1994 MAZDA MX-5 Workshop Manual

K TRANSMISSION Assembly Procedure 1. Assemble the SST as shown. 2. Mount the transmission case onto the SST. 3. Apply petroleum jelly to the bearing, and install it into the rear of the transmission case with the black surface fat- ing outward. Bearing outer diameter: 53.0mm (2.087 in) 4. Install the oil distributor in the transmission case. 5. Insert the output shaft. 6. Install the rear planetary gear unit (connecting drum, rear planetary pinion carrier and one-way clutch) in the low and reverse brake side. 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

K TRANSMISSION I , DRUM SUPPORT I 14. Check and adjust the rear clutch total end play. (1) Position the front of the transmission case upward. (2) Set the drum support bearing and race on the rear clutch. (3) Measure distances A and B with a straight edge and vernier calipers. (4) Calculate the total end play by using the formula be- low. Formula: T=A-B4.l mm (0.0039 in) T Total end play A: The distance between the drum support mounting surface (including the drum support gasket) and the drum support bearing race surface on the rear clutch assembly. B: The distance between the drum support bearing race contact surface and the drum support gasket contact surface. 0.1 :The compression amount of a new gasket. Total end play: 0.254.50mm (0.010-0.019 in) (5) Adjust the total end play by selecting the proper bear- ing race. I BEARING Bearing race sizes mm {in) 15. Check and adjust the front clutch end play. (1) Set the bearing race and bearing in position. Gartner Banana

TRANSMISSION K DRUM SUPPORT (2) Measure distances C and D with a straight edge and vernier calipers. (3) Calculate the front clutch end play by using the for- mula below. Formula: T=C-04.1 mm {0.0039 In) T Front clutch end play. C: The distance between the drum support mounting surface (including the drum support gasket) of the transmission case and the bearing surface on the front clutch assembly. D: The distance between the sliding surface of the bearing and the drum support gasket contact sur- face. 0.1 :The compression amount of a new gasket. (4) Adjust the front clutch end play by selecting the prop- er bearing race. Front clutch end play: 0.5--0.8mm (0.020--0.031 in) Bearing race sizes rnm (in) 16. Set the 2nd brake band and strut in position. 17. Tighten the piston stem lightly. 18. Apply petroleum jelly to the bearings and bearing races, and install them as shown. Bearing outer diameter 0: 35.0mm (1.38 in) @: 70.0mm (2.76 in) Bearing race outer diameter 0: 76.0mm (2.99 in) 0: 33.0mm (1.30 in) Gartner Banana

K TRANSMISSION I BEARING I SENSING ROTOR FOURTH GEAR CASE BEARING 19. Align the marks of the transmission case and fourth gear case. Tap lightly with a plastic hammer to avoid damag- ing the seal rings when installing. 20. Set a new gasket in place. Note The sensing rotor and bearing are part of the oil pump assembly. 21. Check and adjust the fourth gear planetary gear unit to- tal end play. Do not install the direct clutch drum at this .-, time. (1) Position the fourth gear case upright. (2) Install the bearing and race on the fourth gear case. (3) Install the planetary carrier, sun gear, connecting shell, and bearing as unit in the fourth gear case. (4) Install the sensing rotor and bearing on the connect- ing shell. (5) Measure distances E and H with a straightedge and vernier calipers. (6) Calculate the fourth gear train total end play by using the formula below. Formula: T=E-H-O.1 mm (0.0039 in) T Total end play. E: The distance between the oil pump mounting sur- face (including the oil pump gasket) and the sensing rotor bearing surface. H: The distance between the oil pump side sensing ro- tor bearing contact surface and the oil pump gasket contact surface. 0.1 :The compression amount of a new gasket. Total end play: 0.25-0.50mm (0.01 0-0.020 in} Gartner Banana

TRANSMISSION K BEARING RACE 45UOKX-419 ROTOR I GEAR (7) Adjust the total end play by selecting the proper bear- ing race. Bearing race sizes mm linl Note The sensing rotor and bearing are part of the oil pump assembly. Check and adjust the direct clutch end play. Do not install the planetary pinion carrier at this time. (1) Install the bearing race in the fourth gear case. (2) Install the direct clutch, sun gear, connecting shell, and bearings in the fourth gear case. (3) Install the sensing rotor and bearing on the connect- ing shell. (4) Measure distances G and H with a straightedge and vernier calipers. (5) Calculate the direct clutch end play by using the for- mula below. Formula: T=G-H4.l mm (0.0039 in) T: Total end play G: The distance between the oil pump mounting sur- face (including the oil pump gasket) and the sensing rotor bearing surface. H: The distance between the oil pump side sensing ro- tor bearing contact surface and the oil pump gasket contact surface. 0.1 :The compression amount of a new gasket. Total end play: 0.M.8mm (0.020--0.031 in) (6) Adjust the direct clutch end play by selecting the proper bearing race. Bearing race sizes rnm {in} Gartner Banana

K TRANSMISSION APPLY SEALANT a 23. Insert the intermediate shaft. The end with the long splines should face front. 24. Apply petroleum jelly to the large bearing race and install it into the fourth gear case. 2 Bearing race outer diameter: 70mm (2.756 in) 25. Apply petroleum jelly to the small bearing and small bearing race, and install them as shown. Bearing outer diameter: 35.0mm (1.378 in) Bearing race outer diameter: 33.0mm (1.299 in) 26. lnstall the fourth gear brake band and band strut. 27. lnstall the fourth gear connecting shell and fourth gear planetary gear unit (fourth gear sun gear, fourth gear planetary pinion carrier, fourth gear clutch hub) onto the direct clutch. 28. lnstall the direct clutch assembly into the fourth gear case. --/ 29. lnstall the oil pump assembly into the transmission case by hand only, using two converter housing bolts as guides. Measure the height difference between the top of the transmission case and the oil pump. 30. Remove the converter housing bolts. Apply sealant to the bolts. 31. Apply sealant to the contact surfaces of the converter housing and oil pump. 32. lnstall the converter housing onto the oil pump, and tight- en the bolts evenly in a crisscross pattern. Tightening torque: 59-68 N-m (6.0-7.0 kgfm, 44--50 ft4bf) Gartner Banana

TRANSMISSION K 33. Apply ATF to the piston stem. 34. Adjust the 2nd brake band. (1) Loosen the locknut and tighten the piston stem. Tightening torque: 12.3--14.2 N-m (125--145 kgf-cm, lOg--l25 in-lbf) (2) Loosen the stem the number of turns shown below. Stem: 2 112 turns (3) Hold the stem and tighten the locknut. Tightening torque: 15-39 N.m (1.5-4.0 kgf-m, 11-28 ft-lbf) Caution Applying compressed air to the servo piston for longer than 3 seconds at a time will damage the seal. 35. Check the servo piston operation by applying com- pressed air through the oil passages of the 2nd band servo. @: Engage @: Release Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 36. Apply ATF to the piston stem. Adjust the fourth gear brake band. (1) Loosen the locknut and tighten the piston stem. Tightening torque: 12-15 N-m (1.2-1.5 kgf-m, 8.7-11 ft-lbf) 11.8-14.7 N-m (1 20-150 kgf.cm, 105-1 30 in-lbf) (2) Loosen the stem the number of turns shown below. Stem: 2 turns Gartner Banana