transmission oil MAZDA MX-5 1994 Service Manual

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

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 41. Remove the oil distributor. 42. Remove the bearing. TORQUE CONVERTER Inspection 1. Check the outside of the converter for damage and cracks, and replace the torque converter if there is any problem. 2. Check for rust on the pilot hub or on the boss, and re- move the rust completely if there is any. Washing inside the converter 1. Drain any ATF remaining in the converter. 2. Pour in solvent (0.5 L, 0.5 US qt, 0.4 Imp qt). 3. Shake the converter to clean the inside. Pour out the sol- vent. 4. Clean the inside of the converter with compressed air so that the inside is completely empty. 5. Pour in ATF. 6. Shake the converter to clean the inside. Pour out the ATF. Gartner Banana

K TRANSMISSION OIL PUMP Preparation SST 49 SO1 9 OAO Set, centering tool Shaft (Part of P 49 SO 1 9 OAO) 49 SO1 9 004 Pin (Part of 49 SO1 9 OAO) Body (Part of 49 GO30 795) For installation of oil P'""P For installation of oil Pump For installation of oil Pu""P For installation of oil seal 49 SO19 001 Holder (Part of 49 SO 1 9 OAO) 49 SO1 9 003 Stand (Part of 49 SO1 9 OAO) 49 GO30 795 Installer, oil seal Handle (Part of 49 GO30 795) For installation of oil Pump For installation of oil Pump For installation of oil seal For installation of oil seal Gartner Banana

TRANSMISSION K Disassembly I lnspection 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. 0 APPLY PETROLEUM JELLY 1. Snap ring 9. Inner gear 2. Sensing rotor Disassembly note .......... page K-64 3. Bearing Inspection ................. page K-64 4. Input shaft 10. Outer gear 5. O-ring Disassembly note .......... page K-64 6. Oil pump cover Inspection ................. page K-64 Disaseembly note .......... page K-64 11. Oil seal Inspection ................. page K-64 12. Roll pin 7. Oil pump housing 13. Plug Inspection ................. page K-64 14. Spring 8. O-ring Inspection ................. page K-65 15. Lockup control valve Gartner Banana

K TRANSMISSION Disassembly note Oil pump cover Loosen the mounting bolts evenly in the pattern shown, and remove the oil pump cover from the oil pump hous- ,-, ing . Inner gear and outer gear 1. Mark the inner and outer gear positions without scratch- ing or denting the gears. 2. Remove the gears from the housing. Inspection Clearance 1. Measure the clearance between the gears and the pump cover. Standard clearance: 0.02-0.04mm (0.0008-0.0015 in) Maximum clearance: 0.08mm (0.0031 in) 2. Measure the clearance between the outer gear teeth tip and the crescent. Standard clearance: 0.1 4-O.21 mm (0.0056-4.0082 in) Maximum clearance: 0.25mm (0.0098 in) 3. Measure the side clearance between the outer gear and the housing. Standard clearance: 0.05--0.20mm (0.0020--0.0078 in) Maximum clearance: 0.25mm (0.0098 in) 4. If not within specification, replace the oil pump assembly. -/' Gartner Banana

TRANSMISSION K WIRE DIAMETER Spring 1. Measure the spring specifications. Soecifications I Outer dia. I Free Ienpth I cO1ls I :Ired$ mm {in) mm {in) I 2. If not within specification, replace the spring. Assembly procedure 1. Apply ATF to the lockup control valve, spring, and plug, and install them into the oil pump housing. 2. Tap in the new roll pin. 3. Apply ATF to a new oil seal, and install it by using the SST. 4. Assemble the SST and secure it in a vise. 5. Apply ATF to the new O-ring, and place it on the pump cover. 6. Set the pump housing on the SST. 7. Apply ATF to the inner and outer gears, and install them in the pump housing with their matching marks toward the pump cover. Gartner Banana

K TRANSMISSION 8. Carefully install the oil pump cover onto the oil pump housing. 9. Install the SST (pins) for alignment. J 10. Tighten the bolts evenly and gradually in the order shown. Tightening torque: 5.9-7.8 N-m (6040 kgf-cm, 53-69 in-lbf) 11. Remove the SST (pins). 12. Apply ATF to a new O-ring, and install it onto the input shaft. 13. Apply ATF to the input shaft, and install it into the oil Pump. 14. Apply petroleum jelly to the bearing, and install it onto the oil pump. Bearing race outer diameter: 70.0mm (2.756 in) 15. Apply ATF to the sensing rotor splines, and install the sensing rotor onto the input shaft. 16. Install the snap ring on the input shaft with snap ring pli- ers. 17. Set the oil pump on the torque converter, and verify that the pump turns smoothly. Gartner Banana

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