1994 MAZDA MX-5 transmission

TRANSMISSION TRANSMISSION UNIT (REMOVAL) Preparation SST 49 0259 440 Holder, mainshaft For prevention of oil leakage 1. Shift the selector lever to N range. 2. Disconnect the negative battery cable. 3. On level ground, jack up the vehicle and support it evenly on safety stands. 4. The oil pan could contain small chips, shavings, and other particles helpful in checking the condition of the transmission and diagnosing certain problems. To ensure that all foreign particles stay in the oil pan, make sure that the transmission is never tipped completely over while the oil pan is still installed. Warning When the transmission and the ATF are hot, they can cause burns to the skin. Allow the trans- mission and the ATF to cool before doing this procedure. 5. Drain the ATF into a suitable container. 6. Remove in the order shown in the figure, referring to Removal Note. 7. After removal, remove the oil pan to check condition of the transmission. Gartner Banana

TRANSMISSION K 1. Shift rod 12. Lockup solenoid connector 2. Undercover 13. Oil pipe 3. Performance rod 14. Harness 4. Exhaust pipe 15. Power plant frame (PPF) 5. Propeller shaft Removal Note ............. page K-48 Removal .................... section L 1 6. Undercover 6. Speedometer cable 17. Torque converter Nut - 7. Vacuum hose 18. Starter u 8. Parklneutral switch connector 19. Transmission mount bolt 9. Vehicle speed pulse generator connector 20. Transmission 10. Solenoid connector Removal Note ............. page K-49 11. ATF thermosensor connector Gartner Banana

K TRANSMISSION Removal note Power plant frame (PPF) 1. Disconnect the wire harness from the power plant frame. 2. Support the transmission with a jack. 3. Remove the front bolts. BOLT SLEEVE 0 BLOCK BOLT (MI 4 x 1.5 45UOKX-084 4. Remove the rear bolts, and pry out the bolt spacer. 5. Screw a long bolt (MI4 x 1.5) into the sleeve. 6. Twist and pull the bolt and sleeve downward. 7. Install a bolt (M6 x 1) into the hole in the block to kee sleeve from turning and unscrew the long (MI 4 x 1.5). 8. Remove the remaining bolt (M6 x 1). !p the bolt Caution Removing the PPF spacers will reduce the perfor- mance of the PPF. If the spacers are removed, re- place the PPF as an assembly. 9. Remove the power plant frame. Gartner Banana

TRANSMISSION K Transmission Caution Shaking the transmission could damage the crank angle sensor on the engine. When remov- ing the transmission, do not shake it up and down or side to side. Remove the transmission. Gartner Banana

TRANSMISSION TRANSMISSION UNIT (DISASSEMBLY) Preparation SST 49 H075 4958 Body (Part of 49 U019 OAOA) For disassembly of transmission For disassembly of transmission For disassembly of transmission 49 U019 OAOA Hanger set, transmission 49 U019 003 Holder (Part of 49 U019 OAOA) For disassembly of transmission For disassembly of transmission Precaution General notes: 1. The oil pan could contain small chips, shavings, and other particles helpful in checking the condition of the transmission and diagnosing certain problems. To ensure that all foreign particles stay in the oil pan, make sure that the transmission is never tipped completely over while the oil pan is still installed. L/ 2. Disassemble transmission in a clean area (dust proof work space) to prevent entry of dust into the mech- anisms. 3. Inspect the individual transmission components in accordance with the QUICK DIAGNOSIS CHART during disassembly. 4. Use only plastic hammers when applying force to separate the light alloy case joints. 5. Never use rags during disassembly; they may leave particles that can clog fluid passages. 6. Several parts resemble one another; organize them so they do not get mixed up. 7. Disassemble the control valve assembly and thoroughly clean it when a clutch or brake band is burned; or when the ATF has degenerated. Cleaning notes: 1. Clean the transmission exterior thoroughly with steam or cleaning solvents, or both, before disassembly. Warning Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. 2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and check that there are no obstructions. Gartner Banana

TRANSMISSION K Components / @ O-RING. O-RING, REPLACE O-RING, REPLACE 1. Vacuum diaphragm 6. Oil pan On-vehicle Removal ....... page K-130 7. Magnet Inspection ................ page K-130 8. Control valve body On-vehicle Installation ..... page K-131 Disassembly I Inspection ... page K-112 On-vehicle Adjustment ..... page K-131 Assembly ................ page K-125 2. Lockup control solenoid valve On-vehicle Removal ....... page K-128 Inspection ................ page K- 42 On-vehicle Installation ..... page K-129 3. Vehicle speed pulse generator 9. Solenoid valve connector Inspection ................ page K- 41 10. Converter housing 4. ParWneutral switch 11. 2nd band servo w Inspection ................ page K- 39 Disassembly I Inspection I Adjustment ............... page K- 40 Assembly ............... page K- 83 5. Torque converter On-vehicle Adjustment ..... page K- 85 Inspection ................ page K- 61 Gartner Banana

K TRANSMISSION Components (Cont'd) 4 GASKET, REPLACE SELECTIVE %I 12. Fourth gear band servo Disassembly / Inspection / ................ Assembly page K-76 ...... On-vehicle Adjustment page K-78 13. Oil pump Disassembly / Inspection 1 ................ Assembly page K-63 14. Fourth gear connecting shell and Fourth gear planetary gear unit (Fourth gear sun gear, Fourth gear planetary pinion carrier, Fourth gear clutch hub) Disassembly / Inspection / ................ Assembly page K-67 15. Direct clutch Disassembly / Inspection / ................ Assembly page K-71 16. Fourth gear brake band and band strut 17. Intermediate shaft 18. Drum support, accumulator, and Fourth gear case Disassembly / Inspection / ................ Assembly page K-79 Gartner Banana

TRANSMISSION K Components (Cont'd) REPLACE 2nd brake band and band strut 22. Connecting shell and front planetary gear Front clutch unit (rear clutch hub, front planetary pinion Disassembly / Inspection / carrier, rear sun gear) Assembly ................ page K-87 Disassembly / Inspection 1 Rear clutch Assembly ................ page K-96 Disassembly / Inspection / Assembly 23. Snap ring page K-92 24. Rear planetary gear unit (connecting drum, ......................... rear planetary pinion carrier, one-way clutch) Disassembly 1 Inspection / Assembly ................ page K-99 Gartner Banana