gasket MAZDA MX-5 1994 Repair Manual

K TRANSMISSION 8. Apply ATF to the return spring, and install it into the trans- mission case. 9. Apply even pressure to the perimeter of the body, and install it into the transmission case. 4 10. Install the piston assembly. 11. lnstall and tighten the bolts. Tightening torque: 9.81-14.7 N-m (1 00-150 kgfacm, 86.8--130 in-lbf) On-vehicle Adjustment 1. Remove the exhaust pipe. (Refer to page K-46.) 2. Remove the fourth gear band servo cover and gasket. 3. Loosen the locknut and tighten the piston stem. Tightening torque: 11.8-14.7 Nm (1 20-1 50 kgf-cm, 105--130 in4bf) 4. Loosen the stem the number of turns shown below. Stem: 2 turns 5. Hold the piston stem and tighten the locknut. Tightening torque: 15-49 N-m (1.5-4.0 kgf-m, 11-28 ft-lbf) 6. Install a new gasket and the fourth gear band servo cov- er. Tightening torque: 5.0--6.8 N. m (50-70 kgf-cm, 44--60 in4 bf) 7. Install the exhaust pipe. (Refer to page K-148.) Gartner Banana

TRANSMISSION K DRUM SUPPORT, ACCUMULATOR, AND FOURTH GEAR CASE Preparation SST 49 SO19 OAO Set, centering tool Shaft (Part of P 49 SO 1 9 OAO) 49 SO1 9 004 Pin (Part of 49 SO1 9 OAO) For installation for drum support For installation for drum support For installation for drum support Disassembly / Ins~ection / Assemblv 49 SO1 9 001 Holder (Part of I I 49 SO 1 9 OAO) && 49 SO1 9 003 Stand (Part of 49 SO1 9 OAO) For installation for drum support For installation for drum support 1. isa assemble in ihe 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. I REPLACE @- REP, 1. Drum support 9. D ring Disassembly note ............ page K-80 10. Snap ring Inspection ................... page K-80 11. Accumulator ~lua 2. Seal rings 3. Seal rings 4. Roll pin i/ 5. Plug 6. Gasket 7. One-way valve 8. Steel ball . - isa ass em bl iote ............ page K-80 12. O-ring 13. ~ccumulator piston 14. Seal rings 15. Spring Inspection ................... page K-80 16. Fourth gear case Gartner Banana

K TRANSMISSION STEEL BALL ONE-WAY VALVE 13. Apply ATF to the fourth gear case, and mount it onto the oil pump. 14. Install the steel ball and the one-way valve. 15. Apply ATF to the new seal rings, and install them onto the drum support. 16. Apply ATF to the drum support, and install the support and a new gasket onto the fourth gear case, aligning the marks. 17. Install the SST (pins). 18. Tighten the drum support mounting bolts. Tightening torque: 6.94.8 N-m {7&90 kgfncm, 61-78 inelbf) Gartner Banana

K TRANSMISSION On-vehicle Removal 1. Disconnect the negative battery cable. 2. On level ground, jack up the vehicle and support it evenly on safety stands. 3. Remove the exhaust pipe. (Refer to page K-46.) 4. Remove the propeller shaft. (Refer to section L.) 5. Disconnect the speedometer cable. 6. Support the transmission with a transmission jack. 7. Remove the power plant frame. (Refer to page K-46.) 8. Remove the extension housing and gasket, making sure to allow any ATF to drain into a container. On-vehicle Installation 1. lnstall a new gasket on the transmission case. 2. lnstall the extension housing. Tightening torque: 20-24 N-m (2.0-2.5kgf-m, 15--18 ft-lbf} i/ 3. Install the power plant frame. (Refer to page K-148.) 4. Connect the speedometer cable. 5. lnstall the propeller shaft. (Refer to section L.) 6. Install the exhaust pipe. (Refer to page K-148.) 7. Add ATF, and check the ATF level. (Refer to page K-35.) Gartner Banana

TRANSMISSION K CONTROL VALVE BODY Assembly 1. Verify that all parts are clean and free of dust and other small particles. 2. Apply ATF to all O-rings and gaskets. Assembly Procedure 1. Insert the orifice check valve, plug and springs, and the check ball and spring in the lower valve body. 2. Position the separator plate on the lower valve body. Align the plate and valve body and hold them together with large clips. 3. Install the upper valve body on the separator plate. 4. Install the bolts, referring to page K-124 for their correct sizes. Tighten the bolts to the specified torque. Tightening torque: 6.5--7.8 N-m (6-0 kgf-cm, 5-9 in-lbf) 5. Turn over the valve body assembly and insert the orifice check valves and springs in the lower valve body. Gartner Banana

K TRANSMISSION On-vehicle Removal 1. Disconnect the negative battery cable. 2. On level ground, jack up the vehicle and support it evenly on safety stands. w 3. Remove the exhaust pipe. (Refer to page K-45.) 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. 4. Loosen the oil pan installation bolts, and drain the ATF into a container. 5. Disconnect the vacuum hose. 6. Remove the vacuum diaphragm, O-rings, and vacuum diaphragm rod. 7. Remove the oil pan, and the gasket. 8. Disconnect the solenoid valve connector. 9. Remove the harness from the bracket. 10. Remove the control valve body assembly. Gartner Banana

TRANSMISSION K On-vehicle Installation 1. Set the valve body assembly in position, and align the manual plate and manual valve. Tightening torque: 10.8-1 4.7 N.m (11 0-150 kgf-m, 95.5--130 ftalbf) 2. Connect the solenoid valve connector. 3. Install the harness. , . 4. Install the oil pan along with a new gasket. MANUAL PLATE Tightening torque: 5.9-7.8 N.m (60-80 kgf-cm, 53-69 in4bf) 45UOKX-371 5. Install the bolts. Tightening torque: 5.9-7.8 Nsm (60--80 kgf-cm, 53--69 inalbf) 6. Apply ATF to a new O-ring and install it onto the vacuum diaphragm. 7. Apply ATF to a new O-ring and install it into the transmis- sion case. 8. Apply ATF to the vacuum diaphragm rod and vacuum di- aphragm, and install them into the transmission case. Tightening torque: 7.9-1 0.7 N-m (80-1 10 kgf-cm, 70-95.4 in-lbf) 9. Connect the vacuum hose. 10. Install the exhaust pipe. (Refer to page K-148.) 11. Add approximately 4.0 L (4.2 US qt, 3.5 Imp qt) ATF, and check the ATF level. (Refer to page K-35.) 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 Torque specifications (cont'd) GASKET, NEW 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