gasket MAZDA MX-5 1994 Repair Manual

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

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 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

PROPELLER SHAFT L REMOVAL / INSPECTION / INSTALLATION 1. Remove in the order shown in the figure, referring to Removal Note. 2. Inspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to Installation Note. GASKET, REPLACE 36-41 (3.&5.3,28--38) 1. Exhaust pipe 2. Nut 3. Lock washer 4. Bolt 5. Propeller shaft .................. Removal Note below ................... Inspection page L-4 ............. Installation Note page L-4 Removal Note Propeller shaft 1. Before removing the propeller shaft, mark the flanges for correct installation. Gartner Banana

P BRAKE SYSTEM Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 3. Take the following steps after installation: (1) Check and adust the push rod and piston clearance. (Standard: refer to page P-12 1 ABS: refer to page P-15.) (2) Add fluid and bleed the air. (Refer to page P-7.) (3) Check all parts for fluid leakage. (4) Check and adjust the brake pedal height and free play. (Refer to page P-9.) (5) Make an on-vehicle check of the unit. (Refer to page P-20.) (6) Check that the vacuum hose does not contact other parts. ABS 1~22 (1.3--2.2,~.&16} STANDARD 35UOPX-01 1. Fluid level sensor connector 5. Clevis tin 2. Brake pipe and proportioning bypass valve 6. Power 'brake unit 3. Master cylinder 7. Gasket 4. Vacuum hose with check valve Apply sealant to the gasket contact surface Gartner Banana

P ANTILOCK BRAKE SYSTEM (ABS) Disassembly 1 Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. 2.2-2.6 Nm [22-27 kgfcm, 2&29 [2--3,14--22) 6.9-9.8 Nm (70-1 00 kgfcm, 81-47 Inlbf) 1 15--25 11 S-2.5,11-18) 19-25 [1.92.6,14--19) t4.m [kgfm, Wlbf) 25uopx-o: 1. Nut, washer . 2. ABS bracket 3. Connector bolt 4. Gasket 5. Pipe joint 6. Bolt 7. Clip Installation Note 8. Cover 9. Motor relay ................... Inspection page P-56 10. Valve relay ................... Inspection page P-57 11. Casing 12. Mount 13. Stud ................. below 14. Nut, washer 15. Ground wire 16. Hydraulic unit Assembly note A SECTION A-A Clip Secure only the larger part of the wiring harness in the clips. The 2-pin connector part of the harness should re- main outside the clips. Gartner Banana

LIGHTING SYSTEM T Removal 1 Installation Remove and install as shown in the figure. Do not turn the adjusting screws during removal or installa- tion. i/ Retractable headlight u 1. Bezel 2. Headlight housing 3. Headlight Rear Combination Light 4. Motor link 5. Retractor hinge 6. Retractable headlight actuator 1. Lens 2. Gasket 3. Bulb 4. Bracket Gartner Banana