressure This step checks major points of the hydraulic control system.
• Oil pump • Line pressure control • Governer pressure control
By following the above five steps, the cause of the problem should be located.
As another guide to faster location of the causes of problems, the Quick Diagnosis Chart is included
at pages 7C—9 to 7C—11.
In this chart, a circle is used to indicate the components that might be the cause of trouble for 54
types of problems. It is only necessary to check those components indicated by circles, at each step
of the troubleshooting process, in order to quickly locate the cause of the problem.
76G07C-012
7C—8

TROUBLESHOOTING
7C

QUICK DIAGNOSIS CHART
How
to use
Quick Diagnosis Chart
1.
The
numbers indicate
the
order
of
inspection
for
troubleshooting.
2. Circled numbers indicate that
the
transaxle must
be
removed from
the
vehicle.
76G07C-013
Transaxle ON VEHICLE OFF VEHICLE
•

\ Inspection point
\
and
reference
\ page
Condition


7C-25
7C-26
7C-23
10—21
7C—23,24
Section

4A

7C-14
7C—20,22
10—lb
10-12 10—69
7C—5
Section

5

7C—58
7C-62
7C-70
7C-71
7C-55
7C-125
7C-54 7C-71
7C-66,

98

7C-68,

71
\ Inspection point
\
and
reference
\ page
Condition

ATF

level
and
condition

Selector

lever
Inhibitor
switch
and
wiring

^

Vacuum
diaphragm
and

piping

|

Kick-down
solenoid,
kick-down
switch
and
wiring
Engine

idle

speed

and

condition

Engine
stall

speed

Fluid

pressure

(Line

and
governor)
Control
valves

Governor

valve
Band
servo
Transaxle
air
check
Ignition
switch
and
starter
Front
clutch

Rear

clutch
Brake

band

Low

and
reverse
brake

Oil
pump Hydraulic
circuit

Torque

converter

One-way

clutch
Parking

linkage

Planetary
gear

I

Engine

starting
Engine does
not
start
in
N or P
range •
2 3
1

Engine

starting
Engine starts
in
ranges other than
N
and P
ranges •
1 2

Accelerating
Vehicle does
not
move
in
D
range (moves
in 1, 2 & R
ranges) •
• •
•
Accelerating
Vehicle does
not
move
in
forward ranges (moves
in R
range)
Ex-
tremely poor acceleration •
• 5
• •
© •
•
• ©
•
• •
•
Accelerating
Vehicle does
not
move
in R
range (moves
in
forward range) Extremely poor acceleration 1
2 •
•
• •
•
3 4
•
• 5
• ©
© •
©
• ©
•
• •
•
Accelerating
Vehicle does
not
move
in any
range 1
2 •
•
• •
•
3 4
•
• 5
• •
• •
•
© ©
•
• ©
•
Accelerating Slippage felt when accelerating 1
2 •
6
• •
•ST
CO
•
•
• 5
• •
• •
•
© ©
•
• •
• Accelerating
Vehicle moves
in
N
range
Accelerating
Excessive creep
Accelerating
No creep
at all
©
© •
•
© ©
•
• •
•
Accelerating
Low maximum speed
and
poor acceleration 1
2 •
•
• 7
3
4 6
•
5 •
• ©
© ©

No shifting

Does
not
shift from
1
st to 2nd
•
1 •
2
3 •
•
• 4
5
6 7
• •
© ©
•
• ©
•
• •
•

No shifting
Does
not
shift from
2nd to 3rd
•
1 •
2
3 •
•
• 4
5
6 7
•

No shifting

Does
not
shift from
3rd to 2nd
1
• •
2
• •
•
• 3
4
5 6
• ©
• ©
•
• ©
•
• •
•
76G07C-014
7C-9

7C TROUBLESHOOTING
ON VEHICLE OFF VEHICLE
-

\ Inspection point
\ and reference
\ page
Condition


LO
(O
CO CJ OJ CM I
I I
O
O
CJ
r-~
r—
7C-27
7C—23,24
Section

4A

7C—14
7C—20,22
7C-75

CO
O)
in
I
I I
o
o o
r—
r—
Section

5
CO CO
o
WON I
I I
o
o o
1— 1—
m i-
in co
S
IO
i-
1
1 1
o
o o
—
I—
7C—54
7C-71
7C-66,

98

7C—68,

71
\ Inspection point
\ and reference
\ page
Condition

A.TF

level
and

condition

Selector
lever
Inhibitor
switch
and
wiring

Vacuum

diaphragm
and

piping

Kick-down

solenoid,

kick-down

switch
and

wiring

Engine

idle
speed
and
condition
Engine
stall
speed
Fluid
pressure
(Line
and
governor)

Control

valves

Governor

valve
Band
servo

Transaxle

air
check
Ignition
switch
and

starter

Front

clutch

Rear

clutch

Brake

band

Low

and
reverse
brake
Oil pump Hydraulic
circuit
Torque
converter

One-way

clutch

Parking

linkage
Planetary
gear

No
shifting

Does
not
shift from 2nd
to
1
st or from
3rd to
1
st 1
• •
2
• •
•
• 3
4
5 6
•
No
shifting

Does
not
kick-down when accelerator
is
depressed
in 3rd
within
the
kick-down range 1
• •
3
2*
•
• 4
5
• •
• •
• ©
•
• ©
•
• •
•
No
shifting
Excessive engine speed when accelerated
in 3rd
due
to
delayed kick-down 5
• 6
• ©
• •
•
• ©
•
• •
• No
shifting

Does
not
shift from
3rd to 2nd
on
D to
2
range shift 1
2 •
5
6 •
• ©
• ®
•
• ®
•
• •
•
No
shifting

Does
not
shift from
3rd to 2nd
on
D to 1
range shift 5
7 6
• ©
• ®
•
• ®
•
• •
•

Shift

shock

Excessive
N to
D
range shift shock •
• •
2
• 1
•
3 4
•
• •
• •
© •
•
• •
•
• •
•

Shift

shock

Excessive
1
st
to
2nd shift shock 1
• •
2
• •
3
• 4
•
5 6
• •
• ©
•
• •
•
• •
•

Shift

shock

Excissive 2nd
to 3rd
shift shock •
• •
1
• •
•
2 3
•
4 5
• ©
• ©

Shift

shock

Vehicle braked when shifted from
1
st
to 2nd

Shift

shock
Vehicle braked when shifted from 2nd
to 3rd
1
• •
•
• •
•
• 3
.
2 •
•

Shift

shock

Vehicle braked when shifted
to
R range 1
• •
•
• •
•
• •
•
3 2
• •
© ©
•
• •
•
• ©
•
Shift

shock

Shift shock felt when accelerator
is
released
and
deceleration occurs •
1 •
2
3*
•
4 5
6
• •
• •
• •
•
• ©
•
• *
•

Shift

shock

Excessively large 2nd
to 1st
shift shock
in 1
range 1
• •
2
• •
3
4 5
•
• •
•
Shift

point

Excessively high
1st to 2nd
and 2nd
to
3rd shift 1
• •
2
3 •
•
4 5
6
• •
•
Shift

point

Excessively high
3rd to 2nd
and
2nd to
1
st shift point •
1 •
2
3 •
•
4 5
6
• •
• •
• •
•
• ©
•
• •
•
Shift

point
Kick-down operates
or
engine overruns when depressing
ped-
al
in 3rd
beyond kick-down speed limit
1
2 •
3
• •
•
4 5
6
• 7
•

Shift
sequence

Shifts directly from 1st
to 3rd
1
• •
•
• •
•
• 2
3
• 4
• •
• ©
•
• ©
•
• •
•

Shift
sequence
Shifts from
2nd to 1st or
2nd
to
3rd
in
2
range •
1 •
•
• •
•
2 3
•
• •
•
7C-10

TROUBLESHOOTING
7C

ON VEHICLE -OFF VEHICLE
-

\ Inspection point
\
and
reference
\ page
Condition


in cd
ra
CM CM CM
I
I I
o
o o
I—
r~—
r—
7C—27
7C—23,24
Section
4A

7C—14
7C—20,22
7C-75

CM
0>
[—
CO
LO I
I I
O
O O
r^ r—
Section

5
CD CM
O
in (D
s
I
I I
o
o o
r—
r^

w
CM
r-
m f-
I
I I
o
o o
r-— I—
r-—
7C—54
7C-71
7C—66,

98

7C-68,

71 \ Inspection point
\
and
reference
\ page
Condition

ATR

level
and
condition

Selector

lever

Inhibitor

switch
and
wiring

Vacuum

diaphragm
and
piping

Kick-down
solenoid,
kick-down
switch

and

wiring

Engine

idle

speed

and
condition
Engine
stall

speed

Fluid

pressure
(Line
and
governor)
Control
valves

Governor

valve
Band
servo

Transaxle

air
check
Ignition
switch
and

starter

Front
clutch

Rear

clutch

Brake

band

Low
and

reverse

brake
Oil
pump
Hydraulic
circuit

Torque

converter

One-way

clutch
Parking
linkage

Planetary

gear

Snift
sequence

Shifts from
1st to
2nd
or
2nd
to
3rd
in 1
range

Slipping

Practically
no
shift shock,
or
slip-page while 1st
to
2nd shifting 1
2 •
3
• •
•
4 5
•
7 6
• •
• ©
•
• ©
•
• •
•

Slipping

Pracatically
no
shift shock
or
slip-page while 2nd
to
3rd shifting 1
2 •
3
• •
•
4 5
•
7 6
•

Slipping

No shift shock
or
engine runaway
in 1 to 2
range shift 1
2 •
3
• 4
5
• 6
•
• 7
• •
• ©
•
© •
•
• •
•
Slipping

Engine runaway
or
slip when shifting
3rd to 2nd
1
• •
2
• •
•
3 4
•
5 6
• ®
• ©
•
• ®
•
• •
•

Slipping

Slippage evident when vehicle starts moving 1
2 •
5
• •
•
3 4
•
• 6
• •
• •
•
® ©
•
• •
•

Noise

Transaxle noisy
in P and N
range

Noise
Transaxle noisy
in D, 2, 1 and
R ranges •
(D •
•
© •
•
© •
©

Others

No engine brake
in 1
range •
1 •
•
• •
•
2 3
•
• 4
• •
• •
©
• ©
•
• •
•

Others

Vehicle moves
in P
range
or
parking gear
not
disengaged when
P
range disengaged
•

Others
Transaxle overheats 3
4 5
•
2 6
• ®
©
(D ©
© ©
©
• •
©
Others

White smoke from exhaust while running 1
• •
2
• •
3
4 5
•
• 6
• ®
© ©
©
© ©
©
• •
@

Others

Abnormal odor from
oil
level gauge pipe ©
® ©
©
© ®
©
• •
©
76G07C-016
Differential
Problem Probable Cause Remedy Page
Noise Insufficient fluid Add 7C—25
Low fluid quality Replace with specified
ATF
7C-25
Worn bearing Adjust
or
replace 7C-79
Contact surface
of
gears worn Replace 7C-79
Tooth surface
of
gears damaged Replace 7C-79
Contaminated
ATF
Repair
or
replace 7C-25
Differential gear damaged, excessive backlash Replace 7C-79
Excessive bearing preload Adjust 7C—94
76G07C-017
7C—11

7C TROUBLESHOOTING
STEP 1 (PRELIMINARY INSPECTION)
In this step, the main points related to the automatic transaxle are checked. These items must be kept
in the correct condition at all times in order to assure proper operation of the automatic transaxle.
1. Automatic Transaxle Fluid (ATF)
Check ATF level and condition. (Refer to page 7C—25.)
2. Selector Lever
Check selector lever position and adjust it if necessary. (Refer to page 7C—26.)
76G07C-018
3. Oil Leakage
Check for oil leakage.
(1) Warm up the ATF.
(2) Apply the parking brake and block the wheels
to prevent the vehicle from rolling.
(3) Shift the selector lever to R range.
(4) Check if oil leaks from the noted oil seals or
gaskets.
(5) If oil leaks, replace the seal or gasket.
76G07C-019
7C-12

7C TROUBLESHOOTING
Evaluation
Condition Possible cause
Worn oil pump
In all ranges Insufficient line
pressure
Oil leakage from oil pump, control
valve, and/or transaxle case
Stuck pressure regulator valve
In D, 2, and 1 Rear clutch slipping
Above specification In D range only One-way clutch slipping
In 2 range only Brake band slipping
Low and reverse brake slipping
Brake band slipping
In R range only Road test to determine if cause is low and reverse brake or reverse clutch:
a) Engine braking in 1 range Front clutch b) No engine braking in 1 range .... Low and reverse brake
Within specification All shift control elements within transaxle functioning normally
Below specification Engine out of tune Below specification
One-way clutch slipping within torque converter
76G07C-026
7C—16