MAZDA 626 1987 Workshop Manual

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
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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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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 INSPECTION AND REPAIR
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12. Check the coasting clutch clearance.
(1) Measure the clearance between the snap ring
and the retaining plate of the coasting clutch.
(2) If the clearance is not within specification, ad-
just it by selecting a proper retaining plate.
Coasting clutch clearance:
1.0—1.2 mm (0.040—0.047 in)
Retaining plate sizes mm (in)
4.6 (0.181) 4.8 (0.189) 5.0 (0.197)
5.2 (0.205) 5.4 (0.213) 5.6 (0.220)
Forward clutch
1. Install the dished plate with the dished side
downward.
2. Install the drive and driven plates.
Note
Installation order:
Driven-Drive-Driven-Drive-Driven-Drive
3. Install the retaining plate.
4. Install the snap ring.
5. Check the forward clutch clearance.
(1) Measure the clearance between the snap ring
and the retaining plate of the forward clutch.
(2) If the clearance is not within specification, ad-
just it by selecting a proper retaining plate.
Forward clutch clearance:
1.0—1.2 mm (0.040—0.047 in)
Retaining plate sizes mm (in)
5.9 (0.232) 6.1 (0.240) 6.3 (0.248)
6.5 (0.256) 6.7 (0.264) 8.9 (0.350)
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7B—120

INSPECTION AND REPAIR 7B
6. Check for the clutch operation as follows.
(1) Set the clutch assembly onto the oil pump.
(2) Check the clutch operation by applying com-
pressed air through the fluid passages as
shown.
Applied air pressure:
392 kPa (4.0 kg/cm2, 57 psi)
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(3) Pour in ATF so that the reverse piston, coast-
ing clutch drum, and coasting clutch piston are
fully submerged.
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(4) Check that no bubbles come from between the
piston and drum seal when applying com-
pressed air through the fluid passages as
shown.
Caution
The compressed air must be under 392 kPa
(4.0 kg/cm2, 57 psi), and should not applied
for over 3 seconds.
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7. Apply petroleum jelly to the thrust bearings to se-
cure them; then install them on both sides of the
reverse and forward drum.
Thrust bearing outer diameter
Oil pump side: 86.0 mm (3.39 in)
Small sun gear and one-way clutch side:
56.1 mm (2.21 in)
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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
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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.
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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.
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INSPECTION AND REPAIR 7B
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Replacement of one-way clutch
1. Remove the one-way clutch inner race.
2. Remove the one-way clutch.
3. Remove the thrust bearing.
4. Inspect the one-way clutch inner and outer race,
and replace if necessary.
5. 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)
6. Install the one-way clutch into the one-way clutch
outer race.
Caution
Check that the spring cage of the one-way
clutch faces toward the outer race.
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7B INSPECTION AND REPAIR
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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.
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