MAZDA MX-5 1994 Workshop Manual

K TRANSMISSION VACUUM DIAPHRAGM Preparation SST Note Excessive shift shock and improper shifting often indicate a vacuum diaphragm malfunction. 49 GO32 355 Adjustment gauge Warning When the transmission and the ATF are hot, they can cause burns to the skin. Allow the trans- mission and the ATF to cool before doing this procedure. For adjustment of vacuum diaphragm rod On-vehicle Removal 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Remove the exhaust pipe. (Refer to page K-45.) 3. Loosen the oil pan mounting bolts, and drain approx. 1.0 L (1.1 US qt, 0.9 Imp qt) of ATF. L' 4. Disconnect the vacuum hose. 5. Remove the vacuum diaphragm, O-rings, and vacuum diaphragm rod. Inspection 1. Check that the vacuum diaphragm rod moves when vac- uum is applied to the vacuum diaphragm. 2. If not correct, replace the vacuum diaphragm. Gartner Banana

TRANSMISSION K VACUUM DIAGRAM VACUUM THROTTLE VALVE I On-vehicle Installation 1. Apply ATF to a new O-ring, and install it onto the vacuum diaphragm. 2. Apply ATF to a new O-ring ,and install it into the transmis- sion case. 3. Apply ATF to the vacuum diaphragm rod and vacuum di- aphragm, and install them into the transmission case. Tightening torque: 7.9--10.7 N-m (80-11 0 kgfscm, 70-95.4 inslbf) 4. Connect the vacuum hose. 5. Install the exhaust pipe. (Refer to page K-148.) 6. Add approximately 1.0 L (1.1 US qt, 0.9 Imp qt) ATF, and check the ATF level. (Refer to page K-35.) 7. Warm up the ATF to normal operating temperature (50--80°C, 122-176OF), then check for the following: (1) Fluid leakage (2) Vacuum leakage On-vehicle Adjustment 1. Remove the vacuum diaphragm, vacuum diaphragm rod, and O-rings from the transmission case. (Refer to On-vehicle Removal, page K-130.) 2. Measure dimension N indicated in the figure by using the SST and a scale. 3. Select the proper diaphragm rod from the table. Dimension N Below 25.65mm 11.0099 in) Applicable diaphragm rod 29.0mm {I .14 in) 25.65-26.15mm (1.0099-1.0295 in) 25.90-26.40mm 11.0197-1.0394 in) 4. lnstall the correct vacuum diaphragm rod, O-rings, and vacuum diaphragm. (Refer to On-vehicle Installation, page K-131.) 29.5mm {I .16 in) 29.75mm (1.1 7 in) . - 26.1 5-26.65mm (1.0295-1.0492 in) 26.65-27.1 5mm (1.0492-1.0689 in) 27.1 5mm (1.0689 in) or over 30.Omm {I .18 in) 30.5mm {I .20 in) 31.0mm {I .22 in) Gartner Banana

K TRANSMISSION TRANSMISSION UNIT (ASSEMBLY) Preparation SST 49 01 07 680A Engine stand 49 H075 4958 Body (Part of U019 OAOA) 49 GO32 355 Adjustment gauge For assembly of transmission For assembly of transmission For adjustment of vacuum diaphragm rod 49 UOI 9 OAOA Transmission hanger 49 U019 003 Holder (Part of U019 OAOA) For assembly of transmission For assembly of transmission Precaution 1. If the drive plates or brake bands are replaced with new ones, soak the new ones in ATF for at least two hours before installation. 2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts. 3. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit. u 4. Use petroleum jelly, not grease, during reassembly. 5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing. 6. Assemble the housing within 10 minutes after applying sealant, and allow it to cure at least 30 minutes after assembly before filing the transmission with ATF. Gartner Banana

TRANSMISSION K Thrust Washer, Bearing, and Race Location SELECTIVE SELECTIVE Outer diameter of bearing and race 7 35.0 (1.378) 33.0 {I .299) Bearing mrn {in) Race rnm {in) w 1 70.0 (2.756) - K-133 2 70.0 (2.756) - Bearing mm {in) Race mm {in) 9 70.0 (2.756) - 4 35.0 (1.3781 33.0 (1.299) 3 70.0 (2.756) - 12 47.0 (1.850) - 8 53.0 (2.087) - 13 53.0 i2.087) - 10 70.0 {2.756) - 5 70.0 (2.756) 70.0 (2.756) 11 70.0 (2.756) - 6 70.0 (2.7563 76.0 (2.992) Gartner Banana

K TRANSMISSION Torque specifications 7.8--10.8 Nm (60-110 kgfcm, 69-45 in4bf) 5.9-7.8 Nm (60-40 kgfcm, 52-69 in4bf) Gartner Banana

TRANSMISSION K Torque specifications (cont'd) GASKET, NEW Gartner Banana

K TRANSMISSION Assembly Procedure 1. Assemble the SST as shown. 2. Mount the transmission case onto the SST. 3. Apply petroleum jelly to the bearing, and install it into the rear of the transmission case with the black surface fat- ing outward. Bearing outer diameter: 53.0mm (2.087 in) 4. Install the oil distributor in the transmission case. 5. Insert the output shaft. 6. Install the rear planetary gear unit (connecting drum, rear planetary pinion carrier and one-way clutch) in the low and reverse brake side. Gartner Banana

TRANSMISSION K 7. Install a new snap ring onto the front of the output shaft. 8. Install the extension housing along with a new gasket. Tightening torque: 20-24 N-m (2.0-2.5 kgfem, 15--18 ft4bf) 9. Verify that the output shaft is locked with the manual le- ver in P range. 10. Set the rear clutch assembly on the top of the front clutch assembly. 11. Install the connecting shell and front planetary gear unit (rear clutch hub, front planetary pinion carrier, rear sun gear) onto the rear clutch assembly. 12. Install the front clutch, rear clutch, rear clutch hub, front planetary pinion carrier, connecting shell, internal gear, sun gear, bearing, and bearing races as a unit into the transmission case. 13. Set a new gasket into the front of the case. Gartner Banana

K TRANSMISSION I , DRUM SUPPORT I 14. Check and adjust the rear clutch total end play. (1) Position the front of the transmission case upward. (2) Set the drum support bearing and race on the rear clutch. (3) Measure distances A and B with a straight edge and vernier calipers. (4) Calculate the total end play by using the formula be- low. Formula: T=A-B4.l mm (0.0039 in) T Total end play A: The distance between the drum support mounting surface (including the drum support gasket) and the drum support bearing race surface on the rear clutch assembly. B: The distance between the drum support bearing race contact surface and the drum support gasket contact surface. 0.1 :The compression amount of a new gasket. Total end play: 0.254.50mm (0.010-0.019 in) (5) Adjust the total end play by selecting the proper bear- ing race. I BEARING Bearing race sizes mm {in) 15. Check and adjust the front clutch end play. (1) Set the bearing race and bearing in position. Gartner Banana

TRANSMISSION K DRUM SUPPORT (2) Measure distances C and D with a straight edge and vernier calipers. (3) Calculate the front clutch end play by using the for- mula below. Formula: T=C-04.1 mm {0.0039 In) T Front clutch end play. C: The distance between the drum support mounting surface (including the drum support gasket) of the transmission case and the bearing surface on the front clutch assembly. D: The distance between the sliding surface of the bearing and the drum support gasket contact sur- face. 0.1 :The compression amount of a new gasket. (4) Adjust the front clutch end play by selecting the prop- er bearing race. Front clutch end play: 0.5--0.8mm (0.020--0.031 in) Bearing race sizes rnm (in) 16. Set the 2nd brake band and strut in position. 17. Tighten the piston stem lightly. 18. Apply petroleum jelly to the bearings and bearing races, and install them as shown. Bearing outer diameter 0: 35.0mm (1.38 in) @: 70.0mm (2.76 in) Bearing race outer diameter 0: 76.0mm (2.99 in) 0: 33.0mm (1.30 in) Gartner Banana