1994 MAZDA MX-5 light

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 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

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K TROUBLESHOOTING Circuit Diagram - 1-21 AT SHIFT-LOCK SYSTEM Diagnosis chart Problem -- Selector lever cannot be moved from P range with brake pedal depressed and ignition switch ON Possible cause ROOM 1 OA fuse burned or not installed METER 10A fuse burned IG1 system malfunction Wire harness broken Poor connection IG 80A fuse burned Ignition switch malfunction Stop light switch remains OFF Stop light system malfunction Wire harness broken Poor connection STOP 15A fuse burned P range switch remains OFF P range switch system malfunction Wire harness broken (poor ground) Poor connection Shift-lock actuator malfunction Wire harness broken Poor connection Misadjustrnent of selector lever or improper assembly of shift-lock actuator Action I Page Repair or replace Connect firmly Replace Install or replace Replace K-155 K-155 Repair or replace K-155 Connect firmly K-155 Replace K-155 Inspect and replace Adjust or replace section T section T Repair or replace Connect firmly Inspect and replace Repair or replace Connect firmly Adjust or repair K-155 K-I55 K-155 K-155 K-159 Gartner Banana

K ' SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Problem Possible cause Selector lever can be ROOM 1OA fuse burned or not installed moved lrom nnp. [stop light switch remains ON with ignition switch ON, but without brake pedal I Shift-lock actuator malfunction depressed Misadjustment of selector lever or improper assembly of shift-lock actuator Selector lever can be ROOM 10A fuse burned or not installed range Ignition switch malfunction with ignition switch OFF and brake pedal de- Shift-lock actuator malfunction pressed Misadjustrnent of selector lever or improper assembly of shift-iock actuator Shift-lock actuator op- P range switch remains ON eration heard when brake pedal depressed ' Misadjustment of selector lever or improper assembly with ignition switch ON of shift-lock actuator in other than P range Action -- Install or replace Adjust or replace lnspect and replace Adjust or replace Install or replace Inspect and replace inspect and replace Adjust or replace Inspect and replace Adjust or replace section T K-159 Selector lever remains locked when emergency override button oper- ated Emergency override button not pushed fully down Broken emergency override button lgnitlon key can be turned to lock position with selector lever in other than P range Push down fully and hold emergency override but- Misadjustment of indicator pedal ROOM 10A fuse burned or not installed Key interlock solenoid malfunction Wire harness broken Poor connection P range switch remains ON P range switch system malfunction Wire harness broken Poor connection lnspect and replace Repair or replace Connect firmly Adjust Install or replace K-161 - K-151 Inspect and replace Repair or replace Connect firmly I lanition kev cannot be I P ranae switch remains OFF I lns~ect and replace 1 K-158 I K-159 K-166 K-166 Key cylinder (push switch) malfunction Wire harness broken Poor connection Key interlock unit malfunction I ~~~~~$1~~~~ I Key iierlock solenoid malfunction I' I I Inspect and replace I K-158 I range Inspect and replace Repair or replace Connect firmly Inspect and replace Key cylinder (push switch) malfunction I Inspect and replace I section T section T K-155 K-155 section T I I Misadjustment of selector lever 1 Adjust I K-160 ] Gartner Banana

K SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) CONNECTOR B CONNECTOR A 3. Lift up slightly on the selector lever, selector sleeve, and indicator panel, and disconnect the hold switch connec- tor. 4. Disconnect the HOLD switch connector. .--' 5. Shift the selector lever to P range. 6. Turn the ignition switch ON, and check terminal voltages and continuity, referring to the chart below. Disconnect the shift-lock actuator connector to check continuity be- tween terminal c (harness side) and ground. 7. If not as specified, repair the wiring harness and/or shift- lock actuator. I ~~UOKX-477 B+: Battery positive voltage I Connector I Terminal connectd to l terminal I Condition I Correct measurement vaive I I 1 I I A a B-C I P range, selector lever release button not depressed I OR I lBl e I B I P ranae, selector lever release button not depressed I OV I A B B B B 8. Grasp the HOLD switch wiring harness and pull it while pushing the selector knob down fully onto the selector le- ver. 9. Connect the HOLD switch connector. 10. Adjust the indicator panel. (Refer to page K-161.) Install the screws in the order shown in the figure. 11. Apply locking compound to the selector knob screw threads after the threads have been cleaned. Tighten the screws. Tightening torque: 2.0-2.9 N-m (20-30 kgf-cm, 18-26 in-lbf) b a b C (harness side) d 12. Install the rear console. 13. Connect the negative battery cable. 14. Verify correct operation of the shift-lock system. B-C B-C B-C Body B-C Constant Ignition switch OFF Ignition switch ON Constant Brake pedal released -t depressed OR B+ El+ on OV -+ B+ -1 Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K BUTTON NEED NOT BEDEPRESSED BUTTON MUST BE DEPRESSED 0.9--1.0mm 0.64.7mm i0.035--0.039 in} (0.024-0.028 in) I 0.5-0.6mm (0.02-0.024 in) 45UOKX-48 HEAVY-GAUGE WIRE , SLIDER '22EEL SELECTOR LEVER Inspection 1. Verify that the selector lever can only be shifted as shown in the figure. When shifting from P range, do so with the ignition switch ON and the brake pedal de- pressed. 2. Verify there is a click at each range when shifted from P -+ L range. 3. Verify that the positions of the selector lever and the indi- cator are aligned. 4. Verify that the button returns smoothly when pushed to shift. Adjustment Lever position 1. Disconnect the negative battery cable to deactivate the shift-lock. 2. Remove the rear console, selector knob, selector sleeve, and indicator panel. (Refer to "Shift-lock actuator inspection"; page K-159, steps 1-45.) 3. Loosen the locknut. 4. Shift the transmission to P range by pushing the adjust- ment lever forward. 5. Adjust the lever so that the clearance between the guide plate and the guide pin in P range with the push rod light- ly depressed is as shown. 6. Tighten the locknut. Tightening torque: 18-24 Nem (1.8-2.5 kgf-m, 14--18 ft-lbf) 7. Move the selector lever to N and D ranges and verify that there is the same clearance between the guide plate and the guide pin. 8. If not as specified, readjust the lever. 9. lnstall the indicator panel, selector sleeve, selector knob, and rear console in the reverse order of removal. 10. Check the selector lever operation. (Refer to "lnspec- tion"; page K-161.) Indicator panel 1. Remove the rear console. 2. Shift the selector lever to P range. 3. Loosen the indicator screws. 4. Align the alignment hole in the slider with the hole in the indictor panel. Install suitable heavy-gauge wire to hold the slider. 5. Tighten the indicator mounting screws in the order shown in the figure. 6. Remove the wire from the slider. 7. Verify that the selector lever properly aligns with the indi- cator in each range. 8. Verify correct operation of the emergency override but- ton. Gartner Banana

M DIFFERENTIAL 5. Separate the driveshaft from the differential and sus- pend it. 6. Remove the output shaft by using two pry bars as shown in the figure. J 7. Remove the oil seal. 8. Apply lithium-based grease to the new oil seal lip and install it by using'the SST. 9. Install the new clips. 10. Install the output shaft into the side gears by lightly tap- ping with a plastic hammer. 11. Verify that the output shaft is hooked into the side gears by pulling it by hand. ./ 12. Align the marks and install the drive shaft. Tightening torque: 54-64 N.m (5.5--6.5 kgf.m, 40-47 ft-lbf) 13. Install the upper arm installation bolt and nut. Tightening torque: 46-67 N.m (4.7-6.8 kgf.m, 34--49 ftlbf) 14. Add the specified oil. 15. Adjust the rear wheel alignment. (Refer to section R.) I Gartner Banana