1994 MAZDA MX-5 Workshop Manual

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

TRANSMISSION K FOURTH GEAR CONNECTING SHELL AND FOURTH GEAR PLANETARY GEAR UNIT (FOURTH GEAR SUN GEAR, FOURTH GEAR PLANETARY PINION CARRIER, FOURTH GEAR CLUTCH HUB) ,, Disassembly / Inspection l Assembly 1. Disassemble in the order shown in the figure. 2. Inspect all parts, and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly procedure. 1. Bearing 6. Seal sleeve 2. Fourth gear connecting shell 7. Bearing 3. Sun gear 8. Snap ring 4. Snap ring 9. Internal gear 5. Fourth gear planetary pinion carrier 10. Fourth gear clutch hub Inspection . . . . . . . . . . . . . . . . . page K-68 Gartner Banana

K TRANSMISSION Inspection Fourth gear planetary pinion carrier 1. Measure the clearance between the pinion washer and the planetary pinion carrier. Clearance Standard: 0.2--0.7mm (0.008-4.027 in) Maximum: 0.8mm (0.031 in) 2. If not within specification, replace the planetary pinion carrier. Assembly procedure 1. Apply ATF to the fourth gear clutch hub and internal gear, and assemble them with the snap ring. 2. Apply petroleum jelly to the bearing, and install it onto the fourth gear clutch hub with the black surface facing up- ward. Bearing outer diameter: 70.0mm (2,756 in) i 3. Apply ATF to the new seal sleeve, and install it into the fourth gear clutch hub. 4. Apply ATF to the fourth gear planetary pinion carrier, and install it into the internal gear. 5. Apply ATF to the sun gear, and install it into the fourth gear planetary pinion carrier with the snap ring facing the front (arrow). Gartner Banana

TRANSMISSION K 6. Apply ATF to the sun gear, and install it into the fourth gear planetary pinion carrier. 7. Apply petroleum jelly to the bearing, and install it onto the fourth gear connecting shell. Bearing outer diameter: 70mm (2.756 in) 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

TRANSMISSION K Disassembly I Inspection 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. 1. Snap ring 2. Side plate 9. Spring retainer 10. Return spring . - 3. Outer race Inspection ................. page K-72 4. One-way clutch 11. Clutch piston 5. Retaining plate Disassembly note .......... page K-72 6. Snap ring Inspection ................. page K-72 u 7. Drive plates and driven plates 12. Seal ring Inspection ................. page K-72 13. O-ring 8. Snap ring 14. Direct clutch drum Disassembly note .......... page K-72 15. Bearing Gartner Banana