1994 MAZDA MX-5 torque

TRANSMISSION K Procedure 1. Place wooden blocks under the transmission at the con- verter housing and the extension housing positions. 2. Remove the oil pan and gasket. Examine any material found in the pan or on the magnet to determine the condition of the transmission. Clutch facing material . . . . . Drive plate and brake band wear Steel (magnetic) . . . . . . . . . . Bearing, gear, and driven plate wear Aluminum (nonmagnetic) . . Bushings or cast alumi- num parts wear If large amounts of material are found, replace the torque converter and carefully check the transmission for the cause. 3. Install the oil pan and gasket with a few bolts to protect the valve body. 4. Remove the vacuum diaphragm, lockup control solenoid valve, vehicle speed pulse generator, and O-rings. 5. Remove the parwneutral switch. 6. Remove the speedometer driven gear from the exten- sion housing. 7. Remove the O-ring from the speedometer driven gear. Gartner Banana

K TRANSMISSION 8. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to keep any re- maining fluid from spilling. 9. Assemble the SST as shown. 10. Mount the transmission onto the SST. 11. Remove the oil pan and gasket. 12. Remove the magnets. 13. Disconnect the solenoid valve connectors. 14. Remove the harnesses from the bracket. Gartner Banana

TRANSMISSION K 41. Remove the oil distributor. 42. Remove the bearing. TORQUE CONVERTER Inspection 1. Check the outside of the converter for damage and cracks, and replace the torque converter if there is any problem. 2. Check for rust on the pilot hub or on the boss, and re- move the rust completely if there is any. Washing inside the converter 1. Drain any ATF remaining in the converter. 2. Pour in solvent (0.5 L, 0.5 US qt, 0.4 Imp qt). 3. Shake the converter to clean the inside. Pour out the sol- vent. 4. Clean the inside of the converter with compressed air so that the inside is completely empty. 5. Pour in ATF. 6. Shake the converter to clean the inside. Pour out the ATF. Gartner Banana

K TRANSMISSION 8. Carefully install the oil pump cover onto the oil pump housing. 9. Install the SST (pins) for alignment. J 10. Tighten the bolts evenly and gradually in the order shown. Tightening torque: 5.9-7.8 N-m (6040 kgf-cm, 53-69 in-lbf) 11. Remove the SST (pins). 12. Apply ATF to a new O-ring, and install it onto the input shaft. 13. Apply ATF to the input shaft, and install it into the oil Pump. 14. Apply petroleum jelly to the bearing, and install it onto the oil pump. Bearing race outer diameter: 70.0mm (2.756 in) 15. Apply ATF to the sensing rotor splines, and install the sensing rotor onto the input shaft. 16. Install the snap ring on the input shaft with snap ring pli- ers. 17. Set the oil pump on the torque converter, and verify that the pump turns smoothly. Gartner Banana

K TRANSMISSION 8. Apply ATF to the return spring, and install it into the trans- mission case. 9. Apply even pressure to the perimeter of the body, and install it into the transmission case. 4 10. Install the piston assembly. 11. lnstall and tighten the bolts. Tightening torque: 9.81-14.7 N-m (1 00-150 kgfacm, 86.8--130 in-lbf) On-vehicle Adjustment 1. Remove the exhaust pipe. (Refer to page K-46.) 2. Remove the fourth gear band servo cover and gasket. 3. Loosen the locknut and tighten the piston stem. Tightening torque: 11.8-14.7 Nm (1 20-1 50 kgf-cm, 105--130 in4bf) 4. Loosen the stem the number of turns shown below. Stem: 2 turns 5. Hold the piston stem and tighten the locknut. Tightening torque: 15-49 N-m (1.5-4.0 kgf-m, 11-28 ft-lbf) 6. Install a new gasket and the fourth gear band servo cov- er. Tightening torque: 5.0--6.8 N. m (50-70 kgf-cm, 44--60 in4 bf) 7. Install the exhaust pipe. (Refer to page K-148.) Gartner Banana

K TRANSMISSION STEEL BALL ONE-WAY VALVE 13. Apply ATF to the fourth gear case, and mount it onto the oil pump. 14. Install the steel ball and the one-way valve. 15. Apply ATF to the new seal rings, and install them onto the drum support. 16. Apply ATF to the drum support, and install the support and a new gasket onto the fourth gear case, aligning the marks. 17. Install the SST (pins). 18. Tighten the drum support mounting bolts. Tightening torque: 6.94.8 N-m {7&90 kgfncm, 61-78 inelbf) 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 Assembly procedure 1. Apply ATF to a new O-ring and install it onto the piston. 2. Apply ATF to a new seal ring and install it onto the piston. 3. Apply even pressure to the perimeter of the low and re- verse brake piston, and install it into the transmission case. 4. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring and O-ring. 5. Apply ATF to the one-way clutch inner race, thrust wash- er, and return spring. 6. Assemble the one-way clutch inner race, thrust washer, and return spring, and install them in the transmission case. 7. Verify that the return spring, thrust washer, and rings are properly positioned before securing the bolts. RETURN SPVING THRUSTWASHER 45UOKX-291 8. Tighten the allen head bolts by using the SST. Tightening torque: 12.8-1 7.6 N-m (1 30-180 kgfacm, 11 3-156 in-lbf) 9. Soak new drive plates in ATF for at least two hours. 10. Apply ATF to the driven plates immediately before as- sembly. 11. Install the drive and driven plates into the transmission case in the following order: Driven-Drive-Driven-Drive-Driven-Drive-Driven- Drive Gartner Banana