clutch MAZDA 626 1987 Workshop Manual

DISASSEMBLY 7B
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(2) Remove the one-way clutch together with the
carrier hub assembly.
8. Remove the low and reverse brake assembly.
(1) Remove the snap ring.
(2) Remove the retaining plate and the drive and
driven plates.
9. Remove the internal gear.
(1) Remove the snap ring.
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7B DISASSEMBLY
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(2) Remove the internal gear from the 3-4 clutch
drum.
10. Remove the 3-4 clutch assembly.
(1) Remove the O-ring from the turbine shaft at the
converter housing side.
(2) Pull out the turbine shaft to remove the 3-4
clutch assembly.
(3) Remove the 3-4 clutch assembly.
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7B—98

INSPECTION AND REPAIR 7B
INSPECTION AND REPAIR
PRECAUTION
(1) Several of the parts resemble each other; organize them so that they do not get mixed up.
(2) Clean each part with cleaning oil, clean out the oil holes and oil passages with compressed air,
and check that there are no obstructions.
(3) When using cleaning oil and compressed air, wear protective eyewear.
(4) If a clutch plate or brake band is replaced with a new one, soak it in ATF for 2 hours or more
before installing.
(5) Before assembly, apply ATF to all seal rings, rotating parts, and sliding parts.
(6) All seals, gaskets and roll pins must be replaced with new ones during assembly.
(7) Use petroleum jelly, not grease where required.
(8) When it is necessary to replace a bushing, replace the assembly which includes that bushing.
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TORQUE CONVERTER
The torque converter is welded together and cannot
be disassembled.
Inspection
1. Check the outer part of the converter for damage
or cracks, and replace it if necessary.
2. Check whether there is any rust on the pilot hub
of the converter or on the boss. If there is any, re-
move it completely.
3. Measure the bushing of the converter boss. Re-
place the converter assembly if the bushing is
worn.
Bushing inner diameter
Standard: 53.030 mm (2.088 in)
Maximum: 53.076 mm (2.090 in)
Washing Inside of Converter
1. Drain any ATF remaining in the converter.
2. Pour in solvent [approximately 0.5 liter (0.53 US
qt, 0.44 Imp qt) ].
3. Shake the converter to clean the inside. Pour out
the solvent.
4. Clean the inside of the converter with compressed
air so that the inside is perfectly empty.
5. Pour in ATF.
6. Shake the converter to clean the inside. Pour out
the ATF.
7B—107

INSPECTION AND REPAIR 7B
CLUTCH ASSEMBLY
Disassembly
Disassemble in the sequence shown in the figure referring to the disassembly note for the specially
marked parts.
—Forward clutch—
1. Thrust bearings
2. Snap ring
3. Retaining plate
4. Drive and driven plates
5. Dished plate
—Coasting clutch—
6. Snap ring
7. Retaining plate
8. Drive and driven plates
9. Dished plate
10. Snap ring
11. Spring and retainer as-
sembly
12. Coasting clutch drum
13. Coasting piston
14. Outer seal
15. Inner seal
16. Outer seal
17. Seal rings
—Reverse clutch—
18. Snap ring
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19. Retaining plate
20. Drive and driven plates
21. Dished plate
22. Snap ring
23. Return spring stopper
24. Piston return spring
25. Reverse piston
26. Seal rings (inner and outer)
27. Reverse and forward drum
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7B INSPECTION AND REPAIR
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Disassembly note
Coasting clutch drum
1. Install the SST in the coasting clutch drum as
shown.
2. Compress the spring and retainer assembly.
3. Remove the snap ring.
4. Remove the SST, then remove the spring and re-
tainer assembly.
5. Remove the coasting clutch drum from the reverse
and forward drum by applying compressed air
through the fluid passage.
Coasting piston
1. Remove the coasting clutch piston from the coast-
ing clutch drum by applying compressed air
through the fluid passage.
Reverse piston
1. Install the SST in the reverse and forward drum
as shown.
2. Compress the piston return spring.
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INSPECTION AND REPAIR 7B
3. Remove one end of the snap ring from the groove
with snap ring pliers.
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4. Remove the SST from the reverse and forward
drum.
5. Remove the snap ring with a screw driver.
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6. Place the reverse and forward drum on the oil
pump.
7. Remove the reverse piston by applying com-
pressed air through the fluid passage.
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Inspection
Check the following and repair or replace any faulty
parts.
1. Drive and driven plates for damage or wear
Drive plate thickness
Standard: 1.6 mm (0.063 in)
Minimum: 1.4 mm (0.055 in)
2. Clutch piston for damage or cracks
3. Clutch drum for damage or deformation
4. Seal contact area for damage
5. Check ball for leaking sticking
6. Broken or worn snap ring
7. Broken or weakened spring
7B—115

7B INSPECTION AND REPAIR
6. Spring and retainer assembly for separation or
deformation
Free length of spring:
29.8 mm (1.173 in)
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Assembly
Reverse clutch
1. Install the reverse piston.
(1) Apply ATF to inner and outer faces of the seals,
and install them to the reverse piston.
(2) Face the outer seal lip toward the inside by
gently rolling
it
down around the circumference
for easier installation into the reverse clutch
drum.
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(3) Install the reverse piston by pushing evenly
around the circumference, being careful not to
damage the seal rings.
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2. Install the piston return spring with the tabs facing
away from the reverse piston.
3. Install the return spring stopper with the step fac-
ing upwards.
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INSPECTION AND REPAIR 7B
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49 G019 029
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4. Install the snap ring half-way down the reverse for-
ward drum as shown.
5. Install the SST on the reverse and forward drum.
6. Compress the spring and retainer assembly.
7. Install the snap ring with a screwdriver.
8. Remove the SST.
9. Install the dished plate with the dished side facing
the piston as shown.
10. Install the drive and driven plates.
Note
Installation order:
Driven-Drive-Driven-Drive
11. Install the retaining plate with the step facing
downward.
12. Install the snap ring.
13. Check the reverse clutch clearance.
(1) Measure the clearance between the snap ring
and the retaining plate of the reverse clutch.
(2) If the clearance is not within specification, ad-
just it by selecting a proper retaining plate.
Reverse clutch clearance:
2.1—2.4 mm (0.083—0.094 in)
Retaining plate sizes mm (in)
6.6 (0.260) 6.8 (0.268) 7.0 (0.276)
7.2 (0.283) 7.4 (0.291) 7.6 (0.299)
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7B INSPECTION AND REPAIR
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Coasting clutch
1. Install the coasting clutch drum.
(1) Apply ATF to inner and outer faces of the seal,
and install it onto the coasting clutch drum.
(2) Face the outer seal lip toward the inside by
gently rolling it down around the circumference
for easier installation into the drum.
(3) Install the coasting clutch drum the correct po-
sition in the reverse and forward drum.
(4) Push evenly around the circumference, being
careful not to damage the outer seal.
2. Install the coasting piston
(1) Apply ATF to inner and outer faces of the seals
and install them onto the coasting piston.
(2) Face the outer seal lip toward the inside by
gently rolling it down around the circumference
for easier installation into the drum.
(3) Install the coasting piston by pushing evenly
around the circumference, being careful not to
damage the outer seal.
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INSPECTION AND REPAIR 7B
3. Install the spring and retainer assembly.
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4. Install the SST in the coasting clutch as shown.
5. Compress the spring and retainer assembly.
6. Install the snap ring.
7. Remove the SST.
8. Install the dished plate with the dished side upward.
9. Install the drive and driven plates.
Note
Installation order:
Driven-Drive-Driven-Drive
10. Install the retaining plate.
11. Install the snap ring.
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7B—119