1994 MAZDA MX-5 gasket

TRANSMISSION K On-vehicle Installation 1. Set the valve body assembly in position, and align the manual plate and manual valve. Tightening torque: 10.8-1 4.7 N.m (11 0-150 kgf-m, 95.5--130 ftalbf) 2. Connect the solenoid valve connector. 3. Install the harness. , . 4. Install the oil pan along with a new gasket. MANUAL PLATE Tightening torque: 5.9-7.8 N.m (60-80 kgf-cm, 53-69 in4bf) 45UOKX-371 5. Install the bolts. Tightening torque: 5.9-7.8 Nsm (60--80 kgf-cm, 53--69 inalbf) 6. Apply ATF to a new O-ring and install it onto the vacuum diaphragm. 7. Apply ATF to a new O-ring and install it into the transmis- sion case. 8. Apply ATF to the vacuum diaphragm rod and vacuum di- aphragm, and install them into the transmission case. Tightening torque: 7.9-1 0.7 N-m (80-1 10 kgf-cm, 70-95.4 in-lbf) 9. Connect the vacuum hose. 10. Install the exhaust pipe. (Refer to page K-148.) 11. Add approximately 4.0 L (4.2 US qt, 3.5 Imp qt) ATF, and check the ATF level. (Refer to page K-35.) Gartner Banana

K TRANSMISSION TRANSMISSION UNIT (ASSEMBLY) Preparation SST 49 01 07 680A Engine stand 49 H075 4958 Body (Part of U019 OAOA) 49 GO32 355 Adjustment gauge For assembly of transmission For assembly of transmission For adjustment of vacuum diaphragm rod 49 UOI 9 OAOA Transmission hanger 49 U019 003 Holder (Part of U019 OAOA) For assembly of transmission For assembly of transmission Precaution 1. If the drive plates or brake bands are replaced with new ones, soak the new ones in ATF for at least two hours before installation. 2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts. 3. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit. u 4. Use petroleum jelly, not grease, during reassembly. 5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing. 6. Assemble the housing within 10 minutes after applying sealant, and allow it to cure at least 30 minutes after assembly before filing the transmission with ATF. Gartner Banana

TRANSMISSION K Torque specifications (cont'd) GASKET, NEW 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