1994 MAZDA MX-5 clutch

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 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 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

TRANSMISSION K Disassembly / Inspection / Assembly 1. Disassemble in the 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. - 1. Snap ring 7. Return s~rina , " 2. Retaining plate Inspection ................. page K-88 3. Drive plates and driven plates 8. Clutch piston Inspection ................. page K-88 Disassembly note .......... page K-88 4. Dished plate Inspection ................. page K-88 - 5. Snap ring 9. Seal ring Disassembly note .......... page K-88 10. O-ring 6. Spring retainer 11. Front clutch drum Gartner Banana

K TRANSMISSION -&- WIRE DIAMETER Disassembly note Snap ring Caution 4' Depress the spring retainer only enough to install the snap ring. Overpressing will damage the re- tainer assembly edges. 1. Compress the spring by using the SST, then remove the snap ring with snap ring pliers. 2. Remove the spring retainer and spring. Clutch piston 1. Install the front clutch drum onto the drum support along with the seal rings. 2. Remove the piston by applying compressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. Inspection Drive plate 1. Measure the facing thickness in three places, and deter- mine the average of the three readings. Standard thickness: 1.6mm (0,063 in) Minimum thickness: 1.4mm (0.055 in) 2. If not within specification, replace the drive plates. Return spring 1. Measure the spring specifications. Specifications I Outer dia. I Free length I No. of coils I mm {in} mm {in} Wire mm {in) dia. I Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 2. If not within specification, replace the return spring. Clutch piston 1. Verify that there is no air leakage when applying com- pressed air through the oil hole opposite the return spring. 2. Verify that there is airflow when applying compressed air through the oil hole on the return spring side. 3. If not correct, replace the clutch piston. Gartner Banana

Assembly procedure 1. Apply ATF to a new O-ring and install it onto the front clutch drum. 2. Apply ATF to a new seal ring and install it onto the piston. 3. Apply ATF to the inside of the front clutch drum. 4. Apply even pressure to the perimeter of the piston, and install it into the front clutch drum. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal rings. Caution Depress the spring retainer only enough to install the snap ring. Overpressing will damage the re- tainer assembly edges. 6. Install the springs and spring retainer, then compress them by using the SST. 7. While holding the spring retainer down by using the SST, install the snap ring into the spring retainer stopper. 8. Install the dished plate as shown. 9. Soak new drive plates in ATF for at least two hours. 10. Apply ATF to the driven plates immediately before as- sembly. 11. Arrange the drive and driven plates so that the toothless areas are in line with the lubrication hole in the front clutch drum. 12. Install the drive and driven plates into the front clutch drum in the following order: Driven-Drive-Driven-Driven-Drive-Driven-Driven- Drive 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