torque MAZDA MX-5 1994 Manual Online

INDEX, OUTLINE K 1. Hold switch lnspection . . . . . . . . . . . . . . . . page K- 38 Replacement . . . . . . . . . . . . . page K- 39 b 2. ParkINeutral switch lnspection . . . . . . . . . . . . . . . . page K- 39 Adjustment . . . . . . . . . . . . . . . page K- 40 3. Vehicle speed pulse generator lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 42 4. ATF thermosensor lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 41 5. 1-2 shift, 2-3 shift, 3-4 shift, 3-2 control solenoid valves lnspection . . . . . . . . . . . . . . . . page K- 42 6. Lockup control solenoid valve lnspection . . . . . . . . . . . . . . . . page K- 42 7. Powertrain control module (Transmission) lnspection . . . . . . . . . . . . . . . . page K- 43 Replacement . . . . . . . . . . . . . page K- 45 OUTLINE SPECIFICATIONS 8. Automatic transmission Removal . . . . . . . . . . . . . . . . . page K- 46 Disassembly . . . . . . . . . . . . . page K- 50 Assembly . . . . . . . . . . . . . . . . page K-132 lnstallation . . . . . . . . . . . . . . . page K-147 9. Oil cooler Removal 1 Inspection / lnstallation . . . . . . . . . . . . . . page K-151 10. Drive plate Removal 1 Inspection 1 lnstallation . . . . . . . . . . . . . . page K-152 11. P range switch lnspection . . . . . . . . . . . . . . . . page K-159 12. Shift-lock actuator lnspection . . . . . . . . . . . . . . . . page K-159 13. Selector lever lnspection . . . . . . . . . . . . . . . . page K-161 Adjustment . . . . . . . . . . . . . . . page K-160 Removal / Inspection / lnstallation . . . . . . . . . . . . . . page K-163 Disassembly 1 Inspection / Assembly . . . . . . . . . . . . . . . page K-166 - Model Item - Gear ratio NC4A-EL Torque converter stall torque ratio 1 st 1.900 : 1 2.458 4GR Reverse 0.720 2.182 Number of driveldriven plates Servo diameter (Piston outer diameterketainer inner diam- eter) mm{in} Direct clutch Front clutch Rear clutch Automatic transmission fluid (Am 212 315 515 Low and reverse brake Fourth gear band servo 2nd band servo 4/4 56/36 {2.205/1.417} 72/50 {2.835/1.969} Dexron@II or M-111 7.3 {7.7,6.4} 4.0 {4.2,3.5} Type Capacity L {US qt, Imp qtI Total oil pan Gartner Banana

DIRECT CLUTCH LOCKUP PISTON I FOURTH GEAR ONE-WAY CLUTCH / FRONT CLUTCH FRONT PLANETARY GEAR UNlT SENSING ROTOR / 1NPu;sHAn / vE,',lcLE AND BMKE PULSE GENERATOR I 1 INTERMEDIATE SHAFT REAR PLANETARY GEAR UNIT FOURTH GEAR PLANETARY I CONTROL VALVE ASSEMBLY TORQUE CONVERTER REAR CLUTCH Gartner Banana

OUTLINE K POWER FLOW DIAGRAM 1. Torque converter 2. Oil pump 3. Input shaft 4. Fourth gear sun gear 5. Internal gear - 6. Fourth gear one-way clutch (4GR OWC) 7. Fourth gear brake band (4GR Brk.) OPERATION OF COMPONENTS 8. Fourth gear planetary pinion carrier 9. Direct clutch (D/C) 10. Intermediate shaft 11. Front clutch (F/C) 12. 2nd brake band (2nd Brk.) 13. Rear clutch (R/C) 14. Front planetary pinion carrier 15. Internal gear 16. Sun gear 17. Rear planetary pinion carrier 18. Low and reverse brake (L&R Brk.) 19. Internal gear 20. One-way clutch (OWC) 21. Output shaft C3 indicates operation although the band servo remains deactivated due to the large area of the release pressure side. The lockup control solenoid valve operates only during lockup. The 3-2 control solenoid valve operates momentarily during 3-2 downshift. The Fourth gear one-way clutch operates momentarily during 4-3 downshift. Gartner Banana

K OUTLINE FLUID PASSAGE LOCATIONS Transmission Case TO SECOND SERVO RELEASE SlDE TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO SECOND SERVO APPLY SI OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE TO REAR CLUTCH TO FRONT CLUTC OIL PUMP SUCTION , REAR LUBRICATION TO LOW AND REVERSE BRAKE OIL PUMP SUCTION TO FRONT CLUTCH TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO REAR CLUTCH / OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE Oil Pump OIL PUMP DISCHARGE FRONT LOCKUP CONTROL OIL PUMP SUCTION SOLENOID VALVE TORQUE CONVERTER PRESSURE 0i PUMP DISCHARGE Gartner Banana

OUTLINE K Fourth Gear Case TO FRONT CLUTCH TOREARCLUTCH TO FOURTH GEAR SERVO RELEASE SIDE TORQUE CONVERTER OIL PUMP DISCHARGE TO DIRECT CLUTCH TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE FRONT LOCKUP CONTROL VALVE Drum Support - TO DIRECT CLUTCH FRONT AND FOURTH GEAR LUBRICATION 1 OIL PUMP SUCTION TO FRONT CLUTCH TO REAR CLUTCH TORQUE CONVERTER PRESSURE OIL PUMP DISCHARGE Oil Distributor Gartner Banana

ROAD TEST K Evaluation I No lockup shift Condition No 1-2 up or downshift No 2-3 up or downshift No 3-4 up or downshift I Stuck lockup control solenoid valve Stuck locku~ control valve Possible Cause Stuck 1-2 shift solenoid valve Stuck 1-2 shift valve Stuck 2-3 shift solenoid valve Stuck 2-3 shift valve Stuck 3-4 shift solenoid valve Stuck 3-4 shift valve Incorrect shift point I No enaine brakina effect I Worn clutches, brakes I Misadjusted throttle position sensor Sticking shift valves Excessive shift shock or slippage Noise and Vibration Drive the vehicle in fourth gear (lockup), fourth gear (no lockup), and third gear (Hold) and listen closely for any out of the ordinary noise or vibration. The torque converter, propeller shaft, and differential can be sources of abnormal noise and vibration if they are not functioning properly. Check these when searching for sources of noise and vibration. Stuck accumulators Stuck or no one-way check orifice Stuck 3-2 control solenoid valve Stuck 3-2 control valve Worn clutches, brakes, or one-way clutch Kickdown Drive the vehicle in fourth gear, third gear, and 2nd gear and check that kickdown occurs for 4-+3,4-+2, 4+1,3+2,3+1, 2+1, and that the shift points are as shown in the shift diagram. ,U (Refer to pages K-29, 30.) S-RANGE TEST Shift Pattern For this test it is not necessary to inspect shift shock and shift points, since they are almost exactly the same as those for the D-range test. However, in the D-range (Normal) shift diagram, the shift points are different. In S range, the shift patterns for Normal mode are the same. 1. Shift the selector lever to S range and select the Normal mode. 2. Accelerate the vehicle and verify that 1-2 and 2-3 up-and downshifts are obtained, and that no fourth gear and no lockup (below approx. 100 kmlh (63 mph}) are obtained. 3. While driving in S range (Normal mode) and third gear, select the Hold mode and verify that third gear is held until ihe 3-2 downshift point as shown in the S range (Hold) shift diagram is achieved. 4. Accelerate the vehicle in S range (Hold mode) and verify that 2nd gear is held. S-range (Power) shift diagram LOCKUP AVAILABLE WHEN ACCELERATING AND CRUSING LOCKUP AVAILABLE WHEN COASTING -. - VEHICLE SPEED kmlh (rnph} Gartner Banana

ROAD TEST (Hold) shift diagram LOCKUP AVAILABLE WHEN COASTING 818 718 - 618 - 518 ' 418 - 3/8 ' 218 - 118 - 018 0 20 (1 2) 40 (25) 60 (37) 80 (50) 100 (63) 120 (75) 140 (87) 160 (99) VEHICLE SPEED kmh {mph} Noise and Vibration Drive the vehicle in 2nd (Hold) and listen closely for any out of the ordinary noise or vibration. The torque converter, propeller shift, and differential can be sources of abnormal noise and vibration if they are not functioning properly. Check these when searching for sources of noise and vibration. L-RANGE TEST Shift Pattern For this test it is not necessary to inspect shift shock and shift points, since they are almost exactly the same as those for the D-range test. However, in the D-range (Normal) shift diagram, the shift points are different. ,, In L-range, the shift patterns for Normal mode are the same. 1. Shift the selector lever to L-range and select the Normal mode. 2. Accelerate the vehicle and verify that 1-2 up and downshifts are obtained, and that no third gear, no fourth gear, and no lockup are obtained. 3. Drive in 1 st gear, then decelerate and verify that engine braking effect is felt. 4. While driving in D-range (Hold mode) and third gear, shift the selector lever to L-range and verify that third gear is held until the 3-2 downshift point as shown in the L-range (Hold) shift diagram, and that 2nd gear is held until 2-1 downshift point is achieved. 5. Accelerate the vehicle in L-range (Hold mode) and verify that 1 st gear is held. L-range (Power) shift diagram LOCKUP AVAILABLE WHEN COASTING o 20 (12) 40 (25) 60 (37) 80 (50) 100 163) i 20 (75) 14dp7) 160 pgj VEHICLE SPEED kwh {mph) Gartner Banana

ROAD TEST L-range (Hold) shift diagram LOCKUP AVAILABLE WHEN COASTING 0 20 (1 2) 40 (25) 60 {37) 80 {50) 100 {63) 120 {75) 1 40 (87) 1 60 (99) VEHICLE SPEED kmh {mph) Noise and Vibration Drive the vehicle in 1 st (Hold) and listen closely for any out of the ordinary noise or vibration. The torque converter, propeller shift, and differential can be sources of abnormal noise and vibration if they are not functioning properly. Check these when searching for sources of noise and vibration. P-RANGE TEST 1. Shift into P range on a gentle slope, release the brake, and verify that the vehicle does not roll. 2. Shift into P range while driving the vehicle at 4 kmlh (2.5 mph) maximum on a level surface, and verify that the vehicle stops. Gartner Banana

AUTOMATIC TRANSMISSION FLUID (ATF) K REPLACEMENT 1. On level ground, jack up the vehicle and support it evenly on safety stands. 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. 2. Loosen the oil pan installation bolts, and drain the ATF into a container. 3. Remove the oil pan and gasket. 4. Clean the oil pan and the magnet. 5. Install the oil pan along with a new gasket. Tightening torque: 5.9-7.8 N-m (60-80 kgfecm, 53-69 in-lbf) 6. Add approximately 4.0 L (4.2 US qt, 3.5 Imp qt} ATF, and check the ATF level. (Refer to page K-35.) Specified ATF: DexronmII or M-I11 Gartner Banana

ELECTRICAL SYSTEM COMPONENTS K Replacement 1. Disconnect the negative battery cable. 2. Remove the front console. 3. Remove the indicator panel installation screws. 4. Disconnect the connector and remove the hold switch terminals. 5. Remove the selector lever knob assembly. 6. lnstall a new selector lever knob assembly. lnspection of continuity 1. Disconnect the negative battery cable. 2. Disconnect the hold switch connector. 3. Check continuity of the switch. Tightening torque: 2.0-2.9 N.m (20-30 kgfscm, 18-26 in-lbf) Position Normal Depressed 7. lnstall the hold switch terminals and connect the connec- tor. 8. lnstall the indicator panel installation screws. (Refer to page K-163.) 9. lnstall the front console. 10. Connect the negative battery cable. PARKINEUTRAL SWITCH lnspection lnspection of operation 1. Verify that the starter operates only with the ignition switch at the START position and the selector lever in P and N ranges. 2. Verify that the back-up lights illuminate when shifted to R range with the ignition switch in the ON position. 3. Verify that the positions of the selector lever and the se- lector indicator light of the instrument cluster are aligned. 4. Check the ParkINeutral switch if not as specified. 0--4: Continuity 45UOKX-525 4. If not as specified, replace the selector lever knob as- sembly. (Refer to below.) 5. If the switch is OK, check the wiring harness. (Hold switch - powertrain control module (transmission), Hold switch - Body ground.) 6. lnstall the front console. 7. Connect the negative battery cable. Terminal A 0 B 0 Gartner Banana