clutch MAZDA 626 1987 Workshop Manual

7B
AUTOMATIC TRANSAXLE
(Electronically Controlled and 4-Speed)
OUTLINE 7B— 2
SPECIFICATIONS 7B— 2
COMPONENT LOCATION 7B— 3
STRUCTURAL VIEW 7B— 5
OPERATION OF COMPONENTS 7B— 6
FLUID PASSAGE LOCATION 7B— 9
TROUBLESHOOTING (G4A-EL) 7B— 12
GENERAL NOTE 7B— 12
STEP 1
(WARNING CODE RETRIEVAL) 7B— 15
STEP 2
(PRELIMINARY INSPECTION) 7B— 22
STEP 3 (SIGNAL INSPECTION) 7B— 24
STEP 4 (STALL TEST) 7B— 27
STEP 5 (TIME LAG TEST) 7B— 30
STEP 6 (OIL PRESSURE TEST) 7B— 31
STEP 7 (ROAD TEST) 7B— 34
TROUBLESHOOTING (G4A-HL) 7B— 41
GENERAL NOTE 7B— 41
STEP 1
(PRELIMINARY INSPECTION) 7B— 44
STEP 2 (ELECTRICAL
SYSTEM INSPECTION) 7B— 47
STEP 3 (STALL TEST) 7B— 49
STEP 4 (TIME LAG TEST) 7B- 52
STEP 5 (ROAD TEST) 7B— 53
STEP 6 (OIL PRESSURE TEST) 7B— 58
ELECTRICAL SYSTEM
COMPONENTS 7B— 63
MODE SWITCH (G4A-EL) 7B— 63
HOLD SWITCH (G4A-EL) 7B— 63
OD OFF SWITCH (G4A-HL) 7B— 64
INHIBITOR SWITCH 7B- 65
WATER TEMPERATURE SWITCH 7B— 66
FLUID TEMPERATURE SWITCH
(G4A-EL) 7B— 66
BRAKE LIGHT SWITCH
(G4A-EL) 7B— 66
KICK-DOWN SWITCH (G4A-HL) 7B— 67
PULSE GENERATOR (G4A-EL) 7B- 68
VEHICLE SPEED SENSOR
(G4A-EL) 7B— 68
CRUISE CONTROL SWITCH
(CRUISE CONTROL UNIT) 7B— 68
IDLE SWITCH AND THROTTLE
SENSOR (G4A-EL) 7B— 68
OD RELEASE SOLENOID
VALVE (G4A-HL) 7B— 68
SOLENOID VALVES (G4A-EL) 7B— 69
NO LOAD SIGNAL (G4A-EL) 7B— 69
MODE, AND HOLD INDICATOR
LIGHT (G4A-EL) 7B— 69
OD OFF INDICATOR LIGHT
(G4A-HL) 7B— 69
EC-AT CONTROL UNIT
(G4A-EL) 7B— 69
ON-VEHICLE MAINTENANCE 7B— 71
AUTOMATIC TRANSAXLE
FLUID (ATF) 7B— 71
SELECTOR LEVER 7B— 72
THROTTLE CABLE 7B— 73
CONTROL VALVE BODY 7B— 77
OIL STRAINER 7B— 79
ADJUSTMENT OF 2-4 BRAKE
BAND 78— 80
REPLACEMENT OF
DRIVESHAFT OIL SEAL 7B— 80
OIL COOLER 7B— 81
GOVERNOR (G4A-HL) 7B— 82
REMOVAL 7B— 83
PRECAUTION 7B— 83
DISASSEMBLY 7B— 88
DISASSEMBLY-STEP 1 7B— 88
DISASSEMBLY-STEP 2 7B— 94
DISASSEMBLY-STEP 3 7B— 99
DISASSEMBLY-STEP 4 7B—103
INSPECTION AND REPAIR 7B—107
PRECAUTION 7B—107
TORQUE CONVERTER 7B—107
OIL PUMP 7B—108
CLUTCH ASSEMBLY 7B—113
SMALL SUN GEAR AND
ONE-WAY CLUTCH 7B—122
ONE-WAY CLUTCH AND
CARRIER HUB ASSEMBLY 7B-126
3-4 CLUTCH 7B—128
2-3 ACCUMULATOR 7B—132
GOVERNOR ASSEMBLY
(G4A-HL) 7B-133
LOW AND REVERSE BRAKE 7B—134
2-4 BRAKE BAND 7B—135
BAND SERVO 7B—135
OTHER INSPECTION 7B—135
CONTROL VALVE BODY
(G4A-EL) 7B-136
CONTROL VALVE BODY
(G4A-HL) 7B-155
DIFFERENTIAL 7B—177
OUTPUT GEAR 7B—181
IDLE GEAR 7B—182
BEARING COVER ASSEMBLY 7B—185
BEARING HOUSING 7B—186
ASSEMBLY 7B-187
PRECATION 7B—187
ASSEMBLY-STEP 1 7B—187
ASSEMBLY-STEP 2 7B—197
ASSEMBLY-STEP 3 7B—202
ASSEMBLY-STEP 4 7B—208
INSTALLATION 7B—215
TORQUE SPECIFICATIONS 7B—215
HYDRAULIC CIRCUIT (G4A-EL) 7B—221
HYDRAULIC CIRCUIT (G4A-HL) 7B—239
76G07B-001

7B OUTLINE
OUTLINE
SPECIFICATIONS
Model G4A-EL (EC-AT) G4A-HL (4-speed) Model G4A-EL (EC-AT)
FE engine F8 engine

Torque converter stall torque ratio 1.710—1.900
: 1
1.900-2.100
: 1

Gear ratio
First 2.800
Gear ratio
Second 1.540
Gear ratio Third 1.000 Gear ratio
Fourth (OD) 0.700
Gear ratio
Reverse 2.333
Final gear ratio 3.700
Number
of
drive plates/ driven plates
Forward clutch 3/3
Number
of
drive plates/ driven plates
Coasting clutch 2/2
Number
of
drive plates/ driven plates 3-4 clutch 5/5 4/4 Number
of
drive plates/ driven plates
Reverse clutch 2/2
Number
of
drive plates/ driven plates
Low and reverse brake 3/3 4/4
Servo diameter (Piston outer dia./retainer inner dia.) mm (in) 78/53 (3.07/2.09) 78/49 (3.07/1.93) 78/56 (3.07/2.20)
Speedometer gear ratio (Driven/Drive gear) 20
: 25 or
21
: 25

Automatic transmission luid
Type Dexron
n or
MED
Automatic transmission luid Capacity
liters (US qt, Imp
qt)
6.8 (7.2, 6.0)

76G07B-002
7 B—2

OUTLINE 7B
STRUCTUAL VIEW
76G07B-005
1. Coasting clutch 7. Low and reverse brake
2. Forward clutch 8. Output gear
3. Reverse clutch 9. Idle gear
4. Reverse and forward drum 10. Differential
5. 3-4 clutch 11. Parking pawl
6. 2-4 brake band 12. Throttle cable
13. Control body
14. Oil pump
15. Inhibitor switch
16. Pulse generator
17. Fluid temperature switch
7B—5

7B OUTLINE
OPERATION OF COMPONENTS
Low and reverse brake
76U07B-508
Operation Table (G4A-EL)
Range Gear Engine
braking
effect
Operation elements
Range Gear Engine
braking
effect Forward
clutch
Coasting
clutch 3-4
clutch Reverse
clutch
2-4 brake Loftrmm
brake
One-way
clutch 1
One-way clutch 2
Range Gear Engine
braking
effect Forward
clutch
Coasting
clutch 3-4
clutch Reverse
clutch Aoolied Released
Loftrmm
brake
One-way
clutch 1
One-way clutch 2
P — —
R Reverse Yes O O
N -—
D
1st No O O O
D
2nd No o O 0
D 3rd
Below approx.
40 km/h (25 mph)
Yes o O 0 O 0 D 3rd
Above
approx.

40 km/h (25 mph)
Yes 0 o o ® o o
D
OD Yes © o o
S
1st No o 0 o
S
2nd No o 0 0
S
3rd

Below
approx,
40 km/h (25 mph)
Yes 0 0 0 0 o S
3rd Above approx.

40 km/h (25 mph)
Yes o o o ® o o
L 1st No o O o o L 2nd Yes 0 0 o o

HOLD

D
2nd No o o o

HOLD

D 3rd

Below
approx.

40 km/h (25
mpti) Yes o o o 0 o

HOLD

D 3rd Above approx,
40 km/h (25 mph)
Yes o 0 o ® 0 o

HOLD
S
2nd Yes o o 0 o

HOLD
S 3rd
Below approx.
40 km/h (25 mph)
Yes 0 o o 0 o
HOLD
S 3rd Above approx.

40 km/h (25 mph)
Yes o o o ® 0 o

HOLD

L 1st Yes o o o o o

HOLD

L 2nd Yes o 0 0 o
®: Indicates fluid pressure to servo but band not applied due to pressure difference in servo. 76G07B-006 © : Indicates that it does not function to transmition power.
7B-6

OUTLINE 7B
Operation Table (G4A-HL)
Range Gear
Operation elements
Range Gear Engine braking effect
Forward
clutch
Coasting
clutch
3-4 clutch Reverse clutch
2-4 brake Low & One-way
clutch 1
One-way
clutch 2
Range Gear Engine braking effect
Forward
clutch
Coasting
clutch
3-4 clutch Reverse clutch Applied Released reverse brake
One-way
clutch 1
One-way
clutch 2

P
— —

R
—
Yes O 0
N
— —

D
1st No O O O
D 2nd No
o
O
o
D 3rd Yes
o
O 0
®
0
o
D
OD Yes
© O 0

2 2nd Yes
o o o o

1 1st Yes
o o o o o
1 2nd Yes
o o o o
76G07B-007
® : Indicates fluid pressure to servo but band not applied due to pressure difference in servo.
® : Indicates that it does not function to transmit power.
POWER FLOW DIAGRAM
Neutral
1st gear
7B-7

OUTLINE 7B
FLUID PASSAGE LOCATION
Converter Housing
3-4 clutch
T • •• /V/ . Torque converter (Apply side)
Torque converter (Release side)
To governor valve and
2-3 accumulator
Governor pressure
x
To torque converter
(Release side)^
To torque converter
(Apply side)
To 3-4 clutch
Governor pressure
To governor valve
76G07B-008
7B—9

7B OUTLINE
Transaxle Case
To governor valve
/and 2-3 accumulator
Inlet to control valve body
(governor pressure)
Outlet to torque converter
(Release side)
Outlet to torque converter
(Apply side)
Outlet to 3-4 clutch
To governor valve and 2-3 accumulator^
From governor valve (governor pressure)
To torque converter (Release side)
To torque converter (Apply side)
To 3-4 clutch
From oil pump
(To control valve body)
°Lto coasting clutch
y
To reverse clutch
To forward clutch
To low and reverse brake
To 2-4 brake apply side
CgEfey a —* To 2-4 brake release side
7B—10
76G07B-009

OUTLINE 7B
Transaxle Case
Inlet to control valve body
Outlet coasting clutch
Outlet to reverse clutch
Outlet to forward clutch
Oil Pump
Outlet to oil pump
Outlet for lubrication
Outlet to forward clutch
Inlet to oil pump^
Outlet to reverse clutch
Outlet to coasting clutch
Outlet to control valve body
Inlet for lubrication
Inlet to forward clutch Inlet to coasting clutch
Inlet to reverse clutch
76G07B-010
76G07B-011
7B—11

7B TROUBLESHOOTING (G4A-EL)

ON VEHICLE-
-f-
—OFF VEHICLE

\ Inspection point
and

\ reference page

Condition
•

Electronic control system Prelim-
inary
Hydraulic
control
system
Power train \ Inspection point
and

\ reference page

Condition
•
7B-66

m CO I m r--
7B-63

i
cn to I m
Section

4B

|

Section

4B

|

ID to i m
CO CO 1 CD
7B-68
|
en CO 1 IX)
to 1 00 r-.
cn CD 1 CO
7B-69
|

1 CD r--
i no
cn s-1 m
Section
4B

r*-cn
S-1 CD h-
"=1-
rJ CO
7 CD r-
(XI o
1 m
cn CM 1 CD
7B-107

|
CD
7 CD 7 m
I
7B-113
I
CO CM
7 CO r-.
m cn
7 CO r-.
cn
7 DO r-
CM CM
7 CO

|
7B-126

7 00 r-
CO 7 cn
1*-r*-
7 m r-
\ Inspection point
and

\ reference page

Condition
•
Brake

light
switch

|

Inhibitor

switch

|

Mode

switch

|

1
CO. •o o X
Idle

switch

Throttle

sensor

|

Water

temp,

switch

|
0 tn c 0) cn
s
ffi
Q tn 01 o Hi >
Pulse

generator

|

"a o c 0) a to CM
TJ O CL ID s CO C\l 3-4

solenoid

|

Lock-up
solenoid

I

ATF

level
and
condition

|

Selector

lever

m Xj CO CJ 03
1 sz
Idle
speed
and
Ignition
timing

Control

valves

Accumulators
Oil
pump
Hydraulic

circuit

Torque

converter

Forward

clutch
Coasting
clutch

Reverse

clutch
JT O
u TT ro 2-4

brake
band
and

servo
$ 2
B cn cii > £ "O C CO
o
XI y
o >. CO S cb a O
One-way

clutch

2

s CI Cn tz JC 5 0-
Planetary

gear

Differential

assembly
Accelerating

Vehicle does
not
move
in
D,
S,
L,
or R
range
O O O O O O O O O O 0

Accelerating

Vehicle moves
in N
range -0 0 -—

Accelerating
Excessive creep
-0 O O -—

Accelerating
No creep
at all
O o o o
o
G 0 O O

Shifting

|

No shift
O O o
o
0 O 0 0
o
o O

Shifting

|
Abnormal shift sequence
0 o O O 0
o
o 0 O o o 0 O

Shifting

|
Frequent shifting 0 o 0 0 o 0 O O 0

Shifting

|

Excessively high
or
low
shift point 0 o 0 O 0 0 o 0 O 0 0
Shifting

|

No lock-up
0 o 0 0 o 0 O O o O

Shifting

|

No kick-down o o o o

Slipping

Engine
run
away
or
slip when
starting vehicle 0 o 0 O o O

Slipping
Engine
run
away
or
slip when
up-
or
down-shifting o o o 0 o O 0 0 O
8 n cn 4S SI V)
Excessive
N to D or N to R

shift shock o O o o o O
8 n cn 4S SI V)
Excessive shift shock when
up-

shifting
or
downshifting o o o o 0 0 0 8 n cn 4S SI V) Excessive shift shock when
changing range 0 0 o 0 o

j
Noise

Transaxle noisy
in N or P

range o o 0 O

j
Noise

Transaxle noisy
in D, S, L,
or

R range o 0 0 O

I
Others

j

No engine braking o O o 0 o o

I
Others

j

No mode change o 0 o o o o o o o
O
o
0

I
Others

j
Transaxle overheats
o o
0 o 0 o 0

I
Others

j
Vehicle moves
in
"P",
or
park-ing gear
not

disengaged when
"P"
is
dis-
engaged
0 O

I
Others

j

Hold indicator flashes o
0
o
0
o
O
o — — —
I
Others

j

Engine will
not
start
o
o
O — — —
76G07B-014
7B—14

TROUBLESHOOTING (G4A-EL) 7B
7. Perform the stall test for the following ranges in the same manner.
(1) D range (4) L range
(2) D range (Hold) (5) L range (Hold)
(3) S range (Hold)
Caution
Be sure to allow sufficient cooling time between each stall test.
Engine stall speed: D.S.L range 2170—2270 rpm
R range 2130—2230 rpm
Note
The stall test can be performed with the EC-AT Tester in place of a tachometer.
Drum stall speed indication: 0 rpm
76G0/B-029
Evaluation
Condition Possible cause
Above specification
In all ranges Insufficient line
pressure
Worn oil pump
Above specification
In all ranges Insufficient line
pressure Oil leakage from oil pump, control valve, and/or transmission case
Stuck pressure regulator valve
Above specification
In forward ranges Forward clutch slipping One-way clutch 1 slipping
Above specification
In D range One-way clutch 2 slipping
Above specification
In S (Hold) and L (Hold) ranges Coasting clutch slipping
Above specification In D (Hold) and S (Hold) ranges 2-4 brake band slipping Above specification
In R, L and L (Hold) ranges Low and reverse brake slipping
Above specification
In R range
Low and reverse brake slipping Reverse cluch slipping Perform road test to determine whether problem is low and reverse brake or reverse clutch
a) Engine brake applied in 1st ...Reverse clutch
b) Engine brake not applied in 1st ...Low and reverse brake
Within specification All shift control elements within transmission are func-
tioning normally.
Below specification
Engine out of tune
Below specification One-way clutch slipping within torque converter
86U07B-036
7B-29