MAZDA MX-5 1994 Workshop Manual

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 Disassembly I Inspection I 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 2. Side plate 9. Spring retainer 10. Return spring . - 3. Outer race Inspection ................. page K-72 4. One-way clutch 11. Clutch piston 5. Retaining plate Disassembly note .......... page K-72 6. Snap ring Inspection ................. page K-72 u 7. Drive plates and driven plates 12. Seal ring Inspection ................. page K-72 13. O-ring 8. Snap ring 14. Direct clutch drum Disassembly note .......... page K-72 15. Bearing Gartner Banana

WIRE DIAMETER Disassembly note Snap ring Caution Depress the spring retainer only enough to re- d move the snap ring. Overpressing will damage the retainer assembly edges. 1. Compress the spring by using the SST, then remove the snap ring with snap ring pliers. 2. Remove the SST. 3. Remove the spring retainer and spring. Clutch piston 1. Install the direct 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 kglcm2, 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 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. - Outer dia mm {in) 8.0 (0.315) Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. No. ,oils 14.5 - Free length mm {in) 30.5 {1.201} 3. If not correct, replace the clutch piston. Wire dia. rnm {in) 1.3 (0.051) Gartner Banana

TRANSMISSION K Assembly procedure 1. Apply ATF to a new O-ring, and install it onto the direct clutch drum. 2. Apply ATF to a new seal ring, and install it onto the pis- ton. 3. Apply ATF to the inside of the direct clutch drum. 4. Apply even pressure to the perimeter of the clutch pis- ton, and install it into the direct clutch drum by turning it evenly and gradually. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring. Caution Depress the spring retainer only enough to install the snap ring. Overpressing will damage the re- tainer assembly edges. 6. Install the springs and spring retainer and compress them by using the SST. 7. While holding the spring retainer down by using the SST, install the snap into the spring retainer stopper. 8. Remove the SST. 9. Soak new drive plates in ATF for at least two hours. 10. Apply ATF to the driven plates immediately before as- sembly. 11. Arrange the drive and driven plates so that the toothless areas are in line with the lubrication hole in the direct clutch drum. 12. Install the drive and driven plates into the direct clutch drum in the following order: Driven-Drive-Driven-Drive 13. Install the snap ring. 14. Apply ATF to the retaining plate, and install the retaining plate so that the toothless area is in line with the lubrica- tion hole in the direct clutch drum. Gartner Banana

TRANSMISSION 15. Apply ATF to the outer race, and install the outer race so that the toothless area is in line with the lubrication hole in the direct clutch drum. d 16. Apply ATF to the one-way clutch, and install it into the outer race. Verify that the spring cage of the one-way clutch faces toward the direct clutch drum. 17. Apply ATF to the side plate, and install the side plate so that the toothless area is in line with the lubrication hole in the direct clutch drum. 18. Install the snap ring. 19. Apply petroleum jelly to the bearing, and install it onto the direct clutch drum. Bearing outer diameter: 70.0mm (2.756 in) 20. Measure the clearance between the side plate and the snap ring with a feeler gauge. If not within specification, adjust the clearance by installing the correct side plate. Clearance Maximum: 0.2mm (0.008 in) Side plate sizes mm {in) - 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 FOURTH GEAR BAND SERVO Preinspection Fourth gear band servo operation 1. Apply compressed air through the oil passage as shown. .J 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. 45UOKX-183 Disassembly I Inspection I 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. Brake band 2. Band strut 3. Fourth gear band servo cover 4. Gasket 5. Nut 6. Washer 7. Body 8. Piston stem 9. Piston assembly is assembly note . . . . . . . . . . page K-77 10. Seal rings 11. O-rings 12. Return spring Inspection . . . . . . . . . . . . . . . . . page K-77 Gartner Banana

TRANSMISSION K Disassembly note Piston assembly Remove the piston assembly from the body by applying compressed air through the oil passage hole. Air pressure: 392 kPa f4.0 kg/cm2,57 psi) max. Inspection Return spring 1. Measure the spring specifications. I Outer dia. I Free length I No. of tolls I mm (in) mm {in) mm {in} 2. If not within specification, replace the return spring. Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the body. 2. Apply ATF to the new O-rings, and install them 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. 6. Apply ATF to the piston stem and washer, and install them into the body. 7. Loosely tighten the nut. Gartner Banana

K TRANSMISSION 8. Apply ATF to the return spring, and install it into the trans- mission case. 9. Apply even pressure to the perimeter of the body, and install it into the transmission case. 4 10. Install the piston assembly. 11. lnstall and tighten the bolts. Tightening torque: 9.81-14.7 N-m (1 00-150 kgfacm, 86.8--130 in-lbf) On-vehicle Adjustment 1. Remove the exhaust pipe. (Refer to page K-46.) 2. Remove the fourth gear band servo cover and gasket. 3. Loosen the locknut and tighten the piston stem. Tightening torque: 11.8-14.7 Nm (1 20-1 50 kgf-cm, 105--130 in4bf) 4. Loosen the stem the number of turns shown below. Stem: 2 turns 5. Hold the piston stem and tighten the locknut. Tightening torque: 15-49 N-m (1.5-4.0 kgf-m, 11-28 ft-lbf) 6. Install a new gasket and the fourth gear band servo cov- er. Tightening torque: 5.0--6.8 N. m (50-70 kgf-cm, 44--60 in4 bf) 7. Install the exhaust pipe. (Refer to page K-148.) Gartner Banana

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