check oil MAZDA MX-5 1994 Repair 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 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

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

TRANSMISSION K 2. Apply ATF to the spring and install it into the fourth gear case. 3. Apply ATF to the accumulator piston. 4. Apply even pressure to the perimeter of the piston, and install it into the fourth gear case. 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 a new O-ring, and install it on the accumula- tor plug. 7. Install the accumulator plug and snap ring. Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 8. Check the accumulator operation by applying com- pressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 9. Apply ATF to the plug, and install it into the drum support. 10. Tap in a new roll pin. 11. Set the oil pump onto the SST. 12. Apply ATF to a new seal ring, and install it onto the drum support. Gartner Banana

K TRANSMISSION --/b WIRE DIAMETER Inspection Return spring 1. Measure the spring specifications. Specifications 2. If not within specification, replace the return spring. Outer dia. mm {in} 28.2 11.1 10) Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the piston assembly. 2. Apply ATF to a new O-ring, and install it 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. i/ Free length mm {in) 38.7 (1 524) 6. Apply ATF to the piston stem and washer, and install them into the body. 7. Loosely tighten the nut. 8. Apply even pressure to the perimeter of the body, and install it into the transmission case. 9. Install the piston assembly. No, of coils 6.324 Wire dia. mm {in} 3.5 (0.1 38) Gartner Banana

K TRANSMISSION FRONT CLUTCH Preparation SST Preinspection Front clutch operation 1. Install the front clutch onto the drum support along with the seal rings. Apply compressed air through the oil pas- sage as shown. 49 0378 375 Compressor, clutch spring Air pressure: 392 kPa (4.0 kglcm*, 57 psi} max. For removal / installation of front clutch 2. Verify that the retaining 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 replace when assembling. Clearance between retaining plate and snap ring Measure the clearance between the retaining plate and the snap ring. Clearance: 0.9--1 .l mm (0.036-0.043 in} .--- Select and install the correct retaining plate when as- sembling. Gartner Banana

K TRANSMISSION 13. Arrange the retaining plate so that the toothless area is in line with the lubrication hole in the front clutch drum. 14. Install the retaining plate into the front clutch drum, with the step of the retaining plate facing upward. 15. Install the snap ring. 16. Measure the clearance between the retaining plate and snap ring with a feeler gauge. If not within specification, adjust the clearance by installing the correct retaining plate. Clearance: 0.9-1 .l mm (0.035--0.043 in} Retaining plate size mm {in) I 5.8 (0.228) I 6.0 (0.236) I 6.2 (0.244) I Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. u 17. Install the front clutch onto the drum support along with the seal rings. Apply compressed air through the oil pas- sage and check the clutch operation. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. Gartner Banana

TRANSMISSION K REARCLUTCH Preparation SST Preinspection Rear clutch operation 1, Install the rear clutch onto the drum support along with the seal rings. Apply compressed air through the oil pas- sage as shown. i/' Air pressure: 392 kPa {4.0 kg/cm2,57 psi} max. 2. Verify that the retaining 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 replace when assembling. 49 0378 375 Compressor, clutch spring Clearance between retaining plate and snap ring Measure the clearance between the retaining plate and the snap ring. For removal / installation of rear clutch Clearance: 0.8-1.0mm (0.0324.039 in) Adjust the clearance by installing the correct retaining plate. Gartner Banana

TRANSMISSION K 13. Arrange the retaining plate so that the toothless area is in line with the lubrication hole in the rear clutch drum. 14. Install the retaining plate into the rear clutch drum, with the step of the retaining plate facing upward. 15. Install the snap ring. 16. Measure the clearance between the retaining plate and snap ring with a feeler gauge. If not within specification, adjust the clearance by installing the correct retaining plate. Clearance: 0.8-1.0mm (0.032-4.039 in) Retaining plate size mm [in) Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 17. Install the rear clutch onto the drum support along with the seal rings. Apply compressed air through the oil pas- sage and check the clutch operation. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 18. Apply petroleum jelly to the bearing, and install it onto the rear clutch drum. Bearing outer diameter: 35.0mm (1.378 in) Gartner Banana

K TRANSMISSION LOW AND REVERSE BRAKE Preparation SST Preinspection Low and reverse brake operation 1. Apply compressed air through the oil passage as shown. 49 0378 346 Hex head wrench Air pressure: 392 kPa (4.0 kglcm2, 57 psi) max. For removal I installation of one-way clutch 2. Verify that the retaining 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 replace as necessary when assembling. Clearance between retaining plate and snap ring 1. Measure the clearance between the retaining plate and the snap ring. Clearance: 0.8-1.05mm (0.032--0.041 in) i/ 2. Select and install the correct retaining plate when as- sembling. Gartner Banana