MAZDA MX-5 1994 Workshop Manual

TRANSMISSION TRANSMISSION UNIT (DISASSEMBLY) Preparation SST 49 H075 4958 Body (Part of 49 U019 OAOA) For disassembly of transmission For disassembly of transmission For disassembly of transmission 49 U019 OAOA Hanger set, transmission 49 U019 003 Holder (Part of 49 U019 OAOA) For disassembly of transmission For disassembly of transmission Precaution General notes: 1. The oil pan could contain small chips, shavings, and other particles helpful in checking the condition of the transmission and diagnosing certain problems. To ensure that all foreign particles stay in the oil pan, make sure that the transmission is never tipped completely over while the oil pan is still installed. L/ 2. Disassemble transmission in a clean area (dust proof work space) to prevent entry of dust into the mech- anisms. 3. Inspect the individual transmission components in accordance with the QUICK DIAGNOSIS CHART during disassembly. 4. Use only plastic hammers when applying force to separate the light alloy case joints. 5. Never use rags during disassembly; they may leave particles that can clog fluid passages. 6. Several parts resemble one another; organize them so they do not get mixed up. 7. Disassemble the control valve assembly and thoroughly clean it when a clutch or brake band is burned; or when the ATF has degenerated. Cleaning notes: 1. Clean the transmission exterior thoroughly with steam or cleaning solvents, or both, before disassembly. Warning Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. 2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and check that there are no obstructions. Gartner Banana

TRANSMISSION K Components / @ O-RING. O-RING, REPLACE O-RING, REPLACE 1. Vacuum diaphragm 6. Oil pan On-vehicle Removal ....... page K-130 7. Magnet Inspection ................ page K-130 8. Control valve body On-vehicle Installation ..... page K-131 Disassembly I Inspection ... page K-112 On-vehicle Adjustment ..... page K-131 Assembly ................ page K-125 2. Lockup control solenoid valve On-vehicle Removal ....... page K-128 Inspection ................ page K- 42 On-vehicle Installation ..... page K-129 3. Vehicle speed pulse generator 9. Solenoid valve connector Inspection ................ page K- 41 10. Converter housing 4. ParWneutral switch 11. 2nd band servo w Inspection ................ page K- 39 Disassembly I Inspection I Adjustment ............... page K- 40 Assembly ............... page K- 83 5. Torque converter On-vehicle Adjustment ..... page K- 85 Inspection ................ page K- 61 Gartner Banana

K TRANSMISSION Components (Cont'd) 4 GASKET, REPLACE SELECTIVE %I 12. Fourth gear band servo Disassembly / Inspection / ................ Assembly page K-76 ...... On-vehicle Adjustment page K-78 13. Oil pump Disassembly / Inspection 1 ................ Assembly page K-63 14. Fourth gear connecting shell and Fourth gear planetary gear unit (Fourth gear sun gear, Fourth gear planetary pinion carrier, Fourth gear clutch hub) Disassembly / Inspection / ................ Assembly page K-67 15. Direct clutch Disassembly / Inspection / ................ Assembly page K-71 16. Fourth gear brake band and band strut 17. Intermediate shaft 18. Drum support, accumulator, and Fourth gear case Disassembly / Inspection / ................ Assembly page K-79 Gartner Banana

TRANSMISSION K Components (Cont'd) REPLACE 2nd brake band and band strut 22. Connecting shell and front planetary gear Front clutch unit (rear clutch hub, front planetary pinion Disassembly / Inspection / carrier, rear sun gear) Assembly ................ page K-87 Disassembly / Inspection 1 Rear clutch Assembly ................ page K-96 Disassembly / Inspection / Assembly 23. Snap ring page K-92 24. Rear planetary gear unit (connecting drum, ......................... rear planetary pinion carrier, one-way clutch) Disassembly 1 Inspection / Assembly ................ page K-99 Gartner Banana

K TRANSMISSION Components (Cont'd) SEAL RING, REPLACE / O-RING, REPLACE /' $,&" $ GASKET, REPLACE 25. Extension housing 27. Oil distributor Disassembly I Inspection I 28. Bearing Assembly ............... page K-107 29. Low and reverse brake On-vehicle Removal ....... page K-110 Disassembly I Inspection / On-vehicle Installation ..... page K-110 Assembly .............. 26. Output shaft 30. Speedometer driven gear page K-103 Gartner Banana

TRANSMISSION K Procedure 1. Place wooden blocks under the transmission at the con- verter housing and the extension housing positions. 2. Remove the oil pan and gasket. Examine any material found in the pan or on the magnet to determine the condition of the transmission. Clutch facing material . . . . . Drive plate and brake band wear Steel (magnetic) . . . . . . . . . . Bearing, gear, and driven plate wear Aluminum (nonmagnetic) . . Bushings or cast alumi- num parts wear If large amounts of material are found, replace the torque converter and carefully check the transmission for the cause. 3. Install the oil pan and gasket with a few bolts to protect the valve body. 4. Remove the vacuum diaphragm, lockup control solenoid valve, vehicle speed pulse generator, and O-rings. 5. Remove the parwneutral switch. 6. Remove the speedometer driven gear from the exten- sion housing. 7. Remove the O-ring from the speedometer driven gear. Gartner Banana

K TRANSMISSION 8. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to keep any re- maining fluid from spilling. 9. Assemble the SST as shown. 10. Mount the transmission onto the SST. 11. Remove the oil pan and gasket. 12. Remove the magnets. 13. Disconnect the solenoid valve connectors. 14. Remove the harnesses from the bracket. Gartner Banana

TRANSMISSION K 15. Remove the control valve body as shown in the figure. 16. Remove the solenoid valve connector from the transmis- sion case. 17. Mark the converter housing, fourth gear case, and trans- mission case for proper reassembly. 18. Remove the converter housing from the fourth gear case. Caution The converter housing is made of aluminum, and is therefore easily dented and scratched by metal tools. When removing old sealant, do not gouge or strike the sealing surface of the converter housing. 19. Clean the sealing compound from the converter hous- ing. 20. Remove the fourth gear band servo cover and gasket. Gartner Banana

K TRANSMISSION 21. Loosen the fourth gear band servo locknut and tighten the piston stem. 22. Mark the fourth gear case and oil pump for proper reas- sembly. 23. Install the SST to the oil pump assembly. 24. Slowly remove the oil pump from the transmission case by evenly sliding the weights of the SST. 25. Remove the SST from the oil pump. 26. Loosen the piston stem of the fourth gear band servo. Remove the fourth gear connecting shell and fourth gear planetary gear unit (fourth gear sun gear, fourth gear planetary pinion carrier, fourth gear clutch hub), and di- rect clutch. 27. Remove the fourth gear brake band, and hold it together with a piece of wire as shown in the figure. 28. Remove the band strut. Gartner Banana

TRANSMISSION K 29. Remove the bearing races and bearing. 30. Remove the intermediate shaft. I 45UOKX-116 31. Loosen the 2nd band servo locknut and tighten the pis- ton stem. I 1 45UOKX-117 32. Separate the drum support, accumulator and fourth gear case from the transmission case by tapping it lightly with a plastic hammer. Remove the gasket. u 45UOKX-118 Remove the bearing races and bearing from the drum support, accumulator and fourth gear case. Remove the bearing from the front clutch hole. Loosen the 2nd band servo piston stem and remove the 2nd band strut. Hold the brake band together with a piece of wire as shown in the figure. Remove the band strut. Gartner Banana