clutch MAZDA 626 1987 Workshop Manual

7B INSPECTION AND REPAIR
3. Install the SST to the 3-4 clutch as shown.
4. Compress the spring and retainer assembly.
5. Install the snap ring.
6. Remove the SST.
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G4A-EL G4A-HL
76G07B-134
76G07B-135
7. Install the dished plate the dished side up ward
(G4A-HL).
8. Install the drive and driven plates.
Note
Installation order:
G4A-EL
Driven-Drive-Driven-Drive-Driven-Drive-
Driven-Drive-Driven-Drive
G4A-HL
Driven-Drive-Driven-Drive-Driven-Drive-
Driven-Drive
9. Install the retaining plate with the step facing
upward.
10. Install the snap ring.
11. Check the 3-4 clutch clearance.
(1) Measure the clearance between the snap ring
and the retaining plate of the 3-4 clutch.
(2) If the clearance is not within specification, ad-
just it by selecting a proper retaining plate.
3-4 clutch clearance:
1.3—1.5 mm (0.051—0.059 in)
Retaining plate sizes
G4A-EL
mm (in)
3.8 (0.150) 4.0 (0.157) 4.2 (0.165)
4.4 (0.173) 4.6 (0.181) 4.8 (0.189)
G4A-HL
4.8 (0.189) 5.0 (0.197) 5.2 (0.205)
5.4 (0.213) 5.6 (0.220)
12. Check clutch operation as follows:
(1) Install the SST as shown, and check clutch
operation by applying compressed air.
Air pressure:
392 kPa (4.0 kg/cm2, 57 psi)
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INSPECTION AND REPAIR 7B
(2) Pour ATF into the clutch drum so that the 3-4
clutch piston is fully submerged.
(3) Check that no bubbles come from the 3-4
clutch piston seal while applying compressed
air.
Caution
The compressed air must be under 392 kPa
(4.0 kg/cm2, 57 psi) and not applied for over
3 seconds.
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13. Apply petroleum jelly to the thrust bearings and se-
cure them to both sides of the 3-4 clutch drum.
Thrust bearing outer diameter
Carrier hub side: 56.1 mm (2.21 in)
Output shell side: 72.1 mm (2.84 in)
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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
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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
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7B—155

7B ASSEMBLY
11. Install the SST to the differential side gear.
Caution
Failure to install the SST may allow the
differential side gears to become misposi-
tioned.
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ASSEMBLY-STEP 3
Procedure
1. Temporarily install the SST to hold the turbine shaft.
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w
2. Install the turbine shaft and 3-4 clutch assembly.
(1) Assemble the turbine shaft and 3-4 clutch as-
sembly.
86U07B-396
(2) Check that the thrust bearing and bearing race
are installed in the correct position.
(3) Install the turbine shaft and 3-4 clutch assem-
bly into the transaxle case.
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ASSEMBLY 7B
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86U07B-399
86U07B-400
3. Adjust the SST position so that it contacts and
holds the turbine shaft.
Install the internal gear.
(1) Install the internal gear to the 3-4 clutch drum.
(2) Install the snap ring.
Install the carrier hub assembly.
(1) Check that the thrust bearing and bearing race
are installed in the correct position.
(2) Hold the turbine shaft with one hand to pre-
vent it from rotating.
(3) Install the carrier hub assembly into the 3-4
clutch drum by rotating it.
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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.
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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.
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ASSEMBLY 7B
(2) Install the clutch assembly by rotating it.
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Note
Measure the height difference between the re-
verse and forward drum and transaxle case.
Standard height: 0.8 mm (0.032 in)
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17. Install the snap ring into the bottom ring groove
of the turbine shaft.
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7B—207

ASSEMBLY 7B
86U07B-418
86U07B-419
76G07B-223
Procedure
1. Use the following procedure to adjust the total end
play and select a suitable bearing race.
(1) Set the thrust bearing onto the clutch assembly.
(2) Remove the previous race and gasket.
(3) Set the thickest bearing race 2.2 mm (0.087
in) onto the oil pump.
(4) Set the oil pump onto the clutch assembly.
(5) Measure clearance between the transaxle case
and oil pump.
(6) Select a suitable bearing race from the chart
below.
Clearance mm (in) Select this bearing race mm (in)
0.91-1.10 (0.036—0.043) 1.2 (0.047)
0.71-0.90 (0.028-0.035) 1.4 (0.055)
0.51-0.70 (0.020—0.027) 1.6 (0.063)
0.31-0.50 (0.012-0.019) 1.8 (0.071)
0.11-0.30 (0.004-0.011) 2.0 (0.078)
0-0.10 (0-0.003) 2.2 (0.087)
(7) Remove the oil pump.
(8) Place the selected bearing race and a new gas-
ket onto the oil pump.
(9) Install the oil pump onto the clutch assembly.
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
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