1994 MAZDA MX-5 transmission

K TRANSMISSION Components (Cont'd) SEAL RING, REPLACE / O-RING, REPLACE /' $,&" $ GASKET, REPLACE 25. Extension housing 27. Oil distributor Disassembly I Inspection I 28. Bearing Assembly ............... page K-107 29. Low and reverse brake On-vehicle Removal ....... page K-110 Disassembly I Inspection / On-vehicle Installation ..... page K-110 Assembly .............. 26. Output shaft 30. Speedometer driven gear page K-103 Gartner Banana

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 15. Remove the control valve body as shown in the figure. 16. Remove the solenoid valve connector from the transmis- sion case. 17. Mark the converter housing, fourth gear case, and trans- mission case for proper reassembly. 18. Remove the converter housing from the fourth gear case. Caution The converter housing is made of aluminum, and is therefore easily dented and scratched by metal tools. When removing old sealant, do not gouge or strike the sealing surface of the converter housing. 19. Clean the sealing compound from the converter hous- ing. 20. Remove the fourth gear band servo cover and gasket. Gartner Banana

K TRANSMISSION 21. Loosen the fourth gear band servo locknut and tighten the piston stem. 22. Mark the fourth gear case and oil pump for proper reas- sembly. 23. Install the SST to the oil pump assembly. 24. Slowly remove the oil pump from the transmission case by evenly sliding the weights of the SST. 25. Remove the SST from the oil pump. 26. Loosen the piston stem of the fourth gear band servo. Remove the fourth gear connecting shell and fourth gear planetary gear unit (fourth gear sun gear, fourth gear planetary pinion carrier, fourth gear clutch hub), and di- rect clutch. 27. Remove the fourth gear brake band, and hold it together with a piece of wire as shown in the figure. 28. Remove the band strut. Gartner Banana

TRANSMISSION K 29. Remove the bearing races and bearing. 30. Remove the intermediate shaft. I 45UOKX-116 31. Loosen the 2nd band servo locknut and tighten the pis- ton stem. I 1 45UOKX-117 32. Separate the drum support, accumulator and fourth gear case from the transmission case by tapping it lightly with a plastic hammer. Remove the gasket. u 45UOKX-118 Remove the bearing races and bearing from the drum support, accumulator and fourth gear case. Remove the bearing from the front clutch hole. Loosen the 2nd band servo piston stem and remove the 2nd band strut. Hold the brake band together with a piece of wire as shown in the figure. Remove the band strut. Gartner Banana

K TRANSMISSION 36. Remove the bearing race, front clutch, rear clutch, con- necting shell, and front planetary gear unit (rear clutch hub, front planetary pinion carrier, rear sun gear) as a unit. d 37. Remove the extension housing and gasket. 38. Remove the snap ring from the output shaft with snap ring pliers. 39. Remove the rear planetary gear unit (connecting drum, rear planetary pinion carrier, one-way clutch). 40. Pull out the output shaft. 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