gasket MAZDA MX-5 1994 Service Manual

K AUTOMATIC TRANSMISSION FLUID (ATF) Fluid leaks Check for fluid leaks of the transmission as shown below, and repair or replace as necessary. 1. Gaskets, O-ring, and plugs 2. Oil hoses, oil pipes, and connections 3. Oil cooler @ .... O-RING @ .... GASKET 0 .... OIL SEAL 0 .... PLUG @ .... OTHER Gartner Banana

AUTOMATIC TRANSMISSION FLUID (ATF) K REPLACEMENT 1. On level ground, jack up the vehicle and support it evenly on safety stands. Warning When the transmission and the ATF are hot, they can cause burns to the skin. Allow the transmis- sion and the ATF to cool before doing this proce- dure. 2. Loosen the oil pan installation bolts, and drain the ATF into a container. 3. Remove the oil pan and gasket. 4. Clean the oil pan and the magnet. 5. Install the oil pan along with a new gasket. Tightening torque: 5.9-7.8 N-m (60-80 kgfecm, 53-69 in-lbf) 6. Add approximately 4.0 L (4.2 US qt, 3.5 Imp qt} ATF, and check the ATF level. (Refer to page K-35.) Specified ATF: DexronmII or M-I11 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

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

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

K TRANSMISSION 36. Remove the bearing race, front clutch, rear clutch, con- necting shell, and front planetary gear unit (rear clutch hub, front planetary pinion carrier, rear sun gear) as a unit. d 37. Remove the extension housing and gasket. 38. Remove the snap ring from the output shaft with snap ring pliers. 39. Remove the rear planetary gear unit (connecting drum, rear planetary pinion carrier, one-way clutch). 40. Pull out the output shaft. 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