MAZDA MX-5 1994 Workshop Manual

K TRANSMISSION I BEARING I SENSING ROTOR FOURTH GEAR CASE BEARING 19. Align the marks of the transmission case and fourth gear case. Tap lightly with a plastic hammer to avoid damag- ing the seal rings when installing. 20. Set a new gasket in place. Note The sensing rotor and bearing are part of the oil pump assembly. 21. Check and adjust the fourth gear planetary gear unit to- tal end play. Do not install the direct clutch drum at this .-, time. (1) Position the fourth gear case upright. (2) Install the bearing and race on the fourth gear case. (3) Install the planetary carrier, sun gear, connecting shell, and bearing as unit in the fourth gear case. (4) Install the sensing rotor and bearing on the connect- ing shell. (5) Measure distances E and H with a straightedge and vernier calipers. (6) Calculate the fourth gear train total end play by using the formula below. Formula: T=E-H-O.1 mm (0.0039 in) T Total end play. E: The distance between the oil pump mounting sur- face (including the oil pump gasket) and the sensing rotor bearing surface. H: The distance between the oil pump side sensing ro- tor bearing contact surface and the oil pump gasket contact surface. 0.1 :The compression amount of a new gasket. Total end play: 0.25-0.50mm (0.01 0-0.020 in} Gartner Banana

TRANSMISSION K BEARING RACE 45UOKX-419 ROTOR I GEAR (7) Adjust the total end play by selecting the proper bear- ing race. Bearing race sizes mm linl Note The sensing rotor and bearing are part of the oil pump assembly. Check and adjust the direct clutch end play. Do not install the planetary pinion carrier at this time. (1) Install the bearing race in the fourth gear case. (2) Install the direct clutch, sun gear, connecting shell, and bearings in the fourth gear case. (3) Install the sensing rotor and bearing on the connect- ing shell. (4) Measure distances G and H with a straightedge and vernier calipers. (5) Calculate the direct clutch end play by using the for- mula below. Formula: T=G-H4.l mm (0.0039 in) T: Total end play G: The distance between the oil pump mounting sur- face (including the oil pump gasket) and the sensing rotor bearing surface. H: The distance between the oil pump side sensing ro- tor bearing contact surface and the oil pump gasket contact surface. 0.1 :The compression amount of a new gasket. Total end play: 0.M.8mm (0.020--0.031 in) (6) Adjust the direct clutch end play by selecting the proper bearing race. Bearing race sizes rnm {in} Gartner Banana

K TRANSMISSION APPLY SEALANT a 23. Insert the intermediate shaft. The end with the long splines should face front. 24. Apply petroleum jelly to the large bearing race and install it into the fourth gear case. 2 Bearing race outer diameter: 70mm (2.756 in) 25. Apply petroleum jelly to the small bearing and small bearing race, and install them as shown. Bearing outer diameter: 35.0mm (1.378 in) Bearing race outer diameter: 33.0mm (1.299 in) 26. lnstall the fourth gear brake band and band strut. 27. lnstall the fourth gear connecting shell and fourth gear planetary gear unit (fourth gear sun gear, fourth gear planetary pinion carrier, fourth gear clutch hub) onto the direct clutch. 28. lnstall the direct clutch assembly into the fourth gear case. --/ 29. lnstall the oil pump assembly into the transmission case by hand only, using two converter housing bolts as guides. Measure the height difference between the top of the transmission case and the oil pump. 30. Remove the converter housing bolts. Apply sealant to the bolts. 31. Apply sealant to the contact surfaces of the converter housing and oil pump. 32. lnstall the converter housing onto the oil pump, and tight- en the bolts evenly in a crisscross pattern. Tightening torque: 59-68 N-m (6.0-7.0 kgfm, 44--50 ft4bf) Gartner Banana

TRANSMISSION K 33. Apply ATF to the piston stem. 34. Adjust the 2nd brake band. (1) Loosen the locknut and tighten the piston stem. Tightening torque: 12.3--14.2 N-m (125--145 kgf-cm, lOg--l25 in-lbf) (2) Loosen the stem the number of turns shown below. Stem: 2 112 turns (3) Hold the stem and tighten the locknut. Tightening torque: 15-39 N.m (1.5-4.0 kgf-m, 11-28 ft-lbf) Caution Applying compressed air to the servo piston for longer than 3 seconds at a time will damage the seal. 35. Check the servo piston operation by applying com- pressed air through the oil passages of the 2nd band servo. @: Engage @: Release Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 36. Apply ATF to the piston stem. Adjust the fourth gear brake band. (1) Loosen the locknut and tighten the piston stem. Tightening torque: 12-15 N-m (1.2-1.5 kgf-m, 8.7-11 ft-lbf) 11.8-14.7 N-m (1 20-150 kgf.cm, 105-1 30 in-lbf) (2) Loosen the stem the number of turns shown below. Stem: 2 turns Gartner Banana

K TRANSMISSION 0 (3) Hold the stem and tighten the locknut. Tightening torque: 15--39 N-m (1.5-4.0 kgf-m, 11-28 ftelbf) Caution Applying compressed air to the servo piston for longer than 3 seconds at a time will damage the seal. I 1 37. Check the servo piston operation by applying com- 45UOM431 pressed air through the oil passage of the fourth gear band servo. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. MANUAL PLATE 38. Set a new gasket on the fourth gear band servo. Install the fourth gear band servo cover. Tightening torque: 5.0-6.8 N-m (50-70 kgfscm, 44--60 indbf) 39. Apply ATF to a new O-ring and install it onto the solenoid valve connector. 40. Install the solenoid valve connector in the transmission case. 41. Set the valve body assembly in piston, and align the manual plate and manual valve. 42. Install the bolts. Tightening torque: 10.8-14.7 N.m (110--150 kgf-cm, 95.5--130 in-lbf) Gartner Banana

TRANSMISSION K I I 45UOKX-438 GASKET 43. Connect the solenoid valve connectors. 44. Install the harnesses. 45. Apply ATF to a new O-ring, and install it onto the vacuum diaphragm. 46. Select the diaphragm rod. (1) Measure dimension N by using the SST and a scale. (2) Select the proper diaphragm rod in accordance with the table below. Dimension N Below 25.65mm {I .0099 in) 25.65-26.1 5mm (1.0099--1.0295 in) Applicable diaphragm rod 29.0mm {I .I4 in} 29.5mm {I .16 in) 25.90-26.40mm {I .0197-1.0394 in) 26.15-26.65mm {I .029!3-1.0492 in) 48. Install the vacuum diaphragm to the transmission case. 29.75mm {I. 17 in} 30.0mm {I .I 8 in) 26.65--27.15mm (1.0492-1.0689 in} 27.1 5mm {I .0689 in) or over Tightening torque: 7.9-10.7 N.m (80-110 kgfecm, 70-95.4 in-lbf) 30.5mm {I .20 in} 31.0mm {I .22 in) 49. Set the magnets in the oil pan. 50. Install the oil pan along with a new gasket. 51. Install the oil pan mounting bolts. 47. Apply ATF to a new O-ring, and install it into the transmis- sion case. Tightening torque: 5.9-7.8 N-m (60-80 kgf-cm, 53-69 inqlbf) Gartner Banana

K TRANSMISSION 52. Apply ATF to a new O-ring and install it onto the vehicle speed pulse generator. 53. Apply locking compound to the mounting bolt threads, then install the vehicle speed pulse generator. Tightening torque: 7.9-10.7 N-m (80-110 kgtcm, 70-95.4 inmlbf) 54. Apply ATF to the new O-rings and install them into the transmission case. 55. Install the lockup control solenoid. 56. Rotate the manual shaft fully rearward; then return it two notches to the N position. 57. Loosely tighten the parwneutral switch nuts. 58. Remove the screw on the switch body and move the parklneutral switch so that the screw hole on the switch body is aligned with the small hole inside the switch. - Check their alignment by inserting a 2.0mm (0.0079 in) diameter pin into the holes. 59. Tighten the switch attaching nuts. 60. Remove the pin, and tighten the screw into the hole. Tightening torque: 5.0--6.8 Nem (50-70 kgfecrn, 44-60 in-lbf) 61. Ensure that the torque converter is installed correctly by measuring the distance (A) between the end of the torque converter and the end of the converter housing. "A": 22.5mm (0.89 in) 62. Remove the transmission from the engine stand. Gartner Banana

TRANSMISSION K TRANSMISSION UNIT (INSTALLATION) Preparation SST Wrench d b For installation of torque converter bolts 1. On level ground, raise the vehicle and support it evenly on safety stands. 2. Install in the order shown in figure, referring to Installation Note. 3. Fill the transmission with the specified amount and type of the ATF after installation. 4. Warm up the engine, inspect for oil leakage, and verify correct transmission operation. 49 0259 440 Holder, rnainshaft For prevention of oil leakage Gartner Banana

K TRANSMISSION 1. Transmission 10. ATF thermosensor connector Installation Note . . . . . . . . . . page K-149 11. Solenoid connector 2. Transmission mount bolt 12. Vehicle speed pulse generator connector 3. Starter 13. Parklneutral switch connector 4. Torque converter bolt 14. Vacuum hose lnstallation Note . . . . . . . . . . page K-149 15. Speedometer cable 5. Under cover 16. Propeller shaft 6. Power plant frame (PPF) Installation . . . . . . . . . . . . . . . . . . section L lnstallation Note . . . . . . . . . . page K-149 17. Exhaust pipe 7. Harness 18. Performance rod -1 8. Oil pipe 19. Undercover 9. Lockup solenoid connector 20. Shift rod Gartner Banana

TRANSMISSION K Installation Note Transmission Set the transmission onto the transmission jack, paying special attention not to damage the oil pipes. Make sure that the torque converter side of the transmission is tilted slightly upward. Torque converter bolts 1. Align the holes by turning the torque converter. 2. Lock the drive plate by using a screwdriver. 3. Hand-tighten the torque converter mounting bolts in a crisscross pattern. 4. Modify the torque converter mounting bolts tightening torque to allow for a torque wrench-SST combination (Refer to Section GI "Torque Formulas") 5. Tighten the torque converter mounting bolts by using the SST. Tightening torque: 35-49 N-m (3.5-5.0 kgf-m, 26--36 ft-lbf) Power plant frame (PPF) 1. Support the transmission with a jack so that it is level. 2. Position the power plant frame and tighten the transmis- sion-side bolts by hand. 3. Verify that the sleeve is installed into the block. 4. Install the spacer and reamer bolts in the forward hole, and hand-tighten them. Gartner Banana