1994 MAZDA MX-5 length

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

K TRANSMISSION Disassembly note One-way clutch inner race 1. Remove the allen-head bolts from the rear of the trans- mission case by using the SST. 4 2. Remove the one-wav clutch inner race, thrust washer, and piston return spring. Low and reverse brake &ton Remove the piston by gpplying 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: 2.0mm (0.079 in) Minimum thickness: 1.8mm (0.071 in) 2. If not within specification, replace the drive plates. Return spring 1. Measure the return spring free length. Spring free length: 5.9-6.2mm (0.233-0.244 in) 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. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 3. If not correct, replace the clutch piston. Gartner Banana

K TRANSMISSION t- FREE LENGTH 1 WIRE DIAMETER n CLEARANCE -a Disassembly note Oil seal Remove the oil seal with a screwdriver. Inspection Spring 1. Measure the spring specifications. Specifications . I Outer dia. 2. If not within specification, replace the spring. Oil distributor 1. Measure the clearance between the seal rings and the grooves. - -. - . - - mm {in) 7.2 (0.283) Clearance Standard: 0.04--0.16mm (0.0024.006 in) Maximum: 0.40mm (0.016 in} No. of coils 14.0 Free length mm {in} 32.0 {I .260} 2. If not within specification, replace the oil distributor. Wire dia. mm 0.7 I0.028) Assembly procedure 1. Apply ATF to a new oil seal, and install it into the exten- sion housing. 2. Apply ATF to the springs and retainer and install them into the extension housing. 3. Apply ATF to the steel balls and actuator support and install them into the extension housing. 4. Apply ATF to the retainer plate, and install it into the ex- tension housing. Tightening torque: 7.9--10.7 Nmm (80-11 Okgfmcm, 70-95.4 in-lbf) 5. Apply ATF to the pawl shaft, and install it into the exten- sion housing. 6. Apply ATF to the parking pawl and return spring, and install it into the extension housing. 7. Apply ATF to the dowel spacer, and install it into the ex- tension housing. Gartner Banana

TRANSMISSION K r FREE LENGTH 1 -/i- WIRE DIAMETER 15. Gently remove the separator plate. Note Tag the orifice check valves for proper reassembly, 16. Remove the orifice check valves and springs. Inspection 1. Measure the spring specifications. 2. If not within specification, replace the spring(s). item Outer dia. Spring mm {in} Free length mm {in) 15.5 (0.61 0) 26.8 (1.055) Orifice check Throttle relief 5.0 (0.1 97) 6.5 I0.256) No. of coils 12.0 14.0 Wire dla. mm {in) 0.23 (0.009) 0.9 {0.035) 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 1. Bolts 13. Side plate 2. Clip 14. N-R/2-3 accumulator piston 3. Side plate 15. N-R/2-3 accumulator spring ................ i/ 4. N-D accumulator piston Inspection page K-121 5. N-D accumulator spring 16. Seal ring Inspection ................ page K-121 17. 3-2 control spring 6. Seal ring Inspection ................ page K-121 7. Pin 18. 3-2 control valve 8. Stopper plug 19. 1-2 accumulator spring ................ 9. 1-2 reducing spring Inspection page K-121 Inspection ................ page K-121 20. 1-2 accumulator piston 10. 1-2 reducing valve 21. Seal ring 11. Bolts 22. Lower valve body 12. Clip i- FREE LENGTH 1 --k WIRE DIAMETER lnspection 1. Measure the spring specifications. 2. If not within specification, replace the spring(s). - 3-2 control Item Spring N-R/2-3 accumulator N-D accumulator 1-2 reducing Free length mm {in) 82.5 13.248) Outer dia. mm {in} 8.9 10.3501 9.3 {0.366) 9.4 10.370) 1-2 accumulator No. of coils 29.7 Wire dia. mm {in) 1.1 10.043) 43.4 {I .709) 19.5 {0.768) 11.2 I0.441) 22.0 5.0 62.0 (2.441) 1.4 I0.055) 0.8 {0.031) 21.3 1.2 (0.047) Gartner Banana

L OUTLINE, TROUBLESHOOTING GUIDE, PROPELLER SHAFT OUTLINE SPECIFICATIONS TROUBLESHOOTING GUIDE Enginefrransmission Problem I Possible Cause BP DOHC Vibration Worn universal joint Bent propeller shaft Worn slip yoke splines Runout of propeller shaft Unbalanced propeller shaft Item MI 5M-D Abnormal noise NC4A-EL Worn or damaged universal joint Worn slip yoke splines PROPELLER SHAFT PREPARATION SST 1,001 (39.41) 816 (32.1) 60.5 ( 2.38) Length mm {in) Outer diameter mm{in) Holder, main shaft Ll L2 D For prevention of oil leakage Action 1 Page Replace Replace Replace Replace Replace Replace Replace Gartner Banana

OUTLINE OUTLINE Front axle Rear axle Differentlal Drive shaft Item I Specifications TY pe Bearing Double-wishbone Angular ball bearing Maximum wheel bearing play mm {in} TY pe Bearing 0.05 {0.002} Double-wishbone Angular ball bearing Maximum wheel bearing play mm {in} Type Reduction gear Reduction ratio Oil I Viscosity 0.05 {0.002} -- ---- Differential gear Ring gear size mm {in} Grade Above -1 8°C {O°F}: SAE 90 Below -1 8°C {O°F}: SAE 80 Standard Hypoid gear Straight-bevel gear 182.88 {7.20) API service GL-5 I Capacity L {US qt. imp qt} I 1 .OO {I .06,0.88) "TORSEN" LSD Worm gear 4.100 TY ~e Length mm {in} Constant velocity (double offset) joint 640.6 I25.220) 45UOMX-00 Gartner Banana