1994 MAZDA MX-5 clutch

K TRANSMISSION Disassembly / Inspection 1 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. SELECTIVE @ 9 1. Snap ring 8. Clutch piston 2. Retaining ring Disassembly note .......... page K-93 3. Drive plates and driven plates Inspection ................. page K-93 Inspection ................. page K-93 9. Seal ring 4. Dishes plate 10. O-ring 5. Snap ring 11. Rear clutch drum Disassembly note .......... page K-93 12. Bearing 6. Spring retainer 7. Return spring Inspection ................. page K-93 Gartner Banana

TRANSMISSION K WIRE DIAMETER Disassembly note Snap ring Caution Depress the spring retainer only enough to re- move the snap ring. Overpressing will damage the retainer assembly edges. 1. Compress the spring by using the SST, and remove the snap ring with snap ring pliers. 2. Remove the spring retainer and spring. Clutch piston 1. Install the rear clutch drum onto the drum support along with 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. I Outer dia. I Free length I No. of I ;i;;i I mm fin) mm {in} 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. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 3. If not correct, replace the clutch piston. Gartner Banana

TRANSMISSION Assembly procedure 1. Apply ATF to a new O-ring and install it onto the rear clutch drum. 2. Apply ATF to a new seal ring and install it onto the piston. 3. Apply ATF to the inside of the rear clutch drum. 4. Apply even pressure to the perimeter of the piston, and install it into the rear clutch drum by turning it evenly and gradually. 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 rear clutch drum. 12. Install the drive and driven plates into the front clutch drum in the following order: -1 Driven-Drive-Driven-Drive-Driven-Drive-Driven- Drive-Driven-Drive Gartner Banana

TRANSMISSION K 13. Arrange the retaining plate so that the toothless area is in line with the lubrication hole in the rear clutch drum. 14. Install the retaining plate into the rear 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: 0.8-1.0mm (0.032-4.039 in) Retaining plate size mm [in) Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 17. Install the rear 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. 18. Apply petroleum jelly to the bearing, and install it onto the rear clutch drum. Bearing outer diameter: 35.0mm (1.378 in) Gartner Banana

K TRANSMISSION CONNECTING SHELL AND FRONT PLANETARY GEAR UNIT (REAR CLUTCH HUB, FRONT PLANETARY PINION CARRIER, REAR SUN GEAR) Disassembly / Inspection / Assembly 1. Disassemble in the order shown in the figure. 2. Inspect all parts, and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. 1. Connecting shell 5. Bearing 2. Front sun gear 6. Bearing 3. Snap ring 7. Snap ring 4. Front planetary pinion carrier 8. Rear clutch hub Inspection . . . . . . . . . . . . . . . . . page K-97 9. Internal gear Gartner Banana

TRANSMISSION K It- CLEARANCE Inspection Front planetary pinion carrier 1. Measure the clearance between the pinion washer and the planetary pinion carrier. Clearance Standard : 0.2--0.7mm (0.008-0.027 in} Maximum : 0.8mm (0.031 in) 2. If not within specification, replace the planetary pinion carrier. Assembly procedure 1. Apply ATF to the rear clutch hub and internal gear, and assemble them with the snap ring. 2. Apple petroleum jelly to the bearing, and install it onto the rear clutch hub with the black surface facing upward. Bearing outer diameter: 70.0mm (2.756 in) 3. Apple petroleum jelly to the bearing, and install it onto the rear clutch hub with the black surface facing upward. Bearing outer diameter: 53.0mm (2.087 in} 4. Apply ATF to the front planetary pinion carrier, and install it into the internal gear. Gartner Banana

K TRANSMISSION 5. Apply ATF to the sun gear, and install it into the front planetary pinion carrier with the groove facing the front (arrow). 6. Apply ATF to the sun gear, and install it into the front planetary pinion carrier. REAR PLANETARY GEAR UNIT (CONNECTING DRUM, REAR PLANETARY PINION CARRIER, ONE-WAY CLUTCH) Preinspection One-way clutch operation Install the rear planetary gear unit and verify that the rear , planetary gear unit rotates smoothly when turned clock- wise and locked when turned counterclockwise. If not, replace the one-way clutch. Gartner Banana

TRANSMISSION K Disassembly / Inspection / Assembly 1. Disassemble in the order shown in the figure. 2. Inspect all parts, and repair or replace as necessary. ,, 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. @ APPLY PETROLEUM JELLY 1. Bearing 7. Drive flange 2. Snap ring 8. Internal gear 3. Rear planetary pinion carrier 9. Snap ring u Inspection . . . . . . . . . . . . . . . . page K-100 10. One-way clutch 4. Bearing 11. Snap ring 5. Bearing 12. Connecting drum 6. Snap ring Gartner Banana