1994 MAZDA MX-5 Oil

TRANSMISSION J 9. Install the power plant frame bracket. Tightening torque @ : lO4--123 N.m (1 0.6-1 2.6 kgf.m, 76.7-91.1 ft-lbf) @: 37-43 N.m (3.7-5.5 kgf-m, 27-39 ftlbf) 10. Remove the jack, and connect the wire harness. 11. Measure distance A with a straightedge and vernier cali- pers. Distance A: 66.0 2 5mm (2.60 a 0.197 in) 12. If the distance is not within specification, reposition the PPF to the transmission. FRONT Shift lever 1. Pour the specified amount of oil into the change control case. The change control case must also be filled with the specified amount of oil whenever the extension housing has been removed or the transmission has been overhauled. Specified oil Grade: API service GL-4 or GL-5 All season: SAE 75W-90 Above 10°C (50°F): SAE 80W-90 Specified amount: 80-95 cc (4.9-5.8 cu in) 2. Apply oil to the shift lever as shown. 3. Apply sealant to the contact surfaces of the boot panel and the change control case. 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 . AUTOMATIC TRANSMISSION INDEX ................................ K- 2 OUTLINE ............................. K- 3 SPECIFICATIONS ................... K- 3 ........... CROSS-SECTIONAL VIEW K- 4 POWER FLOW DIAGRAM ............ K- 5 OPERATION OF COMPONENTS ...... K- 5 FLUID PASSAGE LOCATIONS ........ K- 6 TROUBLESHOOTING .................. K- 8 GENERAL NOTES ................... K- 8 .......... QUICK DIAGNOSIS CHART K- 9 ON-BOARD DIAGNOSIS SYSTEM ...... K- 11 DESCRIPTION ...................... K- 11 PREPARATION ...................... K- 11 ....... DIAGNOSTIC TROUBLE CODE K- 11 .......... MECHANICAL SYSTEM TEST K- 22 PREPARATION ...................... K- 22 STALL TEST ........................ K- 22 TIME LAG TEST ..................... K- 25 LINE PRESSURE TEST .............. K- 26 ROAD TEST .......................... K- 29 D-RANGE TEST ..................... K- 29 S-RANGE TEST ..................... K- 31 ..................... L-RANGE TEST K- 32 . P-RANGE TEST ..................... K- 33 AUTOMATIC TRANSMISSION FLUID (ATF) ................................ K- 35 ATF ................................ K- 35 REPLACEMENT ..................... K- 37 ELECTRICAL SYSTEM COMPONENTS . . K- 38 PREPARATION ...................... K- 38 HOLD SWITCH ...................... K- 38 PARWNEUTRAL SWITCH ............ K- 39 .............. ATF THERMOSENSOR K- 41 VEHICLE SPEED PULSE GENERATOR ...................... K- 41 1-2 SHIFT. 2-3 SHIFT. 3-4 SHIFT. ... 3-2 CONTROL SOLENOID VALVE K- 42 LOCKUP CONTROL SOLENOID ....... VALVE ............................ K- 42 POWERTRAIN CONTROL MODULE (TRANSMISSION) .................. K- 43 TRANSMISSION ....................... K- 46 TRANSMISSION UNIT (REMOVAL) .... K- 46 TRANSMISSION UNlT (DISASSEMBLY) ................... K- 50 TORQUE CONVERTER .............. K- 61 OILPUMP .......................... K- 62 FOURTH GEAR CONNECTING SHELL AND FOURTH GEAR PLANETARY GEAR UNIT (FOURTH GEAR SUN GEAR. FOURTH GEAR PLANETARY PINION CARRIER. FOURTH GEAR CLUTCH HUB) ...... K- 67 DIRECT CLUTCH .................... K- 70 FOURTH GEAR BAND SERVO ........ K- 76 DRUM SUPPORT. ACCUMULATOR. AND FOURTH GEAR CASE ......... K- 79 2ND BAND SERVO .................. K- 83 FRONT CLUTCH .................... K- 86 REAR CLUTCH ...................... K- 91 CONNECTING SHELL AND FRONT PLANETARY GEAR UNlT (REAR CLUTCH HUB. FRONT PLANETARY PINION CARRIER. REAR SUN GEAR) ................. K- 96 REAR PLANETARY GEAR UNlT (CONNECTING DRUM. REAR PLANETARY PINION CARRIER. ONE-WAY CLUTCH) K- 98 LOW AND REVERSE BRAKE K-102 ................ ......... EXTENSION HOUSING AND PARKING MECHANISM ............. K-107 OIL SEAL ........................... K-ill CONTROL VALVE BODY ............. K-112 UPPER VALVE BODY ................ K-116 LOWER VALVE BODY ............... K-120 CONTROL VALVE BODY ............. K-125 VACUUM DIAPHRAGM ............... K-130 TRANSMISSION UNIT (ASSEMBLY) ... K-132 TRANSMISSION UNIT (INSTALLATION) ................... K-147 OIL COOLER .......................... K-151 REMOVAL I INSPECTION I INSTALLATION ..................... K-151 DRIVE PLATE ......................... K-152 PREPARATION ...................... K-152 REMOVAL 1 INSPECTION I INSTALLATION ..................... K-152 SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) ......... K-154 SHIFT-LOCK SYSTEM COMPONENTS K-154 TROUBLESHOOTING ................ K-155 SHIFT-LOCK ........................ K-157 EMERGENCY OVERRIDE BUTTON ... K-157 KEY INTERLOCK .................... K-157 KEY INTERLOCK SOLENOID ......... K-157 KEY INTERLOCK UNIT ............... K-158 P RANGE SWITCH .................. K-159 SHIFT-LOCKACTUATOR ............. K-159 SELECTOR LEVER .................. K-161 HYDRAULIC CIRCUIT .................. K-168 P RANGE ........................... K-168 R RANGE ........................... K-169 N RANGE; BELOW 7 kmlh I4.34 mph) . K-170 N RANGE; ABOVE 9 kmlh (5.58 mph} . K-171 D RANGE; 1 ST GEAR ................ K-172 D RANGE; 2ND GEAR ............... K-173 D RANGE; THIRD GEAR ............. K-174 D RANGE; FOURTH GEAR. LOCKUP ON ....................... K-175 S RANGE; 1 ST GEAR ................ K-176 S RANGE; 2ND GEAR ............... K-177 S RANGE; THIRD GEAR ............. K-178 L RANGE; 1 ST GEAR ................ K-179 L RANGE; 2ND GEAR ................ K-180 Gartner Banana

INDEX, OUTLINE K 1. Hold switch lnspection . . . . . . . . . . . . . . . . page K- 38 Replacement . . . . . . . . . . . . . page K- 39 b 2. ParkINeutral switch lnspection . . . . . . . . . . . . . . . . page K- 39 Adjustment . . . . . . . . . . . . . . . page K- 40 3. Vehicle speed pulse generator lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 42 4. ATF thermosensor lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 41 5. 1-2 shift, 2-3 shift, 3-4 shift, 3-2 control solenoid valves lnspection . . . . . . . . . . . . . . . . page K- 42 6. Lockup control solenoid valve lnspection . . . . . . . . . . . . . . . . page K- 42 7. Powertrain control module (Transmission) lnspection . . . . . . . . . . . . . . . . page K- 43 Replacement . . . . . . . . . . . . . page K- 45 OUTLINE SPECIFICATIONS 8. Automatic transmission Removal . . . . . . . . . . . . . . . . . page K- 46 Disassembly . . . . . . . . . . . . . page K- 50 Assembly . . . . . . . . . . . . . . . . page K-132 lnstallation . . . . . . . . . . . . . . . page K-147 9. Oil cooler Removal 1 Inspection / lnstallation . . . . . . . . . . . . . . page K-151 10. Drive plate Removal 1 Inspection 1 lnstallation . . . . . . . . . . . . . . page K-152 11. P range switch lnspection . . . . . . . . . . . . . . . . page K-159 12. Shift-lock actuator lnspection . . . . . . . . . . . . . . . . page K-159 13. Selector lever lnspection . . . . . . . . . . . . . . . . page K-161 Adjustment . . . . . . . . . . . . . . . page K-160 Removal / Inspection / lnstallation . . . . . . . . . . . . . . page K-163 Disassembly 1 Inspection / Assembly . . . . . . . . . . . . . . . page K-166 - Model Item - Gear ratio NC4A-EL Torque converter stall torque ratio 1 st 1.900 : 1 2.458 4GR Reverse 0.720 2.182 Number of driveldriven plates Servo diameter (Piston outer diameterketainer inner diam- eter) mm{in} Direct clutch Front clutch Rear clutch Automatic transmission fluid (Am 212 315 515 Low and reverse brake Fourth gear band servo 2nd band servo 4/4 56/36 {2.205/1.417} 72/50 {2.835/1.969} Dexron@II or M-111 7.3 {7.7,6.4} 4.0 {4.2,3.5} Type Capacity L {US qt, Imp qtI Total oil pan Gartner Banana

OUTLINE K POWER FLOW DIAGRAM 1. Torque converter 2. Oil pump 3. Input shaft 4. Fourth gear sun gear 5. Internal gear - 6. Fourth gear one-way clutch (4GR OWC) 7. Fourth gear brake band (4GR Brk.) OPERATION OF COMPONENTS 8. Fourth gear planetary pinion carrier 9. Direct clutch (D/C) 10. Intermediate shaft 11. Front clutch (F/C) 12. 2nd brake band (2nd Brk.) 13. Rear clutch (R/C) 14. Front planetary pinion carrier 15. Internal gear 16. Sun gear 17. Rear planetary pinion carrier 18. Low and reverse brake (L&R Brk.) 19. Internal gear 20. One-way clutch (OWC) 21. Output shaft C3 indicates operation although the band servo remains deactivated due to the large area of the release pressure side. The lockup control solenoid valve operates only during lockup. The 3-2 control solenoid valve operates momentarily during 3-2 downshift. The Fourth gear one-way clutch operates momentarily during 4-3 downshift. Gartner Banana

K OUTLINE FLUID PASSAGE LOCATIONS Transmission Case TO SECOND SERVO RELEASE SlDE TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO SECOND SERVO APPLY SI OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE TO REAR CLUTCH TO FRONT CLUTC OIL PUMP SUCTION , REAR LUBRICATION TO LOW AND REVERSE BRAKE OIL PUMP SUCTION TO FRONT CLUTCH TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO REAR CLUTCH / OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE Oil Pump OIL PUMP DISCHARGE FRONT LOCKUP CONTROL OIL PUMP SUCTION SOLENOID VALVE TORQUE CONVERTER PRESSURE 0i PUMP DISCHARGE Gartner Banana

OUTLINE K Fourth Gear Case TO FRONT CLUTCH TOREARCLUTCH TO FOURTH GEAR SERVO RELEASE SIDE TORQUE CONVERTER OIL PUMP DISCHARGE TO DIRECT CLUTCH TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE FRONT LOCKUP CONTROL VALVE Drum Support - TO DIRECT CLUTCH FRONT AND FOURTH GEAR LUBRICATION 1 OIL PUMP SUCTION TO FRONT CLUTCH TO REAR CLUTCH TORQUE CONVERTER PRESSURE OIL PUMP DISCHARGE Oil Distributor Gartner Banana

TROUBLESHOOTING If the 3 steps on page K-8 are followed, the cause of the problem should be located. Another guide to faster location of the causes of problems, the QUICK DIAGNOSIS CHART, is on page K-1 0. b In this chart, numbers are used to indicate the components that may be the cause of 22 possible prob- lems. It is necessary to check only those components indicated by numbers during each step of the trouble- shooting process to locate the cause of the problem quickly. QUICK DIAGNOSIS CHART The QUICK DIAGNOSIS CHART shows different .problems and the relationship of components that might be the cause. 1. Components indicated in the "Adjustment" row indicate the possibility that the problem may result from an incorrect adjustment. Check the adjustment of each component, and readjust if necessary. 2. Components indicated in the "Self-DiagnosisWrow are diagnosed by the Powertrain control module (Transmission) self-diagnostic function. 3. Input and output signals of the Powertrain control module (Transmission) for components indicated in the "Tester" row can be easily checked with the Engine signal Monitor. 4. Components indicated in the "Mechanical System Test" row can be checked for malfunction by the re- sults of oil pressure test. 5. Components indicated in the "Road Test" row can be checked for malfunction by the results of the road test. 6. The numbers in the chart indicate the order of inspection for detecting malfunctions. 7. Circled numbers indicate that the transmission must be removed from the vehicle. 8. The checking, adjusting, repair, and replacement procedures for components are described in the page(s) shown in the "Reference page" row. Gartner Banana

K MECHANICAL SYSTEM TEST MECHANICAL SYSTEM TEST PREPARATION SST STALL TEST 49 0378 400A Gauge set, oil pressure 49 801 9 901 Gauge, oil pressure For oil pressure test For oil pressure test This test is performed to determine if there is slippage of the friction elements or malfunction of the hy- draulic components. Preparation 1. Check the engine coolant, engine oil, and ATF levels before testing. 2. Warm the engine thoroughly to raise the ATF temperature to operating level (50--80°C, 122-176°F). 3. Engage the parking brake and use wheel chocks at the front and rear of the wheels. ENGAGE PARKING BRAKE WARM UP ENGINE COOLANT LEVEL ENGINE OIL LEVEL TEMPERATURE 60-70°C (1 40-1 58°F) ATF LEVEL Gartner Banana