1994 MAZDA MX-5 Workshop Manual

K TRANSMISSION 0 (3) Hold the stem and tighten the locknut. Tightening torque: 15--39 N-m (1.5-4.0 kgf-m, 11-28 ftelbf) Caution Applying compressed air to the servo piston for longer than 3 seconds at a time will damage the seal. I 1 37. Check the servo piston operation by applying com- 45UOM431 pressed air through the oil passage of the fourth gear band servo. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. MANUAL PLATE 38. Set a new gasket on the fourth gear band servo. Install the fourth gear band servo cover. Tightening torque: 5.0-6.8 N-m (50-70 kgfscm, 44--60 indbf) 39. Apply ATF to a new O-ring and install it onto the solenoid valve connector. 40. Install the solenoid valve connector in the transmission case. 41. Set the valve body assembly in piston, and align the manual plate and manual valve. 42. Install the bolts. Tightening torque: 10.8-14.7 N.m (110--150 kgf-cm, 95.5--130 in-lbf) Gartner Banana

TRANSMISSION K I I 45UOKX-438 GASKET 43. Connect the solenoid valve connectors. 44. Install the harnesses. 45. Apply ATF to a new O-ring, and install it onto the vacuum diaphragm. 46. Select the diaphragm rod. (1) Measure dimension N by using the SST and a scale. (2) Select the proper diaphragm rod in accordance with the table below. Dimension N Below 25.65mm {I .0099 in) 25.65-26.1 5mm (1.0099--1.0295 in) Applicable diaphragm rod 29.0mm {I .I4 in} 29.5mm {I .16 in) 25.90-26.40mm {I .0197-1.0394 in) 26.15-26.65mm {I .029!3-1.0492 in) 48. Install the vacuum diaphragm to the transmission case. 29.75mm {I. 17 in} 30.0mm {I .I 8 in) 26.65--27.15mm (1.0492-1.0689 in} 27.1 5mm {I .0689 in) or over Tightening torque: 7.9-10.7 N.m (80-110 kgfecm, 70-95.4 in-lbf) 30.5mm {I .20 in} 31.0mm {I .22 in) 49. Set the magnets in the oil pan. 50. Install the oil pan along with a new gasket. 51. Install the oil pan mounting bolts. 47. Apply ATF to a new O-ring, and install it into the transmis- sion case. Tightening torque: 5.9-7.8 N-m (60-80 kgf-cm, 53-69 inqlbf) Gartner Banana

K TRANSMISSION 52. Apply ATF to a new O-ring and install it onto the vehicle speed pulse generator. 53. Apply locking compound to the mounting bolt threads, then install the vehicle speed pulse generator. Tightening torque: 7.9-10.7 N-m (80-110 kgtcm, 70-95.4 inmlbf) 54. Apply ATF to the new O-rings and install them into the transmission case. 55. Install the lockup control solenoid. 56. Rotate the manual shaft fully rearward; then return it two notches to the N position. 57. Loosely tighten the parwneutral switch nuts. 58. Remove the screw on the switch body and move the parklneutral switch so that the screw hole on the switch body is aligned with the small hole inside the switch. - Check their alignment by inserting a 2.0mm (0.0079 in) diameter pin into the holes. 59. Tighten the switch attaching nuts. 60. Remove the pin, and tighten the screw into the hole. Tightening torque: 5.0--6.8 Nem (50-70 kgfecrn, 44-60 in-lbf) 61. Ensure that the torque converter is installed correctly by measuring the distance (A) between the end of the torque converter and the end of the converter housing. "A": 22.5mm (0.89 in) 62. Remove the transmission from the engine stand. Gartner Banana

TRANSMISSION K TRANSMISSION UNIT (INSTALLATION) Preparation SST Wrench d b For installation of torque converter bolts 1. On level ground, raise the vehicle and support it evenly on safety stands. 2. Install in the order shown in figure, referring to Installation Note. 3. Fill the transmission with the specified amount and type of the ATF after installation. 4. Warm up the engine, inspect for oil leakage, and verify correct transmission operation. 49 0259 440 Holder, rnainshaft For prevention of oil leakage Gartner Banana

K TRANSMISSION 1. Transmission 10. ATF thermosensor connector Installation Note . . . . . . . . . . page K-149 11. Solenoid connector 2. Transmission mount bolt 12. Vehicle speed pulse generator connector 3. Starter 13. Parklneutral switch connector 4. Torque converter bolt 14. Vacuum hose lnstallation Note . . . . . . . . . . page K-149 15. Speedometer cable 5. Under cover 16. Propeller shaft 6. Power plant frame (PPF) Installation . . . . . . . . . . . . . . . . . . section L lnstallation Note . . . . . . . . . . page K-149 17. Exhaust pipe 7. Harness 18. Performance rod -1 8. Oil pipe 19. Undercover 9. Lockup solenoid connector 20. Shift rod Gartner Banana

TRANSMISSION K Installation Note Transmission Set the transmission onto the transmission jack, paying special attention not to damage the oil pipes. Make sure that the torque converter side of the transmission is tilted slightly upward. Torque converter bolts 1. Align the holes by turning the torque converter. 2. Lock the drive plate by using a screwdriver. 3. Hand-tighten the torque converter mounting bolts in a crisscross pattern. 4. Modify the torque converter mounting bolts tightening torque to allow for a torque wrench-SST combination (Refer to Section GI "Torque Formulas") 5. Tighten the torque converter mounting bolts by using the SST. Tightening torque: 35-49 N-m (3.5-5.0 kgf-m, 26--36 ft-lbf) Power plant frame (PPF) 1. Support the transmission with a jack so that it is level. 2. Position the power plant frame and tighten the transmis- sion-side bolts by hand. 3. Verify that the sleeve is installed into the block. 4. Install the spacer and reamer bolts in the forward hole, and hand-tighten them. Gartner Banana

K TRANSMISSION 5. Tighten the transmission-side bolts. Tightening torque: 104--123 N.m (10.6-12.6 kgf-m, 76.7-91.1 ft-lbf} 6. Tighten the differential-side bolts. Tightening torque: lO4--123 N.m {10.6-1 2.6 kgf-m, 76.7-91.1 ft-lbf} 7. Remove the jack. 8. Measure distance A with a straightedge and vernier cali- pers. Distance A: 51.5-61 Smm (2.023--2.417 in} 9. If the distance is not within specification, reposition the power plant frame at the transmission. Gartner Banana

OIL COOLER K OIL COOLER REMOVAL / INSPECTION / INSTALLATION 1. Remove in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to lnstallation Note. 45UOKX-57 1. Connector bolts 4. Oil pipe Inspect for clogging ins~ect for damaae or cracks -- - - 2. Packing installation Note ................ below 3. Transmission 5. Oil hose Removal ................. page K- 45 Inspect for damage or cracks Installation ............... page K-148 6. Radiator I UP SIDE DOWN SlDE lnstallation Note Oil pipe 1. Align the marks, and slide the oil cooler hose onto the oil cooler pipe until it contacts the ridge. 2. Install the hose clamp onto the hose at the center of the mark and at the angle shown. If reusing the hose, posi- tion the new hose clamp in the mark left by the previous hose clamp. 3. Verify that the hose clamp does not interfere with any other parts. Gartner Banana