transmission MAZDA MX-5 1994 Workshop Manual

TRANSMISSION K DRUM SUPPORT, ACCUMULATOR, AND FOURTH GEAR CASE Preparation SST 49 SO19 OAO Set, centering tool Shaft (Part of P 49 SO 1 9 OAO) 49 SO1 9 004 Pin (Part of 49 SO1 9 OAO) For installation for drum support For installation for drum support For installation for drum support Disassembly / Ins~ection / Assemblv 49 SO1 9 001 Holder (Part of I I 49 SO 1 9 OAO) && 49 SO1 9 003 Stand (Part of 49 SO1 9 OAO) For installation for drum support For installation for drum support 1. isa assemble in ihe 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 Assembly procedure. I REPLACE @- REP, 1. Drum support 9. D ring Disassembly note ............ page K-80 10. Snap ring Inspection ................... page K-80 11. Accumulator ~lua 2. Seal rings 3. Seal rings 4. Roll pin i/ 5. Plug 6. Gasket 7. One-way valve 8. Steel ball . - isa ass em bl iote ............ page K-80 12. O-ring 13. ~ccumulator piston 14. Seal rings 15. Spring Inspection ................... page K-80 16. Fourth gear case Gartner Banana

K TRANSMISSION t- FREE LENGTH 7 -& WIRE DIAMETER Disassembly note Drum support Mark the fourth gear case and the drum support for prop- er reassembly, then remove the drum support. Accumulator plug Remove the accumulator plug, piston, and spring by ap- plying compressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. Inspection Drum support 1. Apply ATF to the new seal rings and install them into the seal ring grooves of the drum support. 2. Measure the clearance between the seal rings and the seal ring grooves. 4 Clearance Standard: 0.04--0.16mm (0.0016--0.0062 in) Maximum: 0.40mm (0.016 in) 3. If not within specification, replace the drum support. Spring 1. Measure the spring specifications. Specifications I Outer dia. I Free length I No. of I mm linl mm linl mm iinl Wire I 2. If not within specification, replace the return spring. Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the accumulator piston. Gartner Banana

TRANSMISSION K 2. Apply ATF to the spring and install it into the fourth gear case. 3. Apply ATF to the accumulator piston. 4. Apply even pressure to the perimeter of the piston, and install it into the fourth gear case. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring. 6. Apply ATF to a new O-ring, and install it on the accumula- tor plug. 7. Install the accumulator plug and snap ring. Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 8. Check the accumulator operation by applying com- pressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 9. Apply ATF to the plug, and install it into the drum support. 10. Tap in a new roll pin. 11. Set the oil pump onto the SST. 12. Apply ATF to a new seal ring, and install it onto the drum support. Gartner Banana

K TRANSMISSION STEEL BALL ONE-WAY VALVE 13. Apply ATF to the fourth gear case, and mount it onto the oil pump. 14. Install the steel ball and the one-way valve. 15. Apply ATF to the new seal rings, and install them onto the drum support. 16. Apply ATF to the drum support, and install the support and a new gasket onto the fourth gear case, aligning the marks. 17. Install the SST (pins). 18. Tighten the drum support mounting bolts. Tightening torque: 6.94.8 N-m {7&90 kgfncm, 61-78 inelbf) Gartner Banana

TRANSMISSION K 2ND BAND SERVO Preinspection 2ND band servo operation 1. Apply compressed air through the oil passage as shown. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 2. Verify that the piston stem moves to the brake band. If not, the seal rings or the oil seal may be damaged or the piston assembly may be sticking. lnspect them, and re- place as necessary when assembling. Disassembly 1 Inspection / Assembly 1. Disassemble in the order shown in the figure 2. lnspect all parts, and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. 1. Brake band lnspect for wear and burning - 2. Band strut 3. Nut 4. Washer 5. Body 6. Piston stem 7. Piston assemblv 8. Seal rings 9. O-ring 10. Return spring Inspection . . . . . . . . . . . . . . . . . page K-84 Gartner Banana

K TRANSMISSION --/b WIRE DIAMETER Inspection Return spring 1. Measure the spring specifications. Specifications 2. If not within specification, replace the return spring. Outer dia. mm {in} 28.2 11.1 10) Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the piston assembly. 2. Apply ATF to a new O-ring, and install it onto the piston assembly. 3. Apply ATF to the piston assembly and body. 4. Apply even pressure to the perimeter of the piston, and install it into the body. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring. i/ Free length mm {in) 38.7 (1 524) 6. Apply ATF to the piston stem and washer, and install them into the body. 7. Loosely tighten the nut. 8. Apply even pressure to the perimeter of the body, and install it into the transmission case. 9. Install the piston assembly. No, of coils 6.324 Wire dia. mm {in} 3.5 (0.1 38) Gartner Banana

TRANSMISSION K 10. Install and tighten the bolts. Tightening torque: 6.9--8.8 N-m (70-90 kgfmcm, 61-78 in-lbf} On-vehicle Adjustment 1. Remove the exhaust pipe. (Refer to page K-47.) 2. Remove the valve body assembly. (Refer to page K-127.) 3. Loosen the locknut and tighten the piston stem. r u I MANUAL PLATE Tightening torque: 12.3-14.2 N-m (1 2+l45 kgf-cm, 109--125 in-lbf) 4. Loosen the stem the number of turns shown below. Stem: 2 112 turns 5. Hold the piston stem and tighten the locknut. Tightening torque: 1 +39 N.m {l.5--4.O kgf-m, 11-28 ftlbf) 6. Install a new body assembly. (Refer to page K-129.) 7. Install the exhaust pipe. (Refer to page K-148.) Gartner Banana

K TRANSMISSION FRONT CLUTCH Preparation SST Preinspection Front clutch operation 1. Install the front clutch onto the drum support along with the seal rings. Apply compressed air through the oil pas- sage as shown. 49 0378 375 Compressor, clutch spring Air pressure: 392 kPa (4.0 kglcm*, 57 psi} max. For removal / installation of front 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 when assembling. Clearance between retaining plate and snap ring Measure the clearance between the retaining plate and the snap ring. Clearance: 0.9--1 .l mm (0.036-0.043 in} .--- Select and install the correct retaining plate when as- sembling. Gartner Banana

TRANSMISSION K Disassembly / Inspection / 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 Assembly procedure. - 1. Snap ring 7. Return s~rina , " 2. Retaining plate Inspection ................. page K-88 3. Drive plates and driven plates 8. Clutch piston Inspection ................. page K-88 Disassembly note .......... page K-88 4. Dished plate Inspection ................. page K-88 - 5. Snap ring 9. Seal ring Disassembly note .......... page K-88 10. O-ring 6. Spring retainer 11. Front clutch drum Gartner Banana

K TRANSMISSION -&- WIRE DIAMETER Disassembly note Snap ring Caution 4' Depress the spring retainer only enough to install the snap ring. Overpressing will damage the re- tainer assembly edges. 1. Compress the spring by using the SST, then remove the snap ring with snap ring pliers. 2. Remove the spring retainer and spring. Clutch piston 1. Install the front clutch drum onto the drum support along with the seal rings. 2. Remove the piston by applying 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: 1.6mm (0,063 in) Minimum thickness: 1.4mm (0.055 in) 2. If not within specification, replace the drive plates. Return spring 1. Measure the spring specifications. Specifications I Outer dia. I Free length I No. of coils I mm {in} mm {in} Wire mm {in) dia. I Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 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. 3. If not correct, replace the clutch piston. Gartner Banana