Brake MAZDA 626 1987 Workshop Manual

TROUBLESHOOTING
7C

ON VEHICLE -OFF VEHICLE
-

\ Inspection point
\
and
reference
\ page
Condition


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7C—27
7C—23,24
Section
4A

7C—14
7C—20,22
7C-75

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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
STEP 2 (STALL TEST)
This step is performed to determine if there is slippage of the friction elements or malfunction of the
hydraulic components.
Preparation
Check the following items prior to testing:
1. Engine coolant, engine oil and ATF levels.
2. Warm the engine thoroughly to raise the ATF temperature to operating level (50—80°C, 122—176°F).
3. Set the parking brake and block the front and rear of the wheels.
Pull the parking brake Water temperature
ATF
7C—14
76G07C-024

TROUBLESHOOTING 7C
Procedure
76G07C-025
1. Connect a tachometer to the engine.
2. Shift the selector lever to D range.
3. Depress the brake pedal firmly with the left foot, and gradually depress the accelerator pedal with
the right foot.
4. Read and note the engine speed as soon as it becomes constant; then release the accelerator pedal.
Caution
Steps 3 to 4 must be done within 5 seconds.
5. Shift the selector to N range and let the engine idle for one minute or more.
Note The idling cools the ATF and prevents oil degeneration.
6. Perform stall tests for the following ranges in the same manner.
(1) 2 range
(2) 1 range
(3) R range
Standard stall speed:
FE engine 2050—2150 rpm
F6 engine 1800—2050 rpm
Caution
Always provide adequate cooling time between individual range stall tests.
7C-15

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

TROUBLESHOOTING 7C
STEP 3 (TIME LAG TEST)
When the selector lever is shifted while the engine is idling, there is a certain time lapse, or time lag,
before shock is felt. This time lag test checks the condition of the front, rear, and one-way clutch, low
and reverse brake, and orifice check valve.
Preparation
Follow the test preparation procedure shown in STEP 2 (STALL TEST).
Procedure
1. Start the engine and verify that the idle speed is 950tso rpm.
2. Shift from N range to D range
3. Measure the time it takes from shifting until shock is felt with a stop watch.
4. Shift the selector to N range and run the engine at idle for one minute or more.
5. Perform the test for N range to R range in the same manner.
Note
Make three measurements for each test and take the average value.
Specified time lag: N D range 0.5—1.0 second
N R range 0.5—1.0 second
Evaluation
Condition Possible Cause
N -» D shift More than specification
Insufficient line pressure
N -» D shift More than specification Rear clutch slipping N -» D shift More than specification
One-way clutch slipping N -» D shift
Less than specification N-D accumulator not operating properly
N-R shift
More than specification
Insufficient line pressure
N-R shift
More than specification Low and reverse brake slipping
N-R shift
More than specification
Front clutch slipping N-R shift
Less than specification Stuck orifice check valve
N-R shift
Less than specification Excessive line pressure
76G07C-027
7C-17

7C TROUBLESHOOTING
STEP 4 (ROAD TEST)
This step is performed to check for problems in the various ranges. If these tests show any problems,
adjust or replace by referring to the QUICK DIAGNOSIS CHART and mechanical sections.
Caution
Perform the test at normal ATF operating temperature (50—80°C, 122—176°F).
Gearshift Function Check Items
1. Shift shock must be minimal, and shifting must be smooth.
2. Engine speed must not run away, and the shifting must not be delayed.
3. Transaxle must shift through Di D2 -»• D3 in D range.
4. Transaxle must shift from 3rd in D range to 2nd gear when 2 range is selected.
5. Transaxle must shift from 2nd to 1st when 1 range is selected from 3rd gear in D range.
6. Transaxle must not upshift in 1 range.
7. Transaxle must remain in 2nd gear in 2 range.
8. Transaxle must positively lock in P range.
The transaxle must positively lock when P range is selected while moving at a speed below 4 km/h
(2.5 mph) on level ground. The transaxle must positively lock when set in P range with the vehicle
on a gentle slope and the brakes disengaged.
Shift Speed
Throttle condition
(manifold vacuum) Hange Shift Vehicle speed km/h (mph) Throttle condition
(manifold vacuum) Hange Shift FE engine F6 engine
Fully opened 0—100 mmHg (0-3.94 inHg)
D
1st - 2nd 47—57 (29—35) 44-54 (27-33)
Fully opened 0—100 mmHg (0-3.94 inHg)
D 2nd - 3rd 106-119 (66—74) 95-108 (59-67) Fully opened 0—100 mmHg (0-3.94 inHg)
D 3rd - 2nd 95-103 (59-64) 86-94 (53-58)
Fully opened 0—100 mmHg (0-3.94 inHg)
D
2nd - 1st 35-39 (22-24) 34-38 (21-24)
Half-throttle 130 mmHg (5.12 inHg) D 1st - 2nd 18-31 (11-19) 18-31 (11-19) Half-throttle 130 mmHg (5.12 inHg) D 2nd -»• 3rd 39-68 (24—42) 44-73 (27-45)
Fully closed D 2nd - 1st 10-15 (6-9) 10-15 (6-9) Fully closed 1 2nd - 1st 32—39 (20-24) 33-40 (20-25)
1. Full-throttle: The throttle opening during kick-down when the manifold vacuum is between 0—100
mmHg (0—3.94 inHg)
2. Half-throttle: The throttle opening at manifold vacuum of 130 mmHg (5.12 inHg) 76G07C-028
7C-18

7C TROUBLESHOOTING
STEP 5 (OIL PRESSURE TEST)
This step determines line pressure, and governor pressure to check the hydraulic components and
for oil leakage.
Line Pressure Test
Preparation
1. Connect the SST to the line pressure output point.
2. Connect a tachometer to the engine.
3. Follow the test preparation procedure show in STEP 2 (STALL TEST).
Procedure
76G07C-030
1. Start the engine and verify that the idle speed is 950-5° rpm.
2. Shift the selector lever to D range.
3. Read the line pressure at idle.
4. Depress the brake pedal firmly with the left foot, and gradually depress the accelerator pedal with
the right foot.
5. Read the line pressure as soon as the engine speed becomes constant; then release the accelera-
tor pedal.
Caution
Steps 4 to 5 must be done within 5 seconds.
5. Shift the selector lever to N range and let the engine idle for one minute or more.
6. Read the line pressure at idle and engine stall speeds for each range in the same manner.
7C—20

TROUBLESHOOTING 7C
Specified line pressure:
Range Pressure kPa (kg/cm2, psi) Range
Idle Stall
D 294-392 (3-4, 43-57) 883-1079 (9—11, 128-156)
2 785—1177 (8—12, 114—171) 785-1177 (8—12, 114-171)
1 294-392 (3-4, 43—57) 883-1079 (9—11, 128—156)
R 392-687 (4-7, 57-100) 1570—1864 (16—19, 228-270)
76G07C-031
Evaluation
Condition Possible cause
Below standard
In all ranges
Worn oil pump
Below standard
In all ranges Fluid leakage from the oil pump, control valve, or transaxle case
Below standard
In all ranges
Stuck pressure regulator valve Below standard
In D, 1, 2 ranges Fluid leakage from the rear clutch or governor hydraulic circuit, or both
Below standard
In R range only Fluid leakage from the low and reverse brake hydraulic circuit
Excessive line pressure at idle Leaking or disconnected vacuum hose Excessive line pressure at idle
Leaking vacuum diaphragm
76G07C-032
76G07C-033
Vacuum
gauge Line
pressure
Governor pressure
At Atmosphere Radical line Read
& 200 mmHg pressure governor
(7.87 inHg) reduction
Line Pressure Cutback Point
1. Connect the SST to the line pressure output point
and the governor pressure output point in the trans-
axle case, and place the gauges inside the vehicle.
2. Disconnect the hose to the vacuum diaphragm,
and plug it.
3. Connect a vacuum pump to the vacuum di-
aphragm, and place the pump inside the vehicle.
4. Gradually accelerate the vehicle in D range.
5. Read the governor pressure at the point where the
line pressure suddenly drops.
6. Apply 200 mmHg (7.87 inHg) vacuum, and re-
peat steps 4 and 5.
Standard
Vacuum mmHg (InHg) Governor pressure kPa (kg/cm2, psi)
Atmospheric pressure 98-157 (1.0—1.6, 14-23)
200 (7.87) 39-98 (0.4-1.0, 6—14)
Evaluation
Incorrect pressures
1. Missing diaphragm rod or rod length incorrect, or
both.
2. Stuck valve in control valve.
76G07C-034
7C—21

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
76G07C-041
©
i
©
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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.
76G07C-042
7C-25