clutch MAZDA MX-5 1994 Workshop Manual

K TRANSMISSION CONNECTING SHELL AND FRONT PLANETARY GEAR UNIT (REAR CLUTCH HUB, FRONT PLANETARY PINION CARRIER, REAR SUN GEAR) Disassembly / Inspection / Assembly 1. Disassemble in the order shown in the figure. 2. Inspect all parts, and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. 1. Connecting shell 5. Bearing 2. Front sun gear 6. Bearing 3. Snap ring 7. Snap ring 4. Front planetary pinion carrier 8. Rear clutch hub Inspection . . . . . . . . . . . . . . . . . page K-97 9. Internal gear Gartner Banana

TRANSMISSION K It- CLEARANCE Inspection Front planetary pinion carrier 1. Measure the clearance between the pinion washer and the planetary pinion carrier. Clearance Standard : 0.2--0.7mm (0.008-0.027 in} Maximum : 0.8mm (0.031 in) 2. If not within specification, replace the planetary pinion carrier. Assembly procedure 1. Apply ATF to the rear clutch hub and internal gear, and assemble them with the snap ring. 2. Apple petroleum jelly to the bearing, and install it onto the rear clutch hub with the black surface facing upward. Bearing outer diameter: 70.0mm (2.756 in) 3. Apple petroleum jelly to the bearing, and install it onto the rear clutch hub with the black surface facing upward. Bearing outer diameter: 53.0mm (2.087 in} 4. Apply ATF to the front planetary pinion carrier, and install it into the internal gear. Gartner Banana

K TRANSMISSION 5. Apply ATF to the sun gear, and install it into the front planetary pinion carrier with the groove facing the front (arrow). 6. Apply ATF to the sun gear, and install it into the front planetary pinion carrier. REAR PLANETARY GEAR UNIT (CONNECTING DRUM, REAR PLANETARY PINION CARRIER, ONE-WAY CLUTCH) Preinspection One-way clutch operation Install the rear planetary gear unit and verify that the rear , planetary gear unit rotates smoothly when turned clock- wise and locked when turned counterclockwise. If not, replace the one-way clutch. Gartner Banana

TRANSMISSION K Disassembly / Inspection / Assembly 1. Disassemble in the order shown in the figure. 2. Inspect all parts, and repair or replace as necessary. ,, 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. @ APPLY PETROLEUM JELLY 1. Bearing 7. Drive flange 2. Snap ring 8. Internal gear 3. Rear planetary pinion carrier 9. Snap ring u Inspection . . . . . . . . . . . . . . . . page K-100 10. One-way clutch 4. Bearing 11. Snap ring 5. Bearing 12. Connecting drum 6. Snap ring Gartner Banana

K TRANSMISSION CLEARANCE Inspection Rear planetary pinion carrier 1. Measure the clearance between the pinion washer and the planetary pinion carrier. d Clearance Standard : 0.2--0.7mm (0.008-4.027 in) Maximum : 0.8mm (0.031 in) 2. If not within specification, replace the planetary pinion carrier. Assembly procedure 1. Install the snap ring into the connecting drum. 2. Apple ATF to the one-way clutch. Install it into the con- necting drum, with the arrow pointing toward the front. 3. Apply ATF to the drive flange and internal gear, and install it into the internal gear. 4. Install the snap ring. 5. Apple petroleum jelly to the bearing, and install it onto the drive flange. Bearing outer diameter: 47.0mm (1.850 in) 6. Install the internal gear and the drive flange into the con- necting drum. 7. Apple petroleum jelly to the bearing, and install it onto the drive flange with the black surface facing upward. Bearing outer diameter: 70.0mm (2.756 in) Gartner Banana

TRANSMISSION K 8. Apply ATF to the rear planetary pinion carrier, and install it into the connecting drum. 9. Install the snap ring. 10. Apple petroleum jelly to the bearing, and install it onto the rear planetary pinion carrier with the black surface facing upward. Bearing outer diameter: 70.0mm (2.756 in} 11. Insert the rear planetary gear unit into the transmission case, and verify that the one-way clutch turns counter- clockwise. If it does not, then the one-way clutch is installed upside down. Gartner Banana

K TRANSMISSION LOW AND REVERSE BRAKE Preparation SST Preinspection Low and reverse brake operation 1. Apply compressed air through the oil passage as shown. 49 0378 346 Hex head wrench Air pressure: 392 kPa (4.0 kglcm2, 57 psi) max. For removal I installation of one-way clutch 2. Verify that the retaining plate moves toward the snap ring. If not, the seal ring or O-ring may be damaged or fluid may be leaking at the piston check ball. Inspect them, and replace as necessary when assembling. Clearance between retaining plate and snap ring 1. Measure the clearance between the retaining plate and the snap ring. Clearance: 0.8-1.05mm (0.032--0.041 in) i/ 2. Select and install the correct retaining plate when as- sembling. Gartner Banana

TRANSMISSION K Disassembly 1 Inspection 1 Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts, and repair or replace as necessary. .,, 3. Assemble in the reverse order of disassembly, referring to Assemblv ~rocedure. FRONT @k 12.8-1 7.6 N.m (130-1 80 kgfcm, 113-156 In4bf) I b SELECTIVE 1. Allen-head bolts and dished washers 2. One-way clutch inner race Disassembly note ......... page K-104 3. Thrust washer w 4. Return spring Inspection ................ page K-104 5. Snap ring 6. Retaining plate 7. Drive plates and driven plates Inspection ................ page K-104 8. Low and reverse brake piston Disassembly note ......... page K-104 . Inspection ................ page K-104 9. Seal ring 10. O-ring 11. Transmission case Gartner Banana

K TRANSMISSION Disassembly note One-way clutch inner race 1. Remove the allen-head bolts from the rear of the trans- mission case by using the SST. 4 2. Remove the one-wav clutch inner race, thrust washer, and piston return spring. Low and reverse brake &ton Remove the piston by gpplying compressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. Inspection Drive plate 1. Measure the facing thickness in three places, and deter- mine the average of the three readings. Standard thickness: 2.0mm (0.079 in) Minimum thickness: 1.8mm (0.071 in) 2. If not within specification, replace the drive plates. Return spring 1. Measure the return spring free length. Spring free length: 5.9-6.2mm (0.233-0.244 in) 2. If not within specification, replace the return spring. Clutch piston 1. Verify that there is no air leakage when applying com- pressed air through the oil hole opposite the return spring. 2. Verify that there is airflow when applying compressed air through the oil hole on the return spring side. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 3. If not correct, replace the clutch piston. Gartner Banana

TRANSMISSION K Assembly procedure 1. Apply ATF to a new O-ring and install it onto the piston. 2. Apply ATF to a new seal ring and install it onto the piston. 3. Apply even pressure to the perimeter of the low and re- verse brake piston, and install it into the transmission case. 4. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring and O-ring. 5. Apply ATF to the one-way clutch inner race, thrust wash- er, and return spring. 6. Assemble the one-way clutch inner race, thrust washer, and return spring, and install them in the transmission case. 7. Verify that the return spring, thrust washer, and rings are properly positioned before securing the bolts. RETURN SPVING THRUSTWASHER 45UOKX-291 8. Tighten the allen head bolts by using the SST. Tightening torque: 12.8-1 7.6 N-m (1 30-180 kgfacm, 11 3-156 in-lbf) 9. Soak new drive plates in ATF for at least two hours. 10. Apply ATF to the driven plates immediately before as- sembly. 11. Install the drive and driven plates into the transmission case in the following order: Driven-Drive-Driven-Drive-Driven-Drive-Driven- Drive Gartner Banana