1994 MAZDA MX-5 SECTION T

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 On-vehicle Removal 1. Disconnect the negative battery cable. 2. On level ground, jack up the vehicle and support it evenly on safety stands. 3. Remove the exhaust pipe. (Refer to page K-46.) 4. Remove the propeller shaft. (Refer to section L.) 5. Disconnect the speedometer cable. 6. Support the transmission with a transmission jack. 7. Remove the power plant frame. (Refer to page K-46.) 8. Remove the extension housing and gasket, making sure to allow any ATF to drain into a container. On-vehicle Installation 1. lnstall a new gasket on the transmission case. 2. lnstall the extension housing. Tightening torque: 20-24 N-m (2.0-2.5kgf-m, 15--18 ft-lbf} i/ 3. Install the power plant frame. (Refer to page K-148.) 4. Connect the speedometer cable. 5. lnstall the propeller shaft. (Refer to section L.) 6. Install the exhaust pipe. (Refer to page K-148.) 7. Add ATF, and check the ATF level. (Refer to page K-35.) Gartner Banana

TRANSMISSION K Inspection Check for damage, wear, or oil leaking from the oil seal. Replace if necessary. OIL SEAL Preparation SST On-vehicle Replacement 1. Remove the exhaust pipe. (Refer to page K-46.) 2. Remove the propeller shaft. (Refer to section L.) 3. Remove the oil seal from the extension housing. 4. Apply ATF to outer periphery and lip surface. 5. Install the new oil seal by using the SST. 6. lnstall the propeller shaft. (Refer to section L.) 7. Install the exhaust pipe. (Refer to page K-148.) w 49 GO30 795 For installation of oil Installer, oil seal 49 GO30 797 Handle (Part of 49 GO30 795) For installation of oil seal Gartner Banana

K TRANSMISSION 1. Transmission 10. ATF thermosensor connector Installation Note . . . . . . . . . . page K-149 11. Solenoid connector 2. Transmission mount bolt 12. Vehicle speed pulse generator connector 3. Starter 13. Parklneutral switch connector 4. Torque converter bolt 14. Vacuum hose lnstallation Note . . . . . . . . . . page K-149 15. Speedometer cable 5. Under cover 16. Propeller shaft 6. Power plant frame (PPF) Installation . . . . . . . . . . . . . . . . . . section L lnstallation Note . . . . . . . . . . page K-149 17. Exhaust pipe 7. Harness 18. Performance rod -1 8. Oil pipe 19. Undercover 9. Lockup solenoid connector 20. Shift rod Gartner Banana

TRANSMISSION K Installation Note Transmission Set the transmission onto the transmission jack, paying special attention not to damage the oil pipes. Make sure that the torque converter side of the transmission is tilted slightly upward. Torque converter bolts 1. Align the holes by turning the torque converter. 2. Lock the drive plate by using a screwdriver. 3. Hand-tighten the torque converter mounting bolts in a crisscross pattern. 4. Modify the torque converter mounting bolts tightening torque to allow for a torque wrench-SST combination (Refer to Section GI "Torque Formulas") 5. Tighten the torque converter mounting bolts by using the SST. Tightening torque: 35-49 N-m (3.5-5.0 kgf-m, 26--36 ft-lbf) Power plant frame (PPF) 1. Support the transmission with a jack so that it is level. 2. Position the power plant frame and tighten the transmis- sion-side bolts by hand. 3. Verify that the sleeve is installed into the block. 4. Install the spacer and reamer bolts in the forward hole, and hand-tighten them. Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K TROUBLESHOOTING Circuit Diagram - 1-21 AT SHIFT-LOCK SYSTEM Diagnosis chart Problem -- Selector lever cannot be moved from P range with brake pedal depressed and ignition switch ON Possible cause ROOM 1 OA fuse burned or not installed METER 10A fuse burned IG1 system malfunction Wire harness broken Poor connection IG 80A fuse burned Ignition switch malfunction Stop light switch remains OFF Stop light system malfunction Wire harness broken Poor connection STOP 15A fuse burned P range switch remains OFF P range switch system malfunction Wire harness broken (poor ground) Poor connection Shift-lock actuator malfunction Wire harness broken Poor connection Misadjustrnent of selector lever or improper assembly of shift-lock actuator Action I Page Repair or replace Connect firmly Replace Install or replace Replace K-155 K-155 Repair or replace K-155 Connect firmly K-155 Replace K-155 Inspect and replace Adjust or replace section T section T Repair or replace Connect firmly Inspect and replace Repair or replace Connect firmly Adjust or repair K-155 K-I55 K-155 K-155 K-159 Gartner Banana

K ' SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Problem Possible cause Selector lever can be ROOM 1OA fuse burned or not installed moved lrom nnp. [stop light switch remains ON with ignition switch ON, but without brake pedal I Shift-lock actuator malfunction depressed Misadjustment of selector lever or improper assembly of shift-lock actuator Selector lever can be ROOM 10A fuse burned or not installed range Ignition switch malfunction with ignition switch OFF and brake pedal de- Shift-lock actuator malfunction pressed Misadjustrnent of selector lever or improper assembly of shift-iock actuator Shift-lock actuator op- P range switch remains ON eration heard when brake pedal depressed ' Misadjustment of selector lever or improper assembly with ignition switch ON of shift-lock actuator in other than P range Action -- Install or replace Adjust or replace lnspect and replace Adjust or replace Install or replace Inspect and replace inspect and replace Adjust or replace Inspect and replace Adjust or replace section T K-159 Selector lever remains locked when emergency override button oper- ated Emergency override button not pushed fully down Broken emergency override button lgnitlon key can be turned to lock position with selector lever in other than P range Push down fully and hold emergency override but- Misadjustment of indicator pedal ROOM 10A fuse burned or not installed Key interlock solenoid malfunction Wire harness broken Poor connection P range switch remains ON P range switch system malfunction Wire harness broken Poor connection lnspect and replace Repair or replace Connect firmly Adjust Install or replace K-161 - K-151 Inspect and replace Repair or replace Connect firmly I lanition kev cannot be I P ranae switch remains OFF I lns~ect and replace 1 K-158 I K-159 K-166 K-166 Key cylinder (push switch) malfunction Wire harness broken Poor connection Key interlock unit malfunction I ~~~~~$1~~~~ I Key iierlock solenoid malfunction I' I I Inspect and replace I K-158 I range Inspect and replace Repair or replace Connect firmly Inspect and replace Key cylinder (push switch) malfunction I Inspect and replace I section T section T K-155 K-155 section T I I Misadjustment of selector lever 1 Adjust I K-160 ] 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 . FRONT AND REAR AXLES ....................................... INDEX M- 2 ..................................... OUTLINE M- 3 SPECIFICATIONS ........................... M- 3 TROUBLESHOOTING GUIDE .................. M- 4 ............................... FRONT AXLE M- 4 ................................ REAR AXLE M- 4 ............................. DIFFERENTIAL M- 4 ................................. FRONT AXLE M- 5 PREPARATION ............................. M- 5 WHEEL HUB. STEERING KNUCKLE .......... M- 6 .................................. REAR AXLE M-10 PREPARATION ............................. M-10 ......................... DISC BRAKE TYPE M-11 ................................ DRIVE SHAFT M-17 .................... DOUBLE OFFSET JOINT M-17 ............................... DIFFERENTIAL M-23 PREPARATION ............................. M-23 DIFFERENTIAL OIL ......................... M-25 ................. OIL SEAL (OUTPUT SHAFT) M-25 DIFFERENTIAL. STANDARD; DIFFERENTIAL. TORQUE SENSING LIMITED SLIP ("TORSEN" LSD) ........................... M-27 45UOMX-001 "TORSEN" is a registered trademark of ZEXEL-GLEASON USA . INC Gartner Banana