1994 MAZDA MX-5 Workshop Manual

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

TRANSMISSION K Assembly procedure 1. Apply ATF to a new O-ring and install it onto the piston. 2. Apply ATF to a new seal ring and install it onto the piston. 3. Apply even pressure to the perimeter of the low and re- verse brake piston, and install it into the transmission case. 4. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring and O-ring. 5. Apply ATF to the one-way clutch inner race, thrust wash- er, and return spring. 6. Assemble the one-way clutch inner race, thrust washer, and return spring, and install them in the transmission case. 7. Verify that the return spring, thrust washer, and rings are properly positioned before securing the bolts. RETURN SPVING THRUSTWASHER 45UOKX-291 8. Tighten the allen head bolts by using the SST. Tightening torque: 12.8-1 7.6 N-m (1 30-180 kgfacm, 11 3-156 in-lbf) 9. Soak new drive plates in ATF for at least two hours. 10. Apply ATF to the driven plates immediately before as- sembly. 11. Install the drive and driven plates into the transmission case in the following order: Driven-Drive-Driven-Drive-Driven-Drive-Driven- Drive Gartner Banana

K TRANSMISSION SNAP RING RETAINER PLATE 12. lnstall the retaining plate . 13. Install the snap ring with a screwdriver. 14. Measure the clearance between the snap ring and the retaining plate with a feeler gauge. If not within specifica- tion, adjust the clearance by installing the proper retain- ing plate. Clearance: 0.8-1.05mm (0.032-4.041 in) d Retaining plate size rnrn {in) Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 15. Check operation of the piston by applying compressed air through the oil passage of the low and reverse brake. _i Air pressure: 392 kPa (4.0 kglcm*, 57 psi) max. 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

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 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

K TRANSMISSION On-vehicle Removal 1. Disconnect the negative battery cable. 2. On level ground, jack up the vehicle and support it evenly on safety stands. 3. Remove the exhaust pipe. (Refer to page K-46.) 4. Remove the propeller shaft. (Refer to section L.) 5. Disconnect the speedometer cable. 6. Support the transmission with a transmission jack. 7. Remove the power plant frame. (Refer to page K-46.) 8. Remove the extension housing and gasket, making sure to allow any ATF to drain into a container. On-vehicle Installation 1. lnstall a new gasket on the transmission case. 2. lnstall the extension housing. Tightening torque: 20-24 N-m (2.0-2.5kgf-m, 15--18 ft-lbf} i/ 3. Install the power plant frame. (Refer to page K-148.) 4. Connect the speedometer cable. 5. lnstall the propeller shaft. (Refer to section L.) 6. Install the exhaust pipe. (Refer to page K-148.) 7. Add ATF, and check the ATF level. (Refer to page K-35.) Gartner Banana

TRANSMISSION K Inspection Check for damage, wear, or oil leaking from the oil seal. Replace if necessary. OIL SEAL Preparation SST On-vehicle Replacement 1. Remove the exhaust pipe. (Refer to page K-46.) 2. Remove the propeller shaft. (Refer to section L.) 3. Remove the oil seal from the extension housing. 4. Apply ATF to outer periphery and lip surface. 5. Install the new oil seal by using the SST. 6. lnstall the propeller shaft. (Refer to section L.) 7. Install the exhaust pipe. (Refer to page K-148.) w 49 GO30 795 For installation of oil Installer, oil seal 49 GO30 797 Handle (Part of 49 GO30 795) For installation of oil seal Gartner Banana