1994 MAZDA MX-5 Oil

K TRANSMISSION OIL PUMP Preparation SST 49 SO1 9 OAO Set, centering tool Shaft (Part of P 49 SO 1 9 OAO) 49 SO1 9 004 Pin (Part of 49 SO1 9 OAO) Body (Part of 49 GO30 795) For installation of oil P'""P For installation of oil Pump For installation of oil Pu""P For installation of oil seal 49 SO19 001 Holder (Part of 49 SO 1 9 OAO) 49 SO1 9 003 Stand (Part of 49 SO1 9 OAO) 49 GO30 795 Installer, oil seal Handle (Part of 49 GO30 795) For installation of oil Pump For installation of oil Pump For installation of oil seal For installation of oil seal Gartner Banana

TRANSMISSION K Disassembly I lnspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts, and repair or replace as necessary. ,, 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. 0 APPLY PETROLEUM JELLY 1. Snap ring 9. Inner gear 2. Sensing rotor Disassembly note .......... page K-64 3. Bearing Inspection ................. page K-64 4. Input shaft 10. Outer gear 5. O-ring Disassembly note .......... page K-64 6. Oil pump cover Inspection ................. page K-64 Disaseembly note .......... page K-64 11. Oil seal Inspection ................. page K-64 12. Roll pin 7. Oil pump housing 13. Plug Inspection ................. page K-64 14. Spring 8. O-ring Inspection ................. page K-65 15. Lockup control valve Gartner Banana

K TRANSMISSION Disassembly note Oil pump cover Loosen the mounting bolts evenly in the pattern shown, and remove the oil pump cover from the oil pump hous- ,-, ing . Inner gear and outer gear 1. Mark the inner and outer gear positions without scratch- ing or denting the gears. 2. Remove the gears from the housing. Inspection Clearance 1. Measure the clearance between the gears and the pump cover. Standard clearance: 0.02-0.04mm (0.0008-0.0015 in) Maximum clearance: 0.08mm (0.0031 in) 2. Measure the clearance between the outer gear teeth tip and the crescent. Standard clearance: 0.1 4-O.21 mm (0.0056-4.0082 in) Maximum clearance: 0.25mm (0.0098 in) 3. Measure the side clearance between the outer gear and the housing. Standard clearance: 0.05--0.20mm (0.0020--0.0078 in) Maximum clearance: 0.25mm (0.0098 in) 4. If not within specification, replace the oil pump assembly. -/' Gartner Banana

TRANSMISSION K WIRE DIAMETER Spring 1. Measure the spring specifications. Soecifications I Outer dia. I Free Ienpth I cO1ls I :Ired$ mm {in) mm {in) I 2. If not within specification, replace the spring. Assembly procedure 1. Apply ATF to the lockup control valve, spring, and plug, and install them into the oil pump housing. 2. Tap in the new roll pin. 3. Apply ATF to a new oil seal, and install it by using the SST. 4. Assemble the SST and secure it in a vise. 5. Apply ATF to the new O-ring, and place it on the pump cover. 6. Set the pump housing on the SST. 7. Apply ATF to the inner and outer gears, and install them in the pump housing with their matching marks toward the pump cover. 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 DIRECT CLUTCH Preparation SST CLOCKWISE 49 0378 375 Compressor, clutch spring Preinspection Direct clutch operation 1. Install the direct clutch onto the drum support along with the seal rings. Apply compressed air through the oil passage as shown. For removal 1 installation of direct clutch Air pressure: 392 kPa (4.0 kgtcm*, 57 psi) max. 2. Verify that the side plate moves toward the snap ring. If not, the seal ring or O-ring may be damaged or fluid may be leaking at the piston check ball. Inspect them, and re- place as necessary when assembling. Clearance between side plate and snap ring 1. Measure the clearance between the side plate and the snap ring. Clearance Maximum: 0.2mm (0.008 in) i -, 2. Select and install the correct side plate when assern- bling. One-way clutch operation Insert the fourth gear clutch hub on the top of the direct clutch, and verify that the fourth gear clutch hub rotates smoothly when turned clockwise and locks when turned counterclockwise. If not, replace the one-way clutch. 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 21. Insert the fourth gear clutch hub on the top of the direct clutch and verify that the fourth gear clutch hub rotates smoothly when turned clockwise and locks when turned counterclockwise. If it does not, then the one-way clutch is installed upside down. Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 22. Install the direct clutch onto the drum support along with the seal rings. Apply compressed air to the oil passage and check the clutch operation. Air pressure: 392 kPa {4.0 kglcm2, 67 psi) max. Gartner Banana