transmission oil MAZDA MX-5 1994 Owner's Manual

TRANSMISSION J 1. Oil seal Assembly Note .................. below 2. Snap ring u 3. Steel ball 4. Speedometer drive gear 5. Snap ring 6. Transmission case 7. Extension housing Assembly Note .................. below 8. Main drive gear bearing Assembly Note .................. below 9. Snap ring 10. Countershaft front bearing Assembly Note .............. page J-44 11. Snap ring 12. Adjustment shim Assembly Note .............. page J-44 13. Gasket 14. Front cover 15. Speedometer driven gear 16. Neutral switch 17. Back-up light switch 18. Boot 19. Clutch release fork Assembly Note .............. page J-44 20. Clutch release collar Assembly Note .............. page J-44 35UOJX-020 Assembly note Oil seal 1. Apply transmission oil to the outer periphery. 2. lnstall a new oil seal with the SST. Extension housing 1. Apply sealant to the contact surfaces of the bearing housing and transmission case. 2. Align the inner shift lever and shift rod end groove, and install the extension housing. 3. Apply sealant to the bolt threads, and install the bolts. Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, l4--19 ft4bf) Main drive gear bearing Install the main drive gear bearing by using the SST, and secure it with a new snap ring. Gartner Banana

TRANSMISSION J INSTALLATION 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Install in the order shown in the figure, referring to lnstallation Note. L 3. Add the specified amount of the specified transmission oil. (Refer to page J-8.) 4. Warm up the engine and transmission, and inspect for oil leakage and transmission problems. 1. Transmission 7. Exhaust pipe Installation Note ............. page J-46 8. Performance rod 2. Power plant frame (PPF) 9. Differential mounting pipe Installation Note ............. page J-46 10. Undercover 3. S~eedometer cable 11. Shift lever w 4. ~iarter Installation Note ............. page J-47 5. Clutch release cylinder 12. Rear console 6. Propeller shaft 13. Shift lever knob Service ...................... section L Gartner Banana

J TRANSMISSION -=DIFFERENTIAL MOUNTING SPACER 45UOJX-054 Installation note Transmission 1. Tilt the engine by pushing up on the front of the oil pan with a wooden block and a transmission jack. d 2. Support the transmission with a transmission jack. 3. Raise the transmission into place and install and tighten the installation bolts. Tightening torque: 64-89 N-m (6.5--9.1 kgf-m, 48-65 ft.lbf) Power plant frame (PPF) 1. Install the differential mounting spacer. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) 2. Support the transmission with a jack so that it is level. 3. Position the PPF and tighten the transmission-side bolts by hand. 4. Verify that the sleeve is installed into the block. 5. Install the spacer and reamer bolts in the forward hole, then hand tighten them. 6. Snugly install the power plant frame bracket. 7. Tighten the transmission-side bolts. Tightening torque: 104-123 N-m (10.S12.6 kgf.m, 76.7-91.1 ft.lbf) 8. Tighten the differential-side bolts. Tightening torque: 104-1 23 N-m (1 0.S12.6 kgf.m, 76.7-91.1 ft-lbf) Gartner Banana

TRANSMISSION J 9. Install the power plant frame bracket. Tightening torque @ : lO4--123 N.m (1 0.6-1 2.6 kgf.m, 76.7-91.1 ft-lbf) @: 37-43 N.m (3.7-5.5 kgf-m, 27-39 ftlbf) 10. Remove the jack, and connect the wire harness. 11. Measure distance A with a straightedge and vernier cali- pers. Distance A: 66.0 2 5mm (2.60 a 0.197 in) 12. If the distance is not within specification, reposition the PPF to the transmission. FRONT Shift lever 1. Pour the specified amount of oil into the change control case. The change control case must also be filled with the specified amount of oil whenever the extension housing has been removed or the transmission has been overhauled. Specified oil Grade: API service GL-4 or GL-5 All season: SAE 75W-90 Above 10°C (50°F): SAE 80W-90 Specified amount: 80-95 cc (4.9-5.8 cu in) 2. Apply oil to the shift lever as shown. 3. Apply sealant to the contact surfaces of the boot panel and the change control case. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . AUTOMATIC TRANSMISSION INDEX ................................ K- 2 OUTLINE ............................. K- 3 SPECIFICATIONS ................... K- 3 ........... CROSS-SECTIONAL VIEW K- 4 POWER FLOW DIAGRAM ............ K- 5 OPERATION OF COMPONENTS ...... K- 5 FLUID PASSAGE LOCATIONS ........ K- 6 TROUBLESHOOTING .................. K- 8 GENERAL NOTES ................... K- 8 .......... QUICK DIAGNOSIS CHART K- 9 ON-BOARD DIAGNOSIS SYSTEM ...... K- 11 DESCRIPTION ...................... K- 11 PREPARATION ...................... K- 11 ....... DIAGNOSTIC TROUBLE CODE K- 11 .......... MECHANICAL SYSTEM TEST K- 22 PREPARATION ...................... K- 22 STALL TEST ........................ K- 22 TIME LAG TEST ..................... K- 25 LINE PRESSURE TEST .............. K- 26 ROAD TEST .......................... K- 29 D-RANGE TEST ..................... K- 29 S-RANGE TEST ..................... K- 31 ..................... L-RANGE TEST K- 32 . P-RANGE TEST ..................... K- 33 AUTOMATIC TRANSMISSION FLUID (ATF) ................................ K- 35 ATF ................................ K- 35 REPLACEMENT ..................... K- 37 ELECTRICAL SYSTEM COMPONENTS . . K- 38 PREPARATION ...................... K- 38 HOLD SWITCH ...................... K- 38 PARWNEUTRAL SWITCH ............ K- 39 .............. ATF THERMOSENSOR K- 41 VEHICLE SPEED PULSE GENERATOR ...................... K- 41 1-2 SHIFT. 2-3 SHIFT. 3-4 SHIFT. ... 3-2 CONTROL SOLENOID VALVE K- 42 LOCKUP CONTROL SOLENOID ....... VALVE ............................ K- 42 POWERTRAIN CONTROL MODULE (TRANSMISSION) .................. K- 43 TRANSMISSION ....................... K- 46 TRANSMISSION UNIT (REMOVAL) .... K- 46 TRANSMISSION UNlT (DISASSEMBLY) ................... K- 50 TORQUE CONVERTER .............. K- 61 OILPUMP .......................... K- 62 FOURTH GEAR CONNECTING SHELL AND FOURTH GEAR PLANETARY GEAR UNIT (FOURTH GEAR SUN GEAR. FOURTH GEAR PLANETARY PINION CARRIER. FOURTH GEAR CLUTCH HUB) ...... K- 67 DIRECT CLUTCH .................... K- 70 FOURTH GEAR BAND SERVO ........ K- 76 DRUM SUPPORT. ACCUMULATOR. AND FOURTH GEAR CASE ......... K- 79 2ND BAND SERVO .................. K- 83 FRONT CLUTCH .................... K- 86 REAR CLUTCH ...................... K- 91 CONNECTING SHELL AND FRONT PLANETARY GEAR UNlT (REAR CLUTCH HUB. FRONT PLANETARY PINION CARRIER. REAR SUN GEAR) ................. K- 96 REAR PLANETARY GEAR UNlT (CONNECTING DRUM. REAR PLANETARY PINION CARRIER. ONE-WAY CLUTCH) K- 98 LOW AND REVERSE BRAKE K-102 ................ ......... EXTENSION HOUSING AND PARKING MECHANISM ............. K-107 OIL SEAL ........................... K-ill CONTROL VALVE BODY ............. K-112 UPPER VALVE BODY ................ K-116 LOWER VALVE BODY ............... K-120 CONTROL VALVE BODY ............. K-125 VACUUM DIAPHRAGM ............... K-130 TRANSMISSION UNIT (ASSEMBLY) ... K-132 TRANSMISSION UNIT (INSTALLATION) ................... K-147 OIL COOLER .......................... K-151 REMOVAL I INSPECTION I INSTALLATION ..................... K-151 DRIVE PLATE ......................... K-152 PREPARATION ...................... K-152 REMOVAL 1 INSPECTION I INSTALLATION ..................... K-152 SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) ......... K-154 SHIFT-LOCK SYSTEM COMPONENTS K-154 TROUBLESHOOTING ................ K-155 SHIFT-LOCK ........................ K-157 EMERGENCY OVERRIDE BUTTON ... K-157 KEY INTERLOCK .................... K-157 KEY INTERLOCK SOLENOID ......... K-157 KEY INTERLOCK UNIT ............... K-158 P RANGE SWITCH .................. K-159 SHIFT-LOCKACTUATOR ............. K-159 SELECTOR LEVER .................. K-161 HYDRAULIC CIRCUIT .................. K-168 P RANGE ........................... K-168 R RANGE ........................... K-169 N RANGE; BELOW 7 kmlh I4.34 mph) . K-170 N RANGE; ABOVE 9 kmlh (5.58 mph} . K-171 D RANGE; 1 ST GEAR ................ K-172 D RANGE; 2ND GEAR ............... K-173 D RANGE; THIRD GEAR ............. K-174 D RANGE; FOURTH GEAR. LOCKUP ON ....................... K-175 S RANGE; 1 ST GEAR ................ K-176 S RANGE; 2ND GEAR ............... K-177 S RANGE; THIRD GEAR ............. K-178 L RANGE; 1 ST GEAR ................ K-179 L RANGE; 2ND GEAR ................ K-180 Gartner Banana

INDEX, OUTLINE K 1. Hold switch lnspection . . . . . . . . . . . . . . . . page K- 38 Replacement . . . . . . . . . . . . . page K- 39 b 2. ParkINeutral switch lnspection . . . . . . . . . . . . . . . . page K- 39 Adjustment . . . . . . . . . . . . . . . page K- 40 3. Vehicle speed pulse generator lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 42 4. ATF thermosensor lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 41 5. 1-2 shift, 2-3 shift, 3-4 shift, 3-2 control solenoid valves lnspection . . . . . . . . . . . . . . . . page K- 42 6. Lockup control solenoid valve lnspection . . . . . . . . . . . . . . . . page K- 42 7. Powertrain control module (Transmission) lnspection . . . . . . . . . . . . . . . . page K- 43 Replacement . . . . . . . . . . . . . page K- 45 OUTLINE SPECIFICATIONS 8. Automatic transmission Removal . . . . . . . . . . . . . . . . . page K- 46 Disassembly . . . . . . . . . . . . . page K- 50 Assembly . . . . . . . . . . . . . . . . page K-132 lnstallation . . . . . . . . . . . . . . . page K-147 9. Oil cooler Removal 1 Inspection / lnstallation . . . . . . . . . . . . . . page K-151 10. Drive plate Removal 1 Inspection 1 lnstallation . . . . . . . . . . . . . . page K-152 11. P range switch lnspection . . . . . . . . . . . . . . . . page K-159 12. Shift-lock actuator lnspection . . . . . . . . . . . . . . . . page K-159 13. Selector lever lnspection . . . . . . . . . . . . . . . . page K-161 Adjustment . . . . . . . . . . . . . . . page K-160 Removal / Inspection / lnstallation . . . . . . . . . . . . . . page K-163 Disassembly 1 Inspection / Assembly . . . . . . . . . . . . . . . page K-166 - Model Item - Gear ratio NC4A-EL Torque converter stall torque ratio 1 st 1.900 : 1 2.458 4GR Reverse 0.720 2.182 Number of driveldriven plates Servo diameter (Piston outer diameterketainer inner diam- eter) mm{in} Direct clutch Front clutch Rear clutch Automatic transmission fluid (Am 212 315 515 Low and reverse brake Fourth gear band servo 2nd band servo 4/4 56/36 {2.205/1.417} 72/50 {2.835/1.969} Dexron@II or M-111 7.3 {7.7,6.4} 4.0 {4.2,3.5} Type Capacity L {US qt, Imp qtI Total oil pan Gartner Banana

K OUTLINE FLUID PASSAGE LOCATIONS Transmission Case TO SECOND SERVO RELEASE SlDE TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO SECOND SERVO APPLY SI OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE TO REAR CLUTCH TO FRONT CLUTC OIL PUMP SUCTION , REAR LUBRICATION TO LOW AND REVERSE BRAKE OIL PUMP SUCTION TO FRONT CLUTCH TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO REAR CLUTCH / OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE Oil Pump OIL PUMP DISCHARGE FRONT LOCKUP CONTROL OIL PUMP SUCTION SOLENOID VALVE TORQUE CONVERTER PRESSURE 0i PUMP DISCHARGE Gartner Banana

TROUBLESHOOTING If the 3 steps on page K-8 are followed, the cause of the problem should be located. Another guide to faster location of the causes of problems, the QUICK DIAGNOSIS CHART, is on page K-1 0. b In this chart, numbers are used to indicate the components that may be the cause of 22 possible prob- lems. It is necessary to check only those components indicated by numbers during each step of the trouble- shooting process to locate the cause of the problem quickly. QUICK DIAGNOSIS CHART The QUICK DIAGNOSIS CHART shows different .problems and the relationship of components that might be the cause. 1. Components indicated in the "Adjustment" row indicate the possibility that the problem may result from an incorrect adjustment. Check the adjustment of each component, and readjust if necessary. 2. Components indicated in the "Self-DiagnosisWrow are diagnosed by the Powertrain control module (Transmission) self-diagnostic function. 3. Input and output signals of the Powertrain control module (Transmission) for components indicated in the "Tester" row can be easily checked with the Engine signal Monitor. 4. Components indicated in the "Mechanical System Test" row can be checked for malfunction by the re- sults of oil pressure test. 5. Components indicated in the "Road Test" row can be checked for malfunction by the results of the road test. 6. The numbers in the chart indicate the order of inspection for detecting malfunctions. 7. Circled numbers indicate that the transmission must be removed from the vehicle. 8. The checking, adjusting, repair, and replacement procedures for components are described in the page(s) shown in the "Reference page" row. Gartner Banana

K MECHANICAL SYSTEM TEST Evaluation of Stall Test 4bove specification Nithin specification In all ranges In D (Normal), and L ranges In D (Normal) range only In R range only 3elow specification Possible cause I Worn oil Dumo Oil leakage from oil pump, control Insufficient line pressure Direct clutch and overdrive one-way clutch sli~~ina Rear clutch slipping One-way clutch slipping Low and reverse brake slipping Front clutch slipping Perform road test to determine if this is caused by low and reverse brake or front clutch as follows: a) Effective engine braking in L range . . . . . . . . . . Front clutch b) No enaine brakina in L range . . . . . Low and reverse brake All ~hiftcont~elements within transmission are functioning normally Engine out of tune One-wav clutch sli~~ina within toraue converter Gartner Banana

K MECHANICAL SYSTEM TEST LINE PRESSURE TEST This test measures line pressures for checking the hydraulic components and inspecting for oil leakage. Preparation d 1. Perform the preparation procedure shown in the STALL TEST. (Refer to page K-22.) 2. Connect a tachometer to the engine. Warning Removing the square-head plug when the ATF is hot is dangerous. Hot ATF can come out of the opening and badly burn. Before removing the square-head plug, allow the ATF to cool. 3. Connect the SST to the line pressure inspection hole(s). Procedure 1. Start the engine and check the idle speed in P range. (Refer to section F.) Idle speed: 750--850 rpm * 2. Shift the selector lever to D range and read the line pressure at idle. Caution If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed, the transmission could be damaged. Therefore, do steps 3 and 4 within 5 seconds of each oth- er. 3. Depress the brake pedal firmly with the left foot and gradually depress the accelerator pedal with the right foot. 4. Read the line pressure as soon as the engine speed becomes constant, then release the accelerator .- pedal. 5. Shift the selector to N and let the engine idle for 1 minute or more to cool the ATF. 6. Read the line pressure at idle and at the engine stall speed for each range in the same manner. Gartner Banana