clock MAZDA MX-5 1994 User Guide

K TRANSMISSION DIRECT CLUTCH Preparation SST CLOCKWISE 49 0378 375 Compressor, clutch spring Preinspection Direct clutch operation 1. Install the direct clutch onto the drum support along with the seal rings. Apply compressed air through the oil passage as shown. For removal 1 installation of direct clutch Air pressure: 392 kPa (4.0 kgtcm*, 57 psi) max. 2. Verify that the side 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 re- place as necessary when assembling. Clearance between side plate and snap ring 1. Measure the clearance between the side plate and the snap ring. Clearance Maximum: 0.2mm (0.008 in) i -, 2. Select and install the correct side plate when assern- bling. One-way clutch operation Insert the fourth gear clutch hub on the top of the direct clutch, and verify that the fourth gear clutch hub rotates smoothly when turned clockwise and locks when turned counterclockwise. If not, replace the one-way clutch. Gartner Banana

TRANSMISSION K 21. Insert the fourth gear clutch hub on the top of the direct clutch and verify that the fourth gear clutch hub rotates smoothly when turned clockwise and locks when turned counterclockwise. If it does not, then the one-way clutch is installed upside down. Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 22. Install the direct clutch onto the drum support along with the seal rings. Apply compressed air to the oil passage and check the clutch operation. Air pressure: 392 kPa {4.0 kglcm2, 67 psi) max. 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 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

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K 0.9-1.0mm 0.6-0.7mm (0.035-0.039 in) {0.024--0.028 in) 0.5-0.6mm (0.024.024 in) 45UOKX-48 Assembly Note Cam 1. Loosely install the cam to the push rod. Note a Clearance becomes smaller by turning the cam clock- wise. 2. Adjust the clearance between the guide plate and the guide pin by turning the cam. 3. Install the selector lever knob and verify that the clear- ance is as specified. 4. If not, repeat from step 2. 5. Remove the selector lever knob. 6. Apply grease to the cam as shown. Gartner Banana

N MANUAL STEERING STEERING GEAR AND LINKAGE Removal / Installation 1. Turn the wheels to the straight-ahead position. 2. Loosen the wheel lug nuts. 4 3. On level ground, jack up the front of the vehicle and support it on safety stands. 4. Remove the wheel. Note Turning the steering wheel while the steering gear is removed will make reinstallation difficult. Do not turn the steering wheel while the steering gear is removed. If the steering wheel is turned in that condi- tion, the clockspring connector may have to be adjusted. (Refer to section T.) 5. Remove the undercover. 6. With the wheels in the straight-ahead position, remove in the order shown in the figure. 7. Install in the reverse order of removal. 8. Adjust the front wheel alignment. (Refer to section R.) 1. Cotter pin 4. Intermediate shaft bolt 5. Mounting bracket bolt .i 2. Nut 3. Tie-rod endlsteering knuckle 6. Steering gear and linkage Removal Note . . . . . . . . . . . . . . . . page N-7 Gartner Banana

ENGINE SPEED SENSING POWER STEERING N STEERING GEAR AND LINKAGE Removal / Installation 1. Turn the wheels to the straight-ahead position. 2. Loosen the wheel lug nuts. 3. On level ground, jack up the front of the vehicle and support it on safety stands. 4. Remove the wheels. Note Turning the steering wheel while the steering gear is removed will make reinstallation difficult. Do not turn the steering wheel while the steering gear is removed. If the steering wheel is turned in that condi- tion, the clockspring connector may have to be adjusted. (Refer to section T.) 5. Remove in the order shown in the figure, referring to Removal Note. 6. With the wheels in the straight-ahead position, install in the reverse order of removal. 7. Tighten all necessary bolts and nuts to the specified torque. 8. After installation: (1) Check for fluid leakage. (Refer to page N-22.) (2) Bleed air from the system. (Refer to page N-21.) (3) Adjust the front wheel alignment. (Refer to section R.) 1. Cotter pin 5. Pressure pipe 2. Nut ~emovai Note ............... page N-26 3. Tie-rod endlsteering knuckle 6. Return hose Removal Note ............... page N- 7 7. Mounting bracket bolt 4. Bolt 8. Steering gear and linkage Gartner Banana

BRAKE SYSTEM P I I TOUCHING 1 T~~H,IN~ I ADJUSTING NUT 97GOPX-O Removal note Brake pipe Cautlon Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off im- mediately. 1. Modify the brake pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI) "Torque Formulas" 2. Disconnect~connect the brake pipe fromlto the master cylinder by using the SST. 3. Tighten the brake pipe by using the SST. Tightening torque: 13--22 N-m (1 3-2.2 kgf-m, 9.4--16 ft-lbf) Installation note Master cylinder Inspect the push rod clearance as follows. 1. Turn the nut of the SST clockwise to fully retract the SST gauge rod. Attach the SST to the power brake unit. Tightening torque: 9.8-15.7 N.m (1 .&I .6 kgf.m, 7.2-11.6 ft4bf) 2. Apply 66.7 kPa (500 mmHg, 19.7 inHg) vacuum using a vacuum pump. 3. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and SST body. Gartner Banana

BRAKE SYSTEM ,$, .... "P ...% REAR BRAKE (DISC) Quick Inspection, On-vehicle Disc pad 1. On level ground, jack up the rear of the vehicle and sup- port it with safety stands. 2. Remove the wheels. 3. Sight through the caliper inspection hole and verify the remaining thickness of the pad. Thickness: 1 .Omm (0.04 in} min. I I 05UOPX-043 Replacement (Disc pad) 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to Installation Note. 1. Plug 4. M-spring 2. Manual adjustment gear 5. Disc pad Removal Note ................... below Inspection ................... page P-31 Installation Note ............. page P-30 6. Shim 3. Lock bolt 7. Guide plate RETRACTING BRAKE PADS Removal note Manual adjustment gear Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston back. Gartner Banana

BRAKE SYSTEM ADJUSTING BRAKE PADS Installation note Manual adjustment gear 1. Turn the manual adjustment gear clockwise until the brake pads just touch the disc plate. -1 2. Return the manual adjustment gear counterclockwise 113 turn. Removal 1 lnstallation (Caliper) 1. On level ground, jack up the rear of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Inspect all parts and repair or replace as necessary. 5. Tighten all nuts and bolts to the specified torques, referring to the figure. Parking brake cable Removal I Inspection 1 Installation ................. page P-36 Connecting bolt Brake hose Plug Manual adjustment gear Removal Note ............... page P-29 Installation Note ................. above Lock bolt 7. Caliper Disassembly I Inspection 1 Assembly .................. page P-32 8. Disc pad Replacement ................ page P-29 Inspection ................... page P-31 9. Bolt 10. Mounting support 11. Disc plate Inspection ................... page P-31 Gartner Banana