1994 MAZDA MX-5 transmission oil

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

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 21. 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 it does not, then the one-way clutch is installed upside down. Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 22. Install the direct clutch onto the drum support along with the seal rings. Apply compressed air to the oil passage and check the clutch operation. Air pressure: 392 kPa {4.0 kglcm2, 67 psi) max. Gartner Banana

K TRANSMISSION FOURTH GEAR BAND SERVO Preinspection Fourth gear band servo operation 1. Apply compressed air through the oil passage as shown. .J Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 2. Verify that the piston stem moves to the brake band. If not, the seal rings or the oil seal may be damaged or the piston assembly may be sticking. lnspect them, and re- place as necessary when assembling. 45UOKX-183 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. Brake band 2. Band strut 3. Fourth gear band servo cover 4. Gasket 5. Nut 6. Washer 7. Body 8. Piston stem 9. Piston assembly is assembly note . . . . . . . . . . page K-77 10. Seal rings 11. O-rings 12. Return spring Inspection . . . . . . . . . . . . . . . . . page K-77 Gartner Banana

TRANSMISSION K Disassembly note Piston assembly Remove the piston assembly from the body by applying compressed air through the oil passage hole. Air pressure: 392 kPa f4.0 kg/cm2,57 psi) max. Inspection Return spring 1. Measure the spring specifications. I Outer dia. I Free length I No. of tolls I mm (in) mm {in) mm {in} 2. If not within specification, replace the return spring. Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the body. 2. Apply ATF to the new O-rings, and install them onto the piston assembly. 3. Apply ATF to the piston assembly and body. 4. Apply even pressure to the perimeter of the piston, and install it into the body. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring. 6. Apply ATF to the piston stem and washer, and install them into the body. 7. Loosely tighten the nut. Gartner Banana

K TRANSMISSION t- FREE LENGTH 7 -& WIRE DIAMETER Disassembly note Drum support Mark the fourth gear case and the drum support for prop- er reassembly, then remove the drum support. Accumulator plug Remove the accumulator plug, piston, and spring by ap- plying compressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. Inspection Drum support 1. Apply ATF to the new seal rings and install them into the seal ring grooves of the drum support. 2. Measure the clearance between the seal rings and the seal ring grooves. 4 Clearance Standard: 0.04--0.16mm (0.0016--0.0062 in) Maximum: 0.40mm (0.016 in) 3. If not within specification, replace the drum support. Spring 1. Measure the spring specifications. Specifications I Outer dia. I Free length I No. of I mm linl mm linl mm iinl Wire I 2. If not within specification, replace the return spring. Assembly procedure 1. Apply ATF to the new seal rings, and install them onto the accumulator piston. Gartner Banana

TRANSMISSION K 2. Apply ATF to the spring and install it into the fourth gear case. 3. Apply ATF to the accumulator piston. 4. Apply even pressure to the perimeter of the piston, and install it into the fourth gear case. 5. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring. 6. Apply ATF to a new O-ring, and install it on the accumula- tor plug. 7. Install the accumulator plug and snap ring. Caution Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will dam- age the seal. 8. Check the accumulator operation by applying com- pressed air through the oil passage. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 9. Apply ATF to the plug, and install it into the drum support. 10. Tap in a new roll pin. 11. Set the oil pump onto the SST. 12. Apply ATF to a new seal ring, and install it onto the drum support. Gartner Banana

K TRANSMISSION STEEL BALL ONE-WAY VALVE 13. Apply ATF to the fourth gear case, and mount it onto the oil pump. 14. Install the steel ball and the one-way valve. 15. Apply ATF to the new seal rings, and install them onto the drum support. 16. Apply ATF to the drum support, and install the support and a new gasket onto the fourth gear case, aligning the marks. 17. Install the SST (pins). 18. Tighten the drum support mounting bolts. Tightening torque: 6.94.8 N-m {7&90 kgfncm, 61-78 inelbf) Gartner Banana