manual transmission MAZDA MX-5 1994 Workshop Manual

HOW TO USE THIS MANUAL Example: SHOWS EXPENDABLE PARTS SHOWS APPLICATION POINT OF OIL, ETC SHOWS RELATED PAGE FOR. SERVICE SELECTIVE 1. 8011 2. Lock plate 3. Bearing cup t. Adjusting screw 5. Bearing outer race 5. Locknul 16. Bearing inner race 18. drive pinion 1. Washer Removal ..................... .. .... page M-2' SHOWS TIGHTENING TORQUE SPECIFICATIONS *2 SHOWS TIGHTENING TORQUE UNIT -SHOWS VISUAL INSPECTION INFORMATION *1: The numbers (0, etc.) refer to part identification and servicing procedures. *2: Units are in N.m {kgf.m, ftlbf} unless otherwise specified. $ L SYMBOLS There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. Symbol I Meaning ~pp~y oil Apply brake fluid I Apply automatic transmission fluid Apply grease Apply sealant Kind 0 New engine oil or gear oil as appropriate Apply petroleum jelly Appropriate grease Appropriate sealant Appropriate petroleum jelly Gartner Banana

ABBREVIATIONS 4BDC .... 4BS ...... 4CC ...... 4T ........ 4TDC ..... 4TF ...... 4TS ...... 3AC ...... 3BDC .... 3TDC ..... :ID ....... 2U ....... IOHC .... IRL ...... ITM ...... IC-AT .... iGRA .... EGRV .... ELR ...... EPC ...... ESPS ..... ETS ...... EX ....... FMEM .... HFC ...... HLA ...... H U ....... IC ........ IG ........ IN ........ INT ....... LFC ...... LH ....... LSD ...... M ........ MAF RTN . MT ....... PCTS ..... PCV ...... PIP ....... PRC ...... PIS ....... PMI ...... PWR GND RH ....... RPM ...... RTS ...... SIG RTN . . SLS ...... ... SPOUT S R ....... SST ...... ST ....... SW ....... TDC ...... TNS ...... TRS ...... VPWR .... WSS ..... WTS...... After bottom dead center Antilock brake system Accessory Automatic transmission After top dead center Automatic transmission fluid Ambient temperature sensor Bypass air control Before bottom dead center Before top dead center Cylinder identification display Control unit Double overhead camshaft Daytime running light Diagnostic test mode Electronically controlled automatic transmission EGR air solenoid valve EGR vacuum solenoid valve Emergency locking retractor Electronic pressure control Engine speed sensing power steering Evaporator temperature sensor Exhaust Failure mode effects management High fan control Hydraulic lash adjuster Hydraulic unit Integrated circuit Ignition Intake Intermittent Low fan control Left hand Limited slip differential Motor Mass airflow return Manual transmission Passenger compartment temperature sensor Positive crankcase ventilation Profile ignition pickup Pressure regulator control Power steering Power window Power ground Right hand Revolutions per minute Reduce torque signal Signal return Slip lockup signal Spark output Sensor rotor Special service tool Start Switch Top dead center Tail number side (taillights, license plate lights and side marker lights) Torque reduced signal Vehicle power Wheel speed sensor Water temperature sensor Gartner Banana

TOWING TIEDOWN HOOKS - FRONT /-- TIEDOWN HOOKS - REAR - TOWING Proper towing equipment is necessary to prevent dam- age to the vehicle. Laws and regulations applicable to vehicles in tow must always be observed. As a general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies. With either automatic or manual transmission. 1. Set the ignition switch in the ACC position; 2. Place the selector lever or shift lever in N (Neutral); 3. Release the parking brake. With manual transmission If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use wheel dollies. With automatic transmission If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies. If all four wheels are on the ground, the vehicle may be towed only forward. Don't exceed 56 kmlh {35 mph} and a distance of 56 km (35 miles); you could damage the transmission. If speed must exceed 56 kmlh (35 mph} or a towing dis- tance of 56 km (35 miles}, use one of these methods: Place the rear wheels on a dolly; Tow with the rear wheels off the ground; Disconnect the propeller shaft. If the transmission or rear axle is inoperative, two with the rear wheels off the ground. Caution Don't tow with sling-type equipment. This could damage your vehicle. Use wheel-lift or flatbed equipment. Caution Don't use the hook loops under the front for tow- ing. They are designed ONLY for tying down the vehicle when it's being transported. Using them for towing will damage the bumper. GI-I 9 Gartner Banana

PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE The following items may be done at any time prior to delivery to your customer. INSPECT and ADJUST, if necessary, the following items to specification: 0 Glass, exterior bright metal and paint for damage 0 Convertible top and detachable hardtop (if equipped) for damage 0 Wheel lug nuts and locks 89-117 N.m (9-1 2 kgf.m, 66-86 ft4bf) 0 All weatherstrips for damage or detachment Operation of hood release and lock Operation of fuel lid 0 Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps (if equipped) 0 Outside mirror(s) 0 Mast antenna (if equipped) UNDER HOOD-ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification : Fuel, coolant, and hydraulic lines, fittings, connections, and components for leaks Engine oil level 0 Power steering fluid level (if equipped) Brake and clutch master cylinder fluid level 0 Windshield washer reservoir fluid level 0 Radiator coolant level and specific gravity 0 Tightness of battery terminals pKiq INSTALL the following parts: CHECK operation of the following items: 0 Seat controls (sliding and reclining) 0 Door locks 0 Seat belts and warning system 0 Air bag system using indicator light (Refer to section T) Ignition switch and steering lock 0 Starter interlock switch (clutch pedal) All lights, including warning, and indicator lights 0 Audible warning system 0 Horn, wipers, and washers Audio system 0 Cigarette lighter Power windows (if equipped) 0 Power outside mirrors (if equipped) 0 Heater, defroster, and air conditioner at all mode selections (if equipped) CHECK the following items: Presence of spare fuses 0 Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: 0 Pedal height and free play of brake and clutch pedals I Pedal height mm {in} I Ft: $iy I Clutch pedal {6.89--7.28) (with carpet) Parking brake 7-9 notchesil96 N (20 kgf, 44 Ibf) 0.63.1 (0.024. 12) Brake pedal RUNNING AT OPERATING TEMPERATURE CHECK the following items: 0 Automatic transmission oil level 171-181 (6.73--7.13) (with carpet) I ON HOIST I 4--7 {0.16-0.28} CHECK the following items: 0 Underside fuel, coolant, and hydraulic lines, fittings, con- nections, and components for leaks 4 Tires for cuts or bruises 0 Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage Manual transmission oil level Differential oil level I ROAD TEST I CHECK the following items: Brake operation Clutch operation 0 Steering control 0 Operation of meters and gauges Squeaks, rattles and unusual noises 0 Overall engine performance Seat belt emergency locking retractors 0 Cruise control system (if equipped) I AFTER ROAD TEST I CHECK for necessary owner information materials, tools and spare tire in vehicle The following items must be done just before the delivery to your customer. 0 Load test battery and charge if necessary -1 Install fuses for accessories Adjust tire pressure to specification Load test fesuk 0 Remove seat and floor mat protective covers (Refer to Door Label) 0 Vacuum and clean interior of vehicle Clean outside of vehicle Inspect installation of option parts with invoice 45UOAX-002 Gartner Banana

Schedule 1 (Normal driving conditions) (MT) (Cont'd) Maintenance 1 Number of months or kilometers {miles), whichever comes first I I 1 Months 1 6 18 124 130 136 142148 Service data and inspection point 36,000 1 48,000 1 60,000 1 72,000 1 84,000 1 96,000 Maintenance item I CHASSIS AND BODY Brake lines, hoses, and connections Disc plate thickness Front: 18.0mm (0.71 in)--Minimum I I 1 near: 8.0mm {o31 inFMnimum P-6 I Disc brakes I Pad thickness: I I I I I ~10mrn~0.04inMlinimum I Proper attachment and connections Steering operation and linkage I I I I I I I 0-3'0mm (0-1.1 8 in) Operation and looseness Fluid leakaae or oozina I I Front suspension ball joints I I Free play: I I I I I I I - - Manual transmission oil I I I I I , I Damage, looseness and I grease leakage Oil capacity: 2.0 L (2.1 US at. 1.8 Imp qtJ Ill I I I I I Cracking and damage I , I Oil capacity: I I I Differential oil I Drive shaft dust boots I Bolts and nuts on chassis and body I I I n I 1 .OO L {I .06 US qt, 0.88 Imp qt} Ill Exhaust system heat shield I I I I 1 Retiahten all loose bolts and nuts L All locks and hinges lLlLl - AIR CONDITIONER SYSTEM I L Refrigerant pressure Low pressure: 0.1 5-0.25 MPa {I -52.5 kgf/cm2, 21-36 psi) High pressure: 1.37-1 -57 MPa {I 4.0-1 6.0 kgf/cm2, 1 XI-228 psi] - L Corn~ressor I lnswct the o~eration annuallv Refrigerant L Inspect the refrigerant amount annually L I L " Insulator clearance between body and exhaust system Lubricate all locks and hinges F-128 - Gartner Banana

2 (Unique driving conditions) (MT) (Cont'd) Number of months or kilometers miles), whichever comes first 24 28 32 36 40 44 48 48 56 64 72 80 88 96 Service data and inspection point Page Maintenance interval Maintenance item .# CHASSIS AND BODY Proper attachment and connections Brake lines, hoses, and connections IIII Disc brakes I Steering operation and linkage Disc plate thickness Front: 18.0mm (0.71 inkMinimum Rear: 8.0mm I0.31 in)--Minimum Pad thickness: 1 .Omm 10.04 inbMinimum Free play: O-30mm {0-1.18 in) Operation and looseness Fluid leakage or oozing Front suspension ball joints 1111 Damage, looseness and arease leakaae I I I I Drive shaft dust boots Cracking and damage Manual transmission oil Oil capacity: 2.0 L (2.1 US at, 1.8 I~D at1 Differential oil Oil capacity: 1 .OO L(1.06 US qt, 0.88 Imp qt} Retighten all loose bolts and nuts I I I Bolts and nuts on chassis and body Exhaust system heat shield Insulator clearance between bodv and exhaust svstem I I I I All locks and hinges ILlLlLlL Lubricate all locks and hinges - I AIR CONDITIONER SYSTEM ~p - ~-~p- Refrigerant Inspect the refrigerant amount annually Refrigerant pressure Low pressure: 0.1 5-0.25 MPa {I S-2.5 kgf/cm2, 21 -36 psi} High pressure: 1.37-1 57 MPa (1 4.0-1 6.0 kgf/cm2, 194-228 psi) Comoressor I lnsoect the ooeration annuallv I I - Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . MANUAL TRANSMISSION INDEX ....................................... J- 2 ..................................... OUTLINE J- 3 SPECIFICATIONS ........................... J- 3 ........................ STRUCTURAL VIEW J- 4 ............................. COMPONENTS J- 5 ............................. POWER FLOW J- 6 TROUBLESHOOTING GUIDE .................. J- 7 .......................... TRANSMISSION OIL J- 8 ............................... INSPECTION J- 8 ............................ REPLACEMENT J- 8 TRANSMISSION .............................. J- 9 ............................. PREPARATION J- 9 REMOVAL .................................. J-10 DISASSEMBLY ............................. J-13 ............................... INSPECTION 5-23 ASSEMBLY ................................. J-26 INSTALLATION ............................. J-45 25UOJX-011 Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . AUTOMATIC TRANSMISSION INDEX ................................ K- 2 OUTLINE ............................. K- 3 SPECIFICATIONS ................... K- 3 ........... CROSS-SECTIONAL VIEW K- 4 POWER FLOW DIAGRAM ............ K- 5 OPERATION OF COMPONENTS ...... K- 5 FLUID PASSAGE LOCATIONS ........ K- 6 TROUBLESHOOTING .................. K- 8 GENERAL NOTES ................... K- 8 .......... QUICK DIAGNOSIS CHART K- 9 ON-BOARD DIAGNOSIS SYSTEM ...... K- 11 DESCRIPTION ...................... K- 11 PREPARATION ...................... K- 11 ....... DIAGNOSTIC TROUBLE CODE K- 11 .......... MECHANICAL SYSTEM TEST K- 22 PREPARATION ...................... K- 22 STALL TEST ........................ K- 22 TIME LAG TEST ..................... K- 25 LINE PRESSURE TEST .............. K- 26 ROAD TEST .......................... K- 29 D-RANGE TEST ..................... K- 29 S-RANGE TEST ..................... K- 31 ..................... L-RANGE TEST K- 32 . P-RANGE TEST ..................... K- 33 AUTOMATIC TRANSMISSION FLUID (ATF) ................................ K- 35 ATF ................................ K- 35 REPLACEMENT ..................... K- 37 ELECTRICAL SYSTEM COMPONENTS . . K- 38 PREPARATION ...................... K- 38 HOLD SWITCH ...................... K- 38 PARWNEUTRAL SWITCH ............ K- 39 .............. ATF THERMOSENSOR K- 41 VEHICLE SPEED PULSE GENERATOR ...................... K- 41 1-2 SHIFT. 2-3 SHIFT. 3-4 SHIFT. ... 3-2 CONTROL SOLENOID VALVE K- 42 LOCKUP CONTROL SOLENOID ....... VALVE ............................ K- 42 POWERTRAIN CONTROL MODULE (TRANSMISSION) .................. K- 43 TRANSMISSION ....................... K- 46 TRANSMISSION UNIT (REMOVAL) .... K- 46 TRANSMISSION UNlT (DISASSEMBLY) ................... K- 50 TORQUE CONVERTER .............. K- 61 OILPUMP .......................... K- 62 FOURTH GEAR CONNECTING SHELL AND FOURTH GEAR PLANETARY GEAR UNIT (FOURTH GEAR SUN GEAR. FOURTH GEAR PLANETARY PINION CARRIER. FOURTH GEAR CLUTCH HUB) ...... K- 67 DIRECT CLUTCH .................... K- 70 FOURTH GEAR BAND SERVO ........ K- 76 DRUM SUPPORT. ACCUMULATOR. AND FOURTH GEAR CASE ......... K- 79 2ND BAND SERVO .................. K- 83 FRONT CLUTCH .................... K- 86 REAR CLUTCH ...................... K- 91 CONNECTING SHELL AND FRONT PLANETARY GEAR UNlT (REAR CLUTCH HUB. FRONT PLANETARY PINION CARRIER. REAR SUN GEAR) ................. K- 96 REAR PLANETARY GEAR UNlT (CONNECTING DRUM. REAR PLANETARY PINION CARRIER. ONE-WAY CLUTCH) K- 98 LOW AND REVERSE BRAKE K-102 ................ ......... EXTENSION HOUSING AND PARKING MECHANISM ............. K-107 OIL SEAL ........................... K-ill CONTROL VALVE BODY ............. K-112 UPPER VALVE BODY ................ K-116 LOWER VALVE BODY ............... K-120 CONTROL VALVE BODY ............. K-125 VACUUM DIAPHRAGM ............... K-130 TRANSMISSION UNIT (ASSEMBLY) ... K-132 TRANSMISSION UNIT (INSTALLATION) ................... K-147 OIL COOLER .......................... K-151 REMOVAL I INSPECTION I INSTALLATION ..................... K-151 DRIVE PLATE ......................... K-152 PREPARATION ...................... K-152 REMOVAL 1 INSPECTION I INSTALLATION ..................... K-152 SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) ......... K-154 SHIFT-LOCK SYSTEM COMPONENTS K-154 TROUBLESHOOTING ................ K-155 SHIFT-LOCK ........................ K-157 EMERGENCY OVERRIDE BUTTON ... K-157 KEY INTERLOCK .................... K-157 KEY INTERLOCK SOLENOID ......... K-157 KEY INTERLOCK UNIT ............... K-158 P RANGE SWITCH .................. K-159 SHIFT-LOCKACTUATOR ............. K-159 SELECTOR LEVER .................. K-161 HYDRAULIC CIRCUIT .................. K-168 P RANGE ........................... K-168 R RANGE ........................... K-169 N RANGE; BELOW 7 kmlh I4.34 mph) . K-170 N RANGE; ABOVE 9 kmlh (5.58 mph} . K-171 D RANGE; 1 ST GEAR ................ K-172 D RANGE; 2ND GEAR ............... K-173 D RANGE; THIRD GEAR ............. K-174 D RANGE; FOURTH GEAR. LOCKUP ON ....................... K-175 S RANGE; 1 ST GEAR ................ K-176 S RANGE; 2ND GEAR ............... K-177 S RANGE; THIRD GEAR ............. K-178 L RANGE; 1 ST GEAR ................ K-179 L RANGE; 2ND GEAR ................ K-180 Gartner Banana

TRANSMISSION K 10. Install and tighten the bolts. Tightening torque: 6.9--8.8 N-m (70-90 kgfmcm, 61-78 in-lbf} On-vehicle Adjustment 1. Remove the exhaust pipe. (Refer to page K-47.) 2. Remove the valve body assembly. (Refer to page K-127.) 3. Loosen the locknut and tighten the piston stem. r u I MANUAL PLATE Tightening torque: 12.3-14.2 N-m (1 2+l45 kgf-cm, 109--125 in-lbf) 4. Loosen the stem the number of turns shown below. Stem: 2 112 turns 5. Hold the piston stem and tighten the locknut. Tightening torque: 1 +39 N.m {l.5--4.O kgf-m, 11-28 ftlbf) 6. Install a new body assembly. (Refer to page K-129.) 7. Install the exhaust pipe. (Refer to page K-148.) Gartner Banana

TRANSMISSION K EXTENSION HOUSING AND PARKING MECHANISM Disassembly 1 Inspection 1 Assembly u Note The oil seal does not have to be removed unless it is being replaced. 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts, and repair or replace if necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. . - Extension housing 15. Manual shaft 1 2. Dowel spacer 3. Return spring 4. Parking pawl 5. Pawl shaft 6. Retainer plate 7. Actuator support 8. Steel ball 9. Retainer 10. Spring Inspection .................. page K-108 11. Spring pin 12. Retaining ring 13. Manual plate 14. Parking rod 16. O-ring 17. O-ring 18. Oil distributor Inspection ................ page K-108 19. Seal rings 20. Transmission case 21. Output shaft 22. Snap ring 23. Speedometer drive gear 24. Key 25. Snap ring 26. Oil seal Disassembly note ........... page K-108 Gartner Banana