clock MAZDA 626 1987 User Guide

DISASSEMBLY 7 A
Disassembly Note
Transaxle
Mount the transaxle on the SST.
86U07A-037
Lock nut
1. Lock the primary shaft with the SST.
2. Shift to 1st or 2nd gear.
3. Remove the lock nut.
86U07A-038
Shift rod
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Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the
control lever, then turn the shift rod counter-
clockwise.
2. While holding the 1st-2nd shift fork with one hand
and the 3rd-4th shift fork with the other, raise them
both at the same time and shift each of the clutch
hub sleeves.
86U07A-039
3. Lift the control end and remove the steel ball, and,
at the same time, remove the shift rod from the
clutch housing.
4. Separate the shift rod and shift fork assembly from
each of the clutch hub sleeves.
76U07A-227
7A-19

ELECTRICAL SYSTEM COMPONENTS 7B
Inspection of Continuity
1. Disconnect the brake light switch connector.
2. Check for continuity between the terminals while
depressing the brake pedal.
79G07C-114
76G07B-076
KICK-DOWN SWITCH (G4A-HL)
Inspection of Terminal Voltage
1. Turn the ignition switch ON.
2. Check the voltage at terminal (V) with a voltmeter.
Depressing stroke Terminal voltage
7/8-8/8 (Full) Approx. 12V
0-7/8 Below 1,5V
3. If not correct, check the wiring harness, switch, or
adjust the switch position.
Inspection of Continuty
1. Disconnect the kick-down switch connector.
2. Check for continuity of the switch with an
ohmmeter.
Switch Continuity
Pushed Yes
Released No
3. If not correct, replace the kick-down switch.
76G07B-077
Adjustment
1. Loosen the kick-down switch locknuts.
2. Depress the accelerator pedal fully.
3. Turn the switch until the threaded case touches the
stopper.
4. Turn the switch counterclockwise by one half revo-
lution.
5. Secure the switch with the locknut.
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7B—67

ON-VEHICLE MAINTENANCE 7B
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76G07B-093
76G07B-094
Main fuse block (G4A-EL)
Install the main fuse block.
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
Battery carrier
Install the battery carrier.
Tightening torque:
31—40 Nm (3.2—4.1 m-kg, 23—30 ft-lb)
ATF level
After installation, add ATF, and with the engine idling,
check the fluid level and for leaks. (Refer to page
7 B—71)
Adjustment (G4A-EL)
1. Remove the splash shield next to the left front tire.
2. Remove the square head plug L and install the
SST
3. Shift into P range and start the engine. Warm up
the engine to normal operating temperature, and
adjust the idle speed.
Idle speed: 950 ±5o rpm
76G07B-095
3 CO CO 03

(1)

L
Line pressure
beeing to increase
I
Adjusting point

•
clockwise Counter
clockwise Position of locknuts
86U07B-482
4. Adjust locknuts as follows:
When the locknuts are moved, line pressure is in-
creased or decreased as shown. Adjust the lock-
nuts to the correct position using the following
procedure.
(1) Initially install the locknuts fully away from the
throttle cam. (Loosen the cable all the way)
(2) Adjust the locknuts in a clockwise direction as
viewed from the front of the vehicle until the
line pressure begins to increase above the
specification shown below.
7B—75

7B ON-VEHICLE MAINTENANCE
Line pressure decreases
Line pressure increases
86U07B-483
Protector
-7 / Throttle cable
86U07B-080
(3) Adjust the locknuts in a counterclockwise direc-
tion until the line pressure decreases to the
specification. Tighten the locknuts.
Specified pressure: 432—450 kPa
(4.4—4.6 kg/cm2, 63—66 psi)
Note
Transmission in P range
5. Turn off the engine.
6. Reinstall the square head plug.
Tightening torque:
5—10 N m (50—100 cm-kg, 43—87 in-lb)
7. Fully open the throttle valve; then crimp the pin with
the protector installed as shown.
8. Remove the protector.
Adjustment (G4A-HL)
1. Remove the splash shield next to the left front tire.
2. Remove the square head plug T and install the
SST
3. Shift into P range and start the engine. Warm up
the engine to normal operating temperature, and
adjust the idle speed.
Idle speed: 900 -5o rpm
76G07B-096
3 tn tn (1)
L
Counter- ^ clockwise
Throttle pressure
beeing to increase
I Adjusting point
Position of locknuts
Clockwise
4. Adjust locknuts as follows:
When the locknuts are moved, throttle pressure is
increased or decreased as shown. Adjust the lock-
nuts to the correct position using the following
procedure.
(1) Initially install the locknuts fully away from the
throttle cam. (Loosen the cable all the way)
(2) Adjust the locknuts in a clockwise direction as
viewed from the front of the vehicle until the
throttle pressure begins to increase above the
specification shown below.
76G07B-097
7B—76

ON-VEHICLE MAINTENANCE 7B
Line pressure decreases
Line pressure increases
76G07B-098
Protector
NAAA/V^
/NA/w^nJ
Throttle cable Crimp
86U07B-080
(3) Adjust the locknuts in a counterclockwise direc-
tion until the throttle pressure decreases to the
specification. Tighten the locknuts.
Specified pressure: 88—108 kPa
(0.9—1.1 kg/cm2, 13—16 psi)
Note
Transmission in P range
5. Turn off the engine.
6. Reinstall the square head plug.
Tightening torque:
5—10 N m (50—100 cm-kg, 43—87 in-lb)
7. Fully open the throttle valve; then crimp the pin with
the protector installed as shown.
8. Remove the protector.
CONTROL VALVE BODY
Note
Remove the control valve body only if
troubleshooting indicates a probable failure.
Removal
1. Remove the throttle cable. (Refer to 7B—73)
2. Disconnect the solenoid connector.
76G07B-099
3. Remove the control valve body.
Disassembly, Inspection and Assembly
Refer to control valve body section of INSPECTION
AND REPAIR.
86U07B-082
7B—77

7B INSPECTION AND REPAIR
SMALL SUN GEAR AND ONE-WAY CLUTCH
Disassembly
Disassemble in the sequence shown in the figure.
1. Thrust bearing
2. Snap ring
3. One-way clutch
inner race
4. Thrust bearing
5. Snap ring
6. Small sun gear
7. Sun gear drum
8. Thrust bearing
9. One-way clutch
outer race
10. One-way clutch
86U07B-221
Inspection
Check the following and replace any faulty parts.
1. Sun gear drum and small sun gear for damage or
wear
2. Bushing for damage or wear
Specification:
Sun gear drum: 33.425 mm (1.316 in) max.
Small sun gear: 24.021 mm (0.946 in) max.
86U07B-222
3. Inner and outer race for damage or wear
4. Damaged or worn clutch hub
5. Damaged or worn gear
6. Damaged or worn thrust bearing
7. Broken or worn snap ring
8. One-way clutch operation
Hold the one-way clutch outer race. Check that the
inner race turns only counterclockwise.
86U07B-223
7B—122

7B INSPECTION AND REPAIR
86U07B-228
86U07B-229
86U07B-230
7. Install the one-way clutch inner race into the one-
way clutch outer race by turning inner race coun-
terclockwise.
8. Hold the one-way clutch outer race. Check that the
inner race turns only counterclockwise.
Assembly
1. Install the small sun gear into the sun gear drum.
2. Install the snap ring.
3. Apply petroleum jelly to the thrust bearing to se-
cure it; then install it to the one-way clutch inner
race.
Thrust bearing outer diameter:
62.1 mm (2.44 in)
4. Install the one-way clutch inner and outer race to
the sun gear drum.
Note
Align the splines of the one-way clutch inner
race and small sun gear clutch hub.
86U07B-231
7B—124

INSPECTION AND REPAIR 7B
5. Install the snap ring.
86U07B-232
86U07B-233
6. Check that when the small sun gear is held, the
one-way clutch outer race turns smoothly and only
clockwise.
7. Apply petroleum jelly to the thrust bearing to se-
cure it; then install it to the sun gear drum.
Thrust bearing outer diameter:
72.0 mm (2.83 in)
86U07B-234
7B—125

INSPECTION AND REPAIR 7B
One-way clutch 6. Damaged or worn one-way clutch and operation
7. Detached roller
Note
Assemble the one-way clutch and the inner
race, then confirm that the one-way clutch ro-
tates only clockwise and smoothly.
86U07B-238
Assembly
1. Assemble the carrier hub assembly to the inner
race.
86U07B-239
2. Install th snap ring.
86U07B-240
3. Apply petroleum jelly to the bearing races to se-
cure them; then install them to both sides of the
one-way clutch and carrier hub assembly.
Bearing race outer diameter
Sun gear drum side: 72.0 mm (2.83 in)
3-4 clutch side: 57.0 mm (2.21 in)
Note
Install the tabs of the bearing race into the
alignment holes.
86U07B-241
7B—127

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.
86U07B-409
7B-205