1994 MAZDA MX-5 length

TRANSMISSION J Bearing Inspect for damage and rough rotation. Reverse Idler Gear and Shaft 1. Inspect gear teeth for wear and cracks. 2. Measure the clearance between the reverse idler gear b~~shing and shaft. Standard clearance: 0.02-0.05mm {0.000&-0.0020 in) Maximum: 0.15mm (0.006 in) Springs Measure the free length of the springs. Standard free length Shift rod (Sth/Reverse) spring: 75mm (2.953 in) Detent ball spring (lst/2nd, 3rdI4th): 22.5mm (0.886 in) Detent ball spring (Sth/Reverse): 17.0mm (0.669 in) Intermediate housing Measure the intermediate housing pin height. Standard height: 9.0-10.0mm (0.354-0.394 in) Gartner Banana

Bolt length (measured from below the head) @ : 28mm @I : 35mm Adjustment shim Measure the clearance between the countershaft center bearing and the bearing housing. If not within specification, adjust the clearance by instal- i, ling the correct adjustment shim(s). Standard clearance: 04.1 mm (0-4.004 in) Adjustment shim: O.lmm (0.004 in), 0.3mm (0.012 in) Mainshaft front bearing Press the mainshaft front bearing into the bearing hous- ing with a suitable pipe. Outer diameter of pipe: 70.0mm (2.76 in) Adjustment shim Measure the clearance between the mainshaft front bearing and the bearing housing. If not within specification, adjust the clearance by instal- ling the correct adjustment shim(s). Standard clearance: 0-4.1 mm (0--0.004 in) Adjustment shim: O.lmm (0.004 in), 0.15mm (0.006 in), 0.3mm (0.012 in) Reverse idler gear shaft 1. Press the reverse idler gear shaft into the bearing hous- ing. 2. Install and tighten the reverse idler gear shaft installation bolt. Tightening torque: 8.9-12.7 N.m (90-130 kgf.cm, 79-112 in4bf) Reverse idler gear 1. Install the reverse idler gear, end washer, and bearing cover. 2. Tighten the bearing cover installation bolts. Tightening torque @: 18-26 N.m (1.8-2.7 kgf-m, 14--19 ftlbf) @I: 37-53 N.m f3.7-5.5 kgf-m, 27-39 ft4bf) Gartner Banana

K MECHANICAL SYSTEM TEST Incorrect line pressure with specified vacuum at vacuum diaphragm Condition No variation Possible Cause Missing diaphragm rod lncorrect variation (Above or below specification) Incorrect diaphragm rod length Stuck vacuum throttle valve Stuck pressure regulator valve Stuck Dressure regulator ~lua Gartner Banana

WIRE DIAMETER Disassembly note Snap ring Caution Depress the spring retainer only enough to re- d move the snap ring. Overpressing will damage the retainer assembly edges. 1. Compress the spring by using the SST, then remove the snap ring with snap ring pliers. 2. Remove the SST. 3. Remove the spring retainer and spring. Clutch piston 1. Install the direct clutch drum onto the drum support along with the seal rings. 2. Remove the piston by applying compressed air through the oil passage. Air pressure: 392 kPa {4.0 kglcm2, 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. Specifications 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. - Outer dia mm {in) 8.0 (0.315) Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. No. ,oils 14.5 - Free length mm {in) 30.5 {1.201} 3. If not correct, replace the clutch piston. Wire dia. rnm {in) 1.3 (0.051) Gartner Banana

TRANSMISSION K Disassembly note Piston assembly Remove the piston assembly from the body by applying compressed air through the oil passage hole. Air pressure: 392 kPa f4.0 kg/cm2,57 psi) max. Inspection Return spring 1. Measure the spring specifications. I Outer dia. I Free length I No. of tolls I mm (in) mm {in) mm {in} 2. If not within specification, replace the return spring. Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the body. 2. Apply ATF to the new O-rings, and install them onto the piston assembly. 3. Apply ATF to the piston assembly and body. 4. Apply even pressure to the perimeter of the piston, and install it into the body. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring. 6. Apply ATF to the piston stem and washer, and install them into the body. 7. Loosely tighten the nut. Gartner Banana

K TRANSMISSION t- FREE LENGTH 7 -& WIRE DIAMETER Disassembly note Drum support Mark the fourth gear case and the drum support for prop- er reassembly, then remove the drum support. Accumulator plug Remove the accumulator plug, piston, and spring by ap- plying compressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. Inspection Drum support 1. Apply ATF to the new seal rings and install them into the seal ring grooves of the drum support. 2. Measure the clearance between the seal rings and the seal ring grooves. 4 Clearance Standard: 0.04--0.16mm (0.0016--0.0062 in) Maximum: 0.40mm (0.016 in) 3. If not within specification, replace the drum support. Spring 1. Measure the spring specifications. Specifications I Outer dia. I Free length I No. of I mm linl mm linl mm iinl Wire I 2. If not within specification, replace the return spring. Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the accumulator piston. Gartner Banana

K TRANSMISSION --/b WIRE DIAMETER Inspection Return spring 1. Measure the spring specifications. Specifications 2. If not within specification, replace the return spring. Outer dia. mm {in} 28.2 11.1 10) Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the piston assembly. 2. Apply ATF to a new O-ring, and install it onto the piston assembly. 3. Apply ATF to the piston assembly and body. 4. Apply even pressure to the perimeter of the piston, and install it into the body. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring. i/ Free length mm {in) 38.7 (1 524) 6. Apply ATF to the piston stem and washer, and install them into the body. 7. Loosely tighten the nut. 8. Apply even pressure to the perimeter of the body, and install it into the transmission case. 9. Install the piston assembly. No, of coils 6.324 Wire dia. mm {in} 3.5 (0.1 38) Gartner Banana

K TRANSMISSION -&- WIRE DIAMETER Disassembly note Snap ring Caution 4' Depress the spring retainer only enough to install the snap ring. Overpressing will damage the re- tainer assembly edges. 1. Compress the spring by using the SST, then remove the snap ring with snap ring pliers. 2. Remove the spring retainer and spring. Clutch piston 1. Install the front clutch drum onto the drum support along with the 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. Specifications I Outer dia. I Free length I No. of coils I mm {in} mm {in} Wire mm {in) dia. I Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 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. 3. If not correct, replace the clutch piston. Gartner Banana