1994 MAZDA MX-5 manual transmission

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 EXTENSION HOUSING AND PARKING MECHANISM Disassembly 1 Inspection 1 Assembly u Note The oil seal does not have to be removed unless it is being replaced. 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts, and repair or replace if necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. . - Extension housing 15. Manual shaft 1 2. Dowel spacer 3. Return spring 4. Parking pawl 5. Pawl shaft 6. Retainer plate 7. Actuator support 8. Steel ball 9. Retainer 10. Spring Inspection .................. page K-108 11. Spring pin 12. Retaining ring 13. Manual plate 14. Parking rod 16. O-ring 17. O-ring 18. Oil distributor Inspection ................ page K-108 19. Seal rings 20. Transmission case 21. Output shaft 22. Snap ring 23. Speedometer drive gear 24. Key 25. Snap ring 26. Oil seal Disassembly note ........... page K-108 Gartner Banana

TRANSMISSION K 8. Apply ATF to the new O-rings, and install them onto the manual shaft. 9. Apply ATF to the manual shaft, and install it into the transmission case. 10. Install the parking rod and retaining ring. 11. Apply ATF to the manual plate, and install it onto the manual shaft. 12. Drive the spring pin. 13. Check the parking mechanism operation. 14. Apply ATF to the new seal rings, and install them onto the oil distributor. 15. Install the snap ring, key, and speedometer drive gear onto the output shaft. 16. Secure the speedometer drive gear with the snap ring. Gartner Banana

TRANSMISSION 1. Manual valve 12. Separator plate 2. Oil strainer 13. Orifice check valve 3. 3-2 control solenoid valve 14. Orifice check spring ................ ................ i/ Inspection page K- 42 Inspection page K-115 4. Oil strainer 15. Throttle relief ball 5. 1-2 shift solenoid valve 16. Throttle relief spring Inspection ................ page K- 42 Inspection ................ page K-115 6. Oil strainer 17. Valve body cover 7. 2-3 shift solenoid valve 18. Inner strainer Inspection ................ page K- 42 19. Separator plate 8. Oil strainer 20. Orifice check valve 9. 3-4 shift solenoid valve 21. Orifice shock spring ................ Inspection ................ page K- 42 Inspection page K-115 10. Oil strainer 22. Lower valve body 11. Upper valve body Disassembly / Inspection / ................ Disassembly / Inspection / Assembly page K-120 Assembly ............... page K-116 Disassembly procedure 1. Remove the 3-2 control solenoid valve. 2. Remove the oil strainer and O-ring. 3. Remove the 1-2 shift solenoid valve. 4. Remove the oil strainer and O-ring. I I 45UOKX425 5. Remove the 2-3 shift solenoid valve. 6. Remove the oil strainer and O-ring. i/ Gartner Banana

TRANSMISSION 1. Bolts 16. 2-3 shift valve 2. Side plate 17. 2-3 shift spring 3. N-R reducing spring Inspection ................ page K-117 ................ w Inspection page K-117 18. Bolts 4. N-R reducing valve 19. Side plate 5. Pressure regulator sleeve 20. Vacuum throttle valve 6. Pressure regulator plug 21. 3-4 shift sleeve 7. Spring seat 22. 3-4 shift valve 8. Pressure regulator spring 23. 3-4 shift spring Inspection ................ page K-117 Inspection ................ page K-117 9. Pressure regulator valve 24. Backup control valve 10. Bolts 25. Backup control spring 11. Side plate Inspection ................ page K-117 12. Pressure modifier valve 26. Throttle backup spring ................ 13. Pressure modifier spring Inspection page K-117 Inspection ................ page K-117 27. Throttle backup valve 14. 1-2 shift valve 28. Manual valve 15. 1-2 shift spring 29. Upper valve body Inspection ................ page K-117 I t- FREE LENGTH 7 WIRE DIAMETER lnspection 1. Measure the spring specifications. 2. If not within specification, replace the spring(s). item Outer dia. mm (in) Pressure regulator 1-2 shift Free iength mm (in} 2-3 shift 3-4 shift 11.7 (0.461) 7.4 (0.291) Pressure modifier Throttle backup No. of coils 10.0 (0.394) 7.5 (0.295) I I I I Wire dia. mm (in} 43.0 (1.693) 26.4 (1.039) 9.2 (0.362) 9.0 (0.354) N-R reducing Backup control 50.0 (1 .969) 40.2 (1 583) 13.0 9.6 19.8 {0.780} 17.5 {0.689) 8.5 (0.335) 1.2 (0.047) 0.7 (0.028) 13.7 15.0 0.6 (0.024) 7.4 (0.291) 1 .O (0.039) 0.8 (0.031) 5.3 5.2 21.3 (0.639) 0.7 (0.028) 0.9 (0.035) 14.5 (0.571) 5.0 7.3 0.9 (0.035) Gartner Banana

TRANSMISSION K 17. lnstall the oil strainer in the lower valve body. 18. lnstall the 2-3 control solenoid valve. 19. Tighten the installation bolt. Tightening torque: 2.5--3.4 N-m (2545 kgf-cm, 22--30 in4bf) 20. lnstall the oil strainer in the lower valve body. 21. lnstall the 1-2 control solenoid valve. 22. Tighten the installation bolt. Tightening torque: 2.54.4 N-m {25--35 kgf-cm, 22-30 inslbf) 23. Connect the ground terminals and install the bolts, refer- ring to page K-123 for the correct bolt sizes. 24. Tighten the bolt. Tightening torque: 6.5--7.8 N.m (66-80 kgf-cm, 58-69 in-lbf) 25. lnstall the oil strainer. 26. lnstall the bolts, referring to page K-123 for their correct sizes. Tightening torque: 6.5--7.8 N-m (66-80 kgf-cm, 58-69 in-lbf) 27. lnstall the manual valve. Gartner Banana

TRANSMISSION K On-vehicle Installation 1. Set the valve body assembly in position, and align the manual plate and manual valve. Tightening torque: 10.8-1 4.7 N.m (11 0-150 kgf-m, 95.5--130 ftalbf) 2. Connect the solenoid valve connector. 3. Install the harness. , . 4. Install the oil pan along with a new gasket. MANUAL PLATE Tightening torque: 5.9-7.8 N.m (60-80 kgf-cm, 53-69 in4bf) 45UOKX-371 5. Install the bolts. Tightening torque: 5.9-7.8 Nsm (60--80 kgf-cm, 53--69 inalbf) 6. Apply ATF to a new O-ring and install it onto the vacuum diaphragm. 7. Apply ATF to a new O-ring and install it into the transmis- sion case. 8. Apply ATF to the vacuum diaphragm rod and vacuum di- aphragm, and install them into the transmission case. Tightening torque: 7.9-1 0.7 N-m (80-1 10 kgf-cm, 70-95.4 in-lbf) 9. Connect the vacuum hose. 10. Install the exhaust pipe. (Refer to page K-148.) 11. Add approximately 4.0 L (4.2 US qt, 3.5 Imp qt) ATF, and check the ATF level. (Refer to page K-35.) Gartner Banana

TRANSMISSION K 7. Install a new snap ring onto the front of the output shaft. 8. Install the extension housing along with a new gasket. Tightening torque: 20-24 N-m (2.0-2.5 kgfem, 15--18 ft4bf) 9. Verify that the output shaft is locked with the manual le- ver in P range. 10. Set the rear clutch assembly on the top of the front clutch assembly. 11. Install the connecting shell and front planetary gear unit (rear clutch hub, front planetary pinion carrier, rear sun gear) onto the rear clutch assembly. 12. Install the front clutch, rear clutch, rear clutch hub, front planetary pinion carrier, connecting shell, internal gear, sun gear, bearing, and bearing races as a unit into the transmission case. 13. Set a new gasket into the front of the case. Gartner Banana