MAZDA 626 1987 Workshop Manual

INSTALLATION 7A
14. Install the clutch release cylinder.
Tightening torque: 19—26 N-m
(1.9—2.6 m-kg, 14—19 ft-lb)
76G07A-060
15. Install the gusset plates.
Tightening torque: 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
76G07A-061
16. Replace the clips at the end of the driveshafts and
joint shaft with new ones.
17. Install the joint shaft and right driveshaft as follows:
(1) Install and tighten the reamer bolts (A); then in-
stall and tighten the standard bolts (§).
Tightening torque:
® :7—10 N-m
(70—100 cm-kg, 43—61 in-lb)
(B) :42—62 Nm
(4.3—6.3 m-kg, 31—46 ft-lb)
76G07A-062
(2) Remove the SST and insert the shaft into the
transaxle.
(3) Pull the front hub outward and connect the
driveshaft to the joint shaft.
(4) Push the joint at the differential side to secure-
ly connect the driveshaft to the joint shaft.
Note
a) After installation, pull the front hub outward
to confirm that the driveshaft doesn't come
out.
b)Do not damage the oil seal.
86U07A-219
7A-55

7A INSTALLATION
76G07A-063
76G07A-064
18. Install the left driveshaft as follows:
(1) Pull the front hub outward and insert the
driveshaft into the transaxle.
(2) Push the joint at the differential side to connect
the driveshaft to the differential side gear.
Note
a) Do not damage the oil seal.
b) After installation, pull the front hub outward
to confirm that the driveshaft doesn't come
out.
19. Install the lower arm ball joints to the knuckles and
tighten the bolts and nuts.
Tightening torque: 43—54 N-m
(4.4—5.5 m-kg, 32—40 ft-lb)
20. Install the under cover, (except DOHC)
Note
Before installation, fill the notches with sili-
con as shown in the figure.
Tightening torque: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
21. Install the stabilizer bar control links as follows.
(1) Install the stabilizer bar control link.
(2) Adjust protrusion to 20.1 mm (0.79 in)
(3) Tighten bolt to specified torque.
Tightening torque: 16—23 N-m
(1.6—2.3 m-kg , 12—17 ft-lb)
76G07A-065
76G07A-066
22. Install the tie-rod ends and new cotter pine.
Tightening torque: 29—44 N-m
(3.0—4.5 m-kg, 22—33 ft-lb)
23. Install the splash shields.
Tightening torque: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
24. Install the front wheels.
Tightening torque: 88—118 N-m
(9.0—12.0 m-kg, 65—87 ft-lb)
—56

INSTALLATION 7A
25. Install the grounds to the transaxle case.
Tightening torque:
8—11 N-m (80—115 cm-kg, 69—100 in-lb)
26. Connect the speedometer cable.
76G07A-067
76G07A-068
76G07A-069
76G07A-070
27. Install the intercooler pipe and hose. (RF-CX)
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
28. Install the brake vacuum pipe. (RF-CX)
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
29. Connect the brake vacuum hose. (RF-CX)
30. Install the air cleaner assembly and connect the
air flow meter connector.
Tightening torque:
16—27 Nm (1.6—2.8 m-kg, 12—20 ft-lb)
31. Connect the distributor lead.
32. Connect the main fuse block.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
33. Install the battery carrier and battery.
34. Add the correct quantity of the specified transaxle
oil.
Specified
Type
A.T.F.: DEXRON II
Above 0°F:
API: GL-4 or GL-5
SAE 80W-90 or SAE 90
Capacity:
3.35 liters (3.6 US qt, 3.0 Imp qt)
7A-57

7A TRANSAXLE CONTROL
TRANSAXLE CONTROL
REMOVAL AND INSTALLATION
1. Jack up the vehicle and support it with safety stands.
2. Remove in the sequence shown in the figure.
3. Install in the reverse order of removal. 61G07X-165
86U07A-230
1. Change lever knob
2. Assist boot
3. Mounting rubber boot
4. Bolts and nuts
5. Change control rod
6. Bracket installation nuts
7. Nut and washer
8. Extension bar bracket as-
sembly and gasket
9. Bushing
10. Pipe
11. Change lever
12. Spring
13. Ball seat (upper)
14. Bushings
15. Boot
16. Holder
17. Ball seat (lower)
18. Extention bar
Note
Apply a coat of grease (lithium base, NLGI No. 2) to the change lever ball, the ball seats,
and each joint.
7A-58

TRANSAXLE CONTROL 7 A
63U07A-151
61G07X-192
63U07A-153
Spring
Remove the spring by prying on the hooked part of
the spring with a screwdriver.
INSPECTION
Check the following, and replace if necessary:
1. Bent control rod.
2. Wear, damage, or malfunction of any joint.
3. Damaged gear shift lever ball.
4. Weak spring.
5. Wear or damage of bushing.
INSTALLATION
Install in the reverse order of removal and note the
following:
Extension Bar
First, install the extension bar to the floor, and then
install it onto the transaxle.
Tightening torque:
31—46 Nm (3.2—4.7 m-kg, 23—34 ft-lb)
Bracket Installation
Tighten the bracket installation nuts to the specified
torque.
Tightening torque: 7—10 N-m
(70—100 cm-kg, 61—87 in-lb)
76G07A-071
7A-59

7A TRANSAXLE CONTROL
Gear Shift Lever Ball
Apply grease to the ball seat surface, and install the
upper and lower ball seat, holder, and boot.
Note
Apply grease to all joints.
61G07X-193
Spring
Make sure that the hooked part of the spring is
properly seated in the bracket groove, as shown in
the figure.
63U07A-156
Bracket Cavity
Put grease in the bracket cavity.
63U07A-157
Change Control Rod
Install the change control rod so that its relationship
with the shift lever is as shown in the figure.
Tightening torque:
16—22
N
m (1.6—2.3 m-kg, 12—17 ft-lb)
61G07X-195
7A-60

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
COMPONENT LOCATION
G4A-EL
76G07B-003
1. Hold indicator light
2. EC-AT control unit
3. Vehicle speed sensor
4. Mode indicator light
5. Cruise control unit
6. Cruise control switch
7. Mode switch
8. Hold switch
9. Water temperature switch
10. Throttle sensor and idle
switch
11. Fluid temperature switch
12. EC-AT
13. Pulse genelator
14. Solenoid valves
15. Inhibitor switch
7B-3

7B OUTLINE
G4A-HL
1. OD OFF indicator light
2. OD OFF switch
3. Kick-down switch
4. Cruise control unit
5. Cruise control switch
6. Water temperature switch
7. Inhibitor switch
8. OD release solenoid valve
9. Automatic transaxle
76G07B-004
7B—4