Automatic Transmission Workshop Manual SJ6A EL

Transcription

1 Automatic Transmission Workshop Manual SJ6A EL FOEWOD This manual explains the service points for the above-indicated automotive system. This manual covers all models with the above-indicated automotive system, not any one specific model. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully. All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical-including photocopying and recording and the use of any kind of information storage and retrieval system-without permission in writing. CONTENTS Title FEATUES Section SEVICE GENEAL INFOMATION DIVELINE/AXLE TANSMISSION/TANSAXLE There are explanation given only for the sections marked with shadow ( ) Mazda Motor Corporation PINTED IN U.S.A., OCTOBE 2006 Form No U 06J Part No SJ6A-EL Mazda Motor Corporation HIOSHIMA, JAPAN

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3 FEATUES

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5 TANSMISSION/TANSAXLE 05 SECTION Toc of SCT OUTLINE Toc of SCT OUTLINE TANSMISSION/TANSAXLE SPECIFICATIONS End of Toc NG: TANSMISSION/TANSAXLE SPECIFICATIONS AUTOMATIC TANSMISSION id Item Specification Transmission type SJ6A-EL 1G G G Gear ratio 4G G G everse Type JWS3309 ATF Capacity (Approx. quantity) (L {US qt, lmp qt}) 7.4 {7.8, 6.5} Torque converter stall torque ratio 2.00 Hydraulic system (Number of drive/driven plates) Front planetary gear (Number of teeth) Middle planetary gear (Number of teeth) ear planetary gear (Number of teeth) C1 clutch 4/5 C2 clutch 5/5 C3 clutch 4/4 C4 clutch 4/4 B1 brake 3/3 B2 brake 4/3 B3 brake 3/4 B4 brake 5/5 Sun gear 33 Pinion gear (inner) 19 Pinion gear (outer) 18 ing gear 75 Sun gear 26 Pinion gear 20 ing gear 66 Sun gear 26 Pinion gear 20 ing gear 66 Example of automatic transaxle specifications. (MX-5 specifications) End Of Sie

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7 AUTOMATIC TANSMISSION AUTOMATIC TANSMISSION AUTOMATIC TANSMISSION OUTLINE AUTOMATIC TANSMISSION COSS-SECTIONAL VIEW POWEFLOW STUCTUE Description of Components POWEFLOW OPEATION End of Toc 1G G G G G G position NG: TANSMISSION AUTOMATIC TANSMISSION OUTLINE id With the adoption of the line pressure solenoid, TCC control solenoid, solenoid for C3 clutch (shift solenoid F), solenoid for B2 brake (shift solenoid G), and the linear type solenoid, dynamic shift quality has been realized. End Of Sie AUTOMATIC TANSMISSION COSS-SECTIONAL VIEW id TCC OIL PUMP F4 ONE-WAY CLUTCH C3 CLUTCH C4 CLUTCH C2 CLUTCH C1 CLUTCH B3 BAKE F2 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE F3 ONE-WAY CLUTCH B4 BAKE TOQUE CONVETE FONT PLANETAY GEA MIDDLE PLANETAY GEA EA PLANETAY GEA bsj6za End Of Sie

8 AUTOMATIC TANSMISSION POWEFLOW STUCTUE Description of Components id F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT F4 ONE-WAY CLUTCH FONT PLANETAY GEA bsj6za F2 ONE-WAY C4 CLUTCH C2 CLUTCH C3 CLUTCH B3 BAKE B1 BAKE B2 BAKE CLUTCH B4 BAKE F3 ONE-WAY CLUTCH C1 CLUTCH F4 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH FONT PLANETALY GEA MIDDLE PLANETALY GEA EA PLANETAY GEA End Of Sie bsj6za

9 AUTOMATIC TANSMISSION POWEFLOW OPEATION id List of operating components Clutch / Brake Operation C1 clutch Engages input shaft and intermediate shaft via F4 one-way clutch. C2 clutch Engages input shaft and middle planetary carrier. C3 clutch Engages input shaft and front sun gear. C4 clutch Engages input shaft and intermediate shaft. B1 brake Locks rotation of front planetary carrier. B2 brake Locks rotation of front and middle ring gear. B3 brake Locks F2 one-way clutch outer race. B4 brake Locks rotation of rear ring gear. F1 one-way clutch Locks counterclockwise rotation of front planetary carrier on transmission case. F2 one-way clutch Locks counterclockwise rotation of front sun gear during B3 brake operation. Locks counterclockwise rotation of rear ring gear. F3 one-way clutch Locks counterclockwise rotation of middle planetary carrier. F4 one-way clutch Locks counterclockwise rotation of intermediate shaft during C1 clutch operation

10 AUTOMATIC TANSMISSION 1G F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT : OPEATING F4 ONE-WAY CLUTCH FONT PLANETAY GEA : OPEATING WHEN ENGINE BAKING bsj6za

11 AUTOMATIC TANSMISSION 1 INPUT SHAFT OTATES CLOCKWISE. C1 CLUTCH OPEATES. 2 INTEMEDIATE SHAFT OTATES CLOCKWISE. 3 EA SUN GEA OTATES CLOCKWISE EA PLANETAY PINION GEA OTATE COUNTECLOCKWISE. 5 EA ING GEA TIES TO OTATE COUNTECLOCKWISE. F3 ONE-WAY CLUTCH OPEATES (LOCKS COUNTECLOCKWISE OTATION OF EA PLANETAY CAIE). 6 EA PLANETAY CAIE OTATES CLOCKWISE DUE TO EACTION FOCE OF EA PLANETAY PINION GEAS. 7 OUTPUT SHAFT OTATES CLOCKWISE. bsj6za

12 AUTOMATIC TANSMISSION 2G F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT : OPEATING F4 ONE-WAY CLUTCH FONT PLANETAY GEA : OPEATING WHEN ENGINE BAKING bsj6za

13 AUTOMATIC TANSMISSION 1 INPUT SHAFT OTATES CLOCKWISE. C1 CLUTCH OPEATES. 2 INTEMEDIATE SHAFT OTATES CLOCKWISE. 3 MIDDLE SUN GEA OTATES CLOCKWISE. 3 EA SUN GEA OTATES CLOCKWISE MIDDLE PLANETAY PINION GEA OTATE COUNTECLOCKWISE. 5 B3 BAKE, F2 ONE-WAY CLUTCH, AND F1 ONE-WAY CLUTCH OPEATE (LOCKS COUNTECLOCKWISE OTATION OF MIDDLE ING GEA AND FONT ING GEA). 6 MIDDLE PLANETAY CAIE OTATES CLOCKWISE DUE TO EACTION FOCE OF MIDDLE PLANETAY PINION GEAS. 7 EA ING GEA OTATES CLOCKWISE. 8 EA PLANETAY CAIE OTATES CLOCKWISE AT A OTATIONAL SPEED IN WHICH OTATION OF EA ING GEA IS SUBTACTED FOM THAT OF EA SUN GEA (EA PLANETAY PINION GEAS OTATE COUNTECLOCKWISE). 9 OUTPUT SHAFT OTATES CLOCKWISE. bsj6za

14 AUTOMATIC TANSMISSION 3G F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT : OPEATING F4 ONE-WAY CLUTCH FONT PLANETAY GEA : OPEATING WHEN ENGINE BAKING : OPEATING BUT NOT CONTIBUTING TO TANSMISSION POWE bsj6za

15 AUTOMATIC TANSMISSION 1 INPUT SHAFT OTATES CLOCKWISE. C3 CLUTCH OPEATES. C1 CLUTCH OPEATES. 2 FONT SUN GEA OTATES CLOCKWISE. 2 INTEMEDIATE SHAFT OTATES CLOCKWISE. 3 FONT INNE PLANETAY PINION GEA OTATE COUNTECLOCKWISE FONT OUTE PLANETAY PINION GEA OTATES CLOCKWISE. F1 ONE-WAY CLUTCH OPEATES (LOCKS COUNTECLOCKWISE OTATION OF FONT PLANETAY CAIE). 5 FONT ING GEA OTATES CLOCKWISE. 6 MIDDLE ING GEA OTATES CLOCKWISE. 7 MIDDLE PLANETAY CAIE OTATES CLOCKWISE AT A OTATIONAL SPEED IN WHICH OTATION OF MIDDLE ING GEA IS SUBTACTED FOM THAT OF MIDDLE SUN GEA (MIDDLE PLANETAY PINION GEAS OTATE COUNTECLOCKWISE). 8 EA ING GEA OTATES CLOCKWISE. 9 EA PLANETAY CAIE OTATES CLOCKWISE AT A OTATIONAL SPEED IN WHICH OTATION OF EA ING GEA IS SUBTACTED FOM THAT OF EA SUN GEA (EA PLANETAY PINION GEAS OTATE COUNTECLOCKWISE). 10 OUTPUT SHAFT OTATES CLOCKWISE. bsj6za

16 AUTOMATIC TANSMISSION 4G F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT : OPEATING F4 ONE-WAY CLUTCH FONT PLANETAY GEA : OPEATING WHEN ENGINE BAKING : OPEATING BUT NOT CONTIBUTING TO TANSMISSION POWE bsj6za

17 AUTOMATIC TANSMISSION 1 INPUT SHAFT OTATES CLOCKWISE. C2 CLUTCH OPEATES. C1 CLUTCH OPEATES. 2 INTEMEDIATE SHAFT OTATES CLOCKWISE. 3 MIDDLE SUN GEA OTATES CLOCKWISE BECAUSE THE MIDDLE PLANETAY PINION GEAS CANNOT OTATE, THE MIDDLE PLANETAY GEA UNIT OTATES CLOCKWISE AS A SINGLE UNIT. 5 EA ING GEA OTATES CLOCKWISE. 5 EA SUN GEA OTATES CLOCKWISE. 6 THE EA PLANETAY GEA UNIT OTATES CLOCKWISE AS A SINGLE UNIT. 7 OUTPUT SHAFT OTATES CLOCKWISE. bsj6za

18 AUTOMATIC TANSMISSION 5G F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT : OPEATING F4 ONE-WAY CLUTCH FONT PLANETAY GEA : OPEATING BUT NOT CONTIBUTING TO TANSMISSION POWE bsj6za

19 AUTOMATIC TANSMISSION 1 INPUT SHAFT OTATES CLOCKWISE. C3 CLUTCH OPEATES. C2 CLUTCH OPEATES. 2 FONT SUN GEA OTATES CLOCKWISE. 3 FONT INNE PLANETAY PINION GEA OTATE COUNTECLOCKWISE FONT OUTE PLANETAY PINION GEA OTATES CLOCKWISE. B1 BAKE OPEATES (LOCKS OTATION OF FONT PLANETAY CAIE). 5 FONT ING GEA OTATES CLOCKWISE. 6 MIDDLE ING GEA OTATES CLOCKWISE. 6 MIDDLE PLANETAY CAIE OTATES CLOCKWISE. 7 THE MIDDLE PLANETAY PINION GEAS OTATE COUNTECLOCKWISE DUE TO THE DIFFEENCE IN OTATION OF THE MIDDLE ING GEA AND MIDDLE PLANETAY CAIE. 8 MIDDLE SUN GEA OTATES CLOCKWISE. 9 EA SUN GEA OTATES CLOCKWISE. 9 EA ING GEA OTATES CLOCKWISE. 10 EA PLANETAY CAIE OTATES CLOCKWISE. 11 OUTPUT SHAFT OTATES CLOCKWISE. bsj6za

20 AUTOMATIC TANSMISSION 6G F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT : OPEATING F4 ONE-WAY CLUTCH FONT PLANETAY GEA : OPEATING BUT NOT CONTIBUTING TO TANSMISSION POWE bsj6za

21 AUTOMATIC TANSMISSION 1 INPUT SHAFT OTATES CLOCKWISE. C2 CLUTCH OPEATES. 2 MIDDLE PLANETAY CAIE OTATES CLOCKWISE. 3 MIDDLE PLANETAY PINION GEAS OTATE COUNTECLOCKWISE B2 BAKE OPEATES (LOCKS OTATION OF MIDDLE ING GEA). 4 MIDDLE SUN GEA OTATES CLOCKWISE. 5 EA SUN GEA OTATES CLOCKWISE. 5 EA ING GEA OTATES CLOCKWISE. 6 THE EA PLANETAY PINION GEAS OTATE COUNTECLOCKWISE DUE TO THE DIFFEENCE IN OTATION OF THE EA ING GEA AND EA SUN GEA. 7 EA PLANETAY CAIE OTATES CLOCKWISE. 8 OUTPUT SHAFT OTATES CLOCKWISE. bsj6za

22 AUTOMATIC TANSMISSION position F3 ONE-WAY CLUTCH F1 ONE-WAY CLUTCH B1 BAKE B2 BAKE B4 BAKE OUTPUT B3 BAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH C4 CLUTCH MIDDLE PLANETAY GEA EA PLANETAY GEA INPUT : OPEATING F4 ONE-WAY CLUTCH FONT PLANETAY GEA bsj6za

23 AUTOMATIC TANSMISSION 1 INPUT SHAFT OTATES CLOCKWISE. C3 CLUTCH OPEATES. 2 FONT SUN GEA OTATES CLOCKWISE. 3 FONT INNE PLANETAY PINION GEA OTATE COUNTECLOCKWISE FONT OUTE PLANETAY PINION GEA OTATES CLOCKWISE. B1 BAKE AND F1 ONE-WAY CLUTCH OPEATES (LOCKS FONT PLANETAY CAIE). 5 FONT ING GEA OTATES CLOCKWISE. 6 MIDDLE ING GEA OTATES CLOCKWISE. 7 MIDDLE PLANETAY PINION GEA OTATES CLOCKWISE. B4 BAKE OPEATES (LOCKS MIDDLE PLANETAY CAIE AND EA ING GEA). 8 MIDDLE SUN GEA OTATE COUNTECLOCKWISE. 9 EA SUN GEA OTATE COUNTECLOCKWISE. 10 EA PLANETAY PINION GEA OTATES CLOCKWISE. B4 BAKE OPEATES (LOCKS MIDDLE PLANETAY CAIE AND EA ING GEA). 11 EA PLANETAY CAIE OTATE COUNTECLOCKWISE DUE TO EACTION FOCE OF EA PLANETAY PINION GEAS. 12 OUTPUT SHAFT OTATE COUNTECLOCKWISE. End Of Sie bsj6za

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25 SEVICE

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27 GENEAL INFOMATION 00 SECTION Toc of SCT GENEAL INFOMATION Toc of SCT GENEAL INFOMATION HOW TO USE THIS MANUAL ange of Topics Service Procedure Symbols Advisory Messages UNITS Conversion to SI Units (Système International d'unités) ounding Off Upper and Lower Limits FUNDAMENTAL POCEDUES Preparation of Tools and Measuring Equipment Special Service Tools Disassembly Inspection During emoval, Disassembly Arrangement of Parts Cleaning of Parts eassembly Adjustment ubber Parts and Tubing Hose Clamps Torque Formulas Vise ELECTICAL SYSTEM Connectors SAE STANDADS ABBEVIATIONS End of Toc WM: GENEAL INFOMATION HOW TO USE THIS MANUAL id ange of Topics This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: emoval/installation Disassembly/Assembly eplacement Inspection Adjustment Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted

28 GENEAL INFOMATION Service Procedure Inspection, adjustment Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations. SHOWS POCEDUE ODE FO SEVICE Fluid Pressure Inspection 1. Assemble the SSTs as shown in the figure. Tightening torque N m { kgf m, ft lbf} A 49 H H Connect the gauge set from under the vehicle to prevent contact with the drive belt and the cooling fan. SHOWS TIGHTENING TOQUE SPECIFICATIONS acxuuw epair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown. 3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. efer to this information when servicing the related part

29 GENEAL INFOMATION "emoval/installation" Portion "Inspection After Installation" Portion Procedure 2 1 LOWE TAILING LINK, UPPE TAILING LINK EMOVAL/INSTALLATION 1. Jack up the rear of the vehicle and support it with safety stands. 2. emove the undercover. (See Undercover emoval) 3. emove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the rear wheel alignment and adjust it if necessary. SHOWS POCEDUE ODE FO SEVICE 11 SHOWS SEVICE ITEM (S) 9 SST 12 SST GEASE INDICATES ELEVANT EFEENCES THAT NEED TO BE FOLLOWED DUING INSTALLATION SHOWS SPECIAL SEVICE TOOL (SST) FO SEVICE OPEATION INSTALL THE PATS BY PEFOMING STEPS 1 3 IN EVESE ODE SHOWS TIGHTENING TOQUE SPECIFICATIONS { , 32 44} { , 32 41} SHOWS APPLICATION POINTS OF GEASE, ETC. SHOWS EXPENDABLE PATS SHOWS EFEAL NOTES FO SEVICE { , 69 86} 5 SST 3 6 SST GEASE { , } 1 N m {kgf m, ft lbf} SHOWS DETAILS SHOWS TIGHTENING TOQUE UNITS 1 Split pin 2 Nut 3 Lower trailing link ball joint (See Lower Trailing Link Ball Joint emoval Note) 4 Bolt 5 Lower trailing link 6 Dust boot (lower trailing link) 7 Split pin 8 Nut 9 Upper trailing link ball joint (See Upper Trailing Link Ball Joint emoval Note) 10 Nut 11 Upper trailing link 12 Dust boot (upper trailing link) Lower Trailing Link Ball Joint, Upper Trailing Link Ball Joint emoval Note emove the ball joint using the SSTs. 49 T T UPPE TAILING LINK LOWE TAILING LINK SHOWS SPECIAL SEVICE TOOL (SST) NO. KNUCKLE 49 T SHOWS EFEAL NOTES FO SEVICE acxuuw

30 GENEAL INFOMATION Symbols There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service. Symbol Meaning Kind OIL Apply oil New appropriate engine oil or gear oil BAKE FLUID Apply brake fluid New appropriate brake fluid ATF Apply automatic transaxle/ transmission fluid New appropriate automatic transaxle/ transmission fluid GEASE Apply grease Appropriate grease SEALANT Apply sealant Appropriate sealant P Apply petroleum jelly Appropriate petroleum jelly eplace part O-ring, gasket, etc. SST Use SST or equivalent Appropriate tools Advisory Messages You will find several Warnings, s, Notes, Specifications and Upper and Lower Limits in this manual. Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored. A indicates a situation in which damage to the vehicle or parts could result if the caution is ignored. Note A Note provides added information that will help you to complete a particular procedure. Specification The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments. End Of Sie NG: GENEAL INFOMATION

31 GENEAL INFOMATION UNITS id Electrical current Electric power Electric resistance Electric voltage Length Negative pressure Positive pressure Number of revolutions Torque Volume Weight A (ampere) W (watt) ohm V (volt) mm (millimeter) in (inch) kpa (kilo pascal) mmhg (millimeters of mercury) inhg (inches of mercury) kpa (kilo pascal) kgf/cm 2 (kilogram force per square centimeter) psi (pounds per square inch) rpm (revolutions per minute) N m (Newton meter) kgf m (kilogram force meter) kgf cm (kilogram force centimeter) ft lbf (foot pound force) in lbf (inch pound force) L (liter) US qt (U.S. quart) Imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) g (gram) oz (ounce) Conversion to SI Units (Système International d'unités) All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values. ounding Off Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to Upper and Lower Limits When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit, and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm 2 in the following specifications: kpa { kgf/cm 2, psi} kpa { kgf/cm 2, psi} The actual converted values for 2.7 kgf/cm 2 are 265 kpa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39. End Of Sie WM: GENEAL INFOMATION

32 GENEAL INFOMATION FUNDAMENTAL POCEDUES Preparation of Tools and Measuring Equipment Be sure that all necessary tools and measuring equipment are available before starting any work. id acxuuw Special Service Tools Use special service tools or the equivalent when they are required. 49 SE acxuuw Disassembly If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance, and identified so that reassembly can be performed easily and efficiently. acxuuw Inspection During emoval, Disassembly When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems. acxuuw

33 GENEAL INFOMATION Arrangement of Parts All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused acxuuw Cleaning of Parts All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. Warning Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air. acxuuw eassembly Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts Depending on location: Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. Oil should be applied to the moving components of parts. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. acxuuw acxuuw

34 1 0 Adjustment Use suitable gauges and testers when making adjustments. GENEAL INFOMATION acxuuw ubber Parts and Tubing Prevent gasoline or oil from getting on rubber parts or tubing. acxuuw Hose Clamps When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. acxuuw Torque Formulas When using a torque wrench-sst or equivalent combination, the specified torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. ecalculate the torque by using the following formulas. Choose the formula that applies to you. SST Torque Unit N m kgf m kgf cm ft lbf in lbf Formula N m [L/(L+A)] kgf m [L/(L+A)] kgf cm [L/(L+A)] ft lbf [L/(L+A)] in lbf [L/(L+A)] A L 3 2 acxuuw A L : The length of the SST past the torque wrench drive. : The length of the torque wrench

35 GENEAL INFOMATION Vise When using a vise, put protective plates in the jaws of the vise to prevent damage to parts. End Of Sie ELECTICAL SYSTEM Connectors Disconnecting connectors When disconnecting a connector, grasp the connectors, not the wires. POTECTIVE PLATES GOOD NO GOOD acxuuw id Connectors can be disconnected by pressing or pulling the lock lever as shown. acxuuw acxuuw Locking connector When locking connectors, listen for a click indicating they are securely locked. acxuuw

36 GENEAL INFOMATION Inspection To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal. When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side. GOOD NO GOOD Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side. End Of Sie GOOD NO GOOD acxuuw acxuuw SAE STANDADS id In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents. SAE Standard SAE Standard emark Abbreviation Name Abbreviation Name emark AP Accelerator Pedal MAP Manifold Absolute Pressure APP Accelerator Pedal Position MAF sensor Mass Air Flow Sensor ACL Air Cleaner MFL Multiport Fuel Injection A/C Air Conditioning OBD On-board Diagnostic System BAO Barometric Pressure OL Open Loop B+ Battery Positive Voltage OC Oxidation Catalytic Converter CMP sensor Camshaft Position Sensor O2S Oxygen sensor CAC Charge Air Cooler PNP Park/Neutral Position CLS Closed Loop System PSP Power Steering Pressure CTP Closed Throttle Position PCM Powertrain Control Module #3 CPP Clutch Pedal Position Pulsed PAI Pulsed Secondary Air Injection CIS Continuous Fuel Injection System injection CKP sensor Crankshaft Position Sensor Injection DLC Data Link Connector AI Secondary Air Injection with air DTM Diagnostic Test Mode #1 pump DTC Diagnostic Test Code(s) SAPV Secondary Air Pulse Valve DI Distributor Ignition Sequential Multiport Fuel SFI DLI Distributorless Ignition Injection EI Electronic Ignition #2 3G Third Gear ECT Engine Coolant Temperature TWC Three Way Catalytic Converter EM Engine Modification TB Throttle Body EVAP Evaporative Emission TP sensor Throttle Position Sensor

37 GENEAL INFOMATION SAE Standard SAE Standard emark Abbreviation Name Abbreviation Name EG Exhaust Gas ecirculation TCC Torque Converter Clutch FC Fan Control Transmission (Transaxle) Control TCM FF Flexible Fuel Module 4G Fourth Gear T Transmission (Transaxle) ange GEN Generator TC Turbocharger GND Ground VSS Vehicle Speed Sensor HO2S Heated Oxygen Sensor With V Voltage egulator heater VAF sensor Volume Air Flow Sensor IAC Idle Air Control Warm Up Three Way Catalytic WU-TWC IAT Intake Air Temperature Converter KS Knock Sensor WOP Wide Open Throttle MIL Malfunction Indicator Lamp #1: Diagnostic trouble codes depend on the diagnostic test mode. #2: Controlled by the PCM #3: Device that controls engine and powertrain #4: Directly connected to exhaust manifold End Of Sie ABBEVIATIONS ATF LH H SST TFT 2WD End Of Sie Automatic Transaxle Fluid Left Hand ight Hand Special Service Tool Transaxle Fluid Temperature 2 Wheel Drive emark #4 id

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39 TANSMISSION/TANSAXLE 05 SECTION Toc of SCT AUTOMATIC TANSMISSION TECHNICAL DATA SEVICE TOOLS Toc of SCT AUTOMATIC TANSMISSION AUTOMATIC TANSMISSION DISASSEMBLY Precaution Disassembly OIL PUMP DISASSEMBLY Components Disassembly OIL PUMP INSPECTION OIL PUMP ASSEMBLY Components Assembly Procedure CLUTCH DUM COMPONENT AND F4 ONE-WAY CLUTCH COMPONENT DISASSEMBLY Components Disassembly Procedure CLUTCH DUM COMPONENT AND F4 ONE-WAY CLUTCH INSPECTION CLUTCH DUM COMPONENT AND F4 ONE-WAY CLUTCH COMPONENT ASSEMBLY Components Assembly Procedure B1, B3 BAKE AND F1, F2 ONE-WAY CLUTCH COMPONENT DISASSEMBLY Components Disassembly Procedure B1, B3 BAKE AND F1, F2 ONE-WAY CLUTCH INSPECTION B1, B3 BAKE AND F1, F2 ONE-WAY CLUTCH COMPONENT ASSEMBLY Components Assembly Procedure PLANETAY GEA COMPONENT DISASSEMBLY Components Disassembly Procedure PLANETAY GEA COMPONENT INSPECTION PLANETAY GEA COMPONENT ASSEMBLY Components Assembly Procedure B2, B4 BAKE AND F3 ONE-WAY CLUTCH COMPONENT DISASSEMBLY Components Disassembly Procedure B2, B4 BAKE AND F3 ONE-WAY CLUTCH INSPECTION B2, B4 BAKE AND F3 ONE-WAY CLUTCH COMPONENT ASSEMBLY Components Assembly Procedure CONTOL VALVE BODY DISASSEMBLY/ASSEMBLY Components Disassembly Procedure Assembly Procedure AUTOMATIC TANSMISSION ASSEMBLY Assembly Components Disassembly Procedure End of Toc AT: AUTOMATIC TANSMISSION

40 AUTOMATIC TANSMISSION DISASSEMBLY AUTOMATIC TANSMISSION id Precaution The following are precautions that must be followed performing removal/installation. 1. Handle electronic parts with care Do not pull the wiring harness forcibly when disconnecting the connector. Unlock the first and pull the connector. When connecting the connector, verify that it is inserted until it is properly locked. (Verify that a click sound is heard.) Do not apply shock to electronic parts. eplace with new parts if they have been dropped or subjected to shock. 2. Prevent foreign matter from penetrating Be sure to remove foreign matter such as dust and sand from the automatic transaxle before removing parts. Protect removed parts from dust with an object such as a vinyl sheet. Do not use cotton work gloves or shop rags as frayed strings might get caught in the unit. Work with bare hands or use vinyl gloves. 3. Prevent scratching Do not pry with a screwdriver forcibly. Slightly tap the case with a plastic hammer when separating component cases at seams. Do not pull the valve forcibly. Be careful not to get the wiring harness caught between parts during installation. 4. Prevent incorrect or insufficient, installation or missing parts Be careful not to install parts incorrectly or lose parts since there are similar types of O-rings, snap rings, bearings and races. Be careful to for straighten parts and check their installation direction. Be careful not to drop small parts such as check balls or lose them during installation. 5. Wash parts and apply oil Wash each part before installing and dry using compressed air, and then apply the specified ATF type JWS3309. Soak discs in ATF type JWS3309 before installing. In particular, soak a new disc for 2 h or more so that the oil seeps into the lining. If the thrust bearing or race falls during installation, use a small amount of yellow petrolatum grease. Apply ATF type JWS3309 to contact and rotating surfaces. Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave it for one hour or more. Do not wash aluminum parts or rubber parts with alkaline chemicals. Do not wash rubber parts with isopropyl alcohol (IPA). 6. ATF care If ATF is spilled on the floor, wipe it off immediately, as it is quite slippery and dangerous. Be sure to use JWS3309 type ATF. Disassembly Components bsj6za

41 1 Extension dust deflector 2 Extension housing shroud 3 Oil seal 4 Extension housing 5 Filler plug 6 O-ring 7 Drain plug 8 O-ring AUTOMATIC TANSMISSION 9 VSS 10 Breather tube 11 Turbine sensor 12 T switch 13 Torque converter 14 Converter housing 15 Breather pipe bsj6za Drain plug 2 Gasket 3 Overflow plug 4 Gasket 5 Oil pan 6 Oil pan gasket 7 Magnet 8 Oil strainer 9 O-ring 10 Detent spring cover 11 Detent spring 12 Control valve body 13 Oil seal 14 Manual shaft 15 Manual shaft washer 16 Pin 17 Oil seal 18 Manual valve 19 Check valve 20 Spring 21 Accumulator piston 22 Spring 23 Bracket 24 Parking rod 25 Driven plate 26 Shaft parking pawl 27 Spring 28 Parking pawl 29 Snap ring 30 Spring 31 O-ring 32 Accumulator piston

42 AUTOMATIC TANSMISSION 33 Accumulator spring 34 Gasket 35 Gasket 36 O-ring 37 Clip 38 Coupler component bsj6za Oil pump 2 O-ring 3 Bearing race 4 Thrust needle bearing 5 Bearing race 6 Thrust needle bearing 7 Clutch drum component 8 Thrust washer 9 F2 one-way clutch 10 Thrust washer 11 Snap ring 12 Driven plate 13 Drive plate 14 Snap ring 15 B3 brake piston component 16 F1 one-way clutch 17 Thrust washer 18 Bearing race 19 Front planetary gear component 20 Thrust washer 21 Bearing race 22 Thrust needle bearing 23 Front and middle ring gear component 24 Thrust needle bearing 25 Bearing race 26 Front planetary gear component 27 Sun gear

43 AUTOMATIC TANSMISSION bsj6za etaining plate 2 Driven plate component 3 Driven plate 4 Snap ring 5 Pinion return spring 6 B1 brake piston component 7 Snap ring 8 etaining plate 9 Drive plate 10 Driven plate 11 Driven plate 12 Pinion return spring 13 B2 brake piston component 14 Snap ring 15 Inner race 16 F3 one-way clutch 17 ear ring gear component 18 Bearing race 19 Needle bearing 20 Bearing race 21 Intermediate shaft

44 AUTOMATIC TANSMISSION bsj6za Snap ring 2 Bearing race 3 Thrust needle bearing 4 Bearing race 5 Stopper spring 6 O-ring 7 O-ring 8 Inner brake piston 9 O-ring 10 O-ring 11 Sleeve 12 O-ring 13 B4 brake piston 14 Piston return spring 15 Snap ring 16 Brake tube 17 Thrust needle bearing 18 Bearing race 19 ear planetary gear component 20 O-ring 21 Inner brake piston 22 O-ring 23 O-ring

45 Disassembly procedure 1. emove the drain plug and gasket. Do not damage the oil seal. Do not drop the torque converter. AUTOMATIC TANSMISSION GASKET DAIN PLUG 2. emove the torque converter. bsj6za emove the breather hose and breather pipe. Do not damage the turbine sensor. BEATHE PIPE BEATHE TUBE bsj6za emove the turbine sensor. Do not damage the VSS. TUBINE SENSO bsj6za bsj6za

46 AUTOMATIC TANSMISSION 5. emove the VSS. VSS 6. Lift up the lock washer using a flathead screwdriver. bsj6za emove the nut and lock washer. bsj6za Do not damage the T switch. 8. emove the T switch. bsj6za emove the bolts as shown in the figure. T SWITCH bsj6za Do not damage the fitting surface of the transmission case and the converter housing. BOLT BOLT BOLT bsj6za

47 10. Using a plastic hammer, tap the converter housing to remove it. Do not damage the fitting surface of the extension housing and the extension dust deflector. AUTOMATIC TANSMISSION Using a plastic hammer and slab of wood, tap the extension dust deflector to remove it. bsj6za Do not damage the extension housing. 12. Using a flathead screwdriver, remove the extension housing shroud. bsj6za Do not damage the extension housing. 13. Using a flathead screwdriver, remove the oil seal. bsj6za emove the bolts as shown in the figure. bsj6za Do not damage the fitting surface of the transmission case and the extension housing. BOLT BOLT BOLT bsj6za

48 15. Using a plastic hammer, tap the extension housing to remove it. AUTOMATIC TANSMISSION 16. emove the snap ring using snap ring pliers. Do not damage the fitting surface of the transmission case and the oil pan. Do not deform the oil pan. THUST NEEDLE BEAING BEAING ACE bsj6za SNAP ING BEAING ACE bsj6za emove the bolt as shown in the figure and remove the oil pan and gasket. 18. emove the magnet from the oil pan. BOLT Note Inspect the oil pan for foreign material and determine the worn areas of the transmission. For ferrous metal related areas, check for wear of the bearings, gears, and plates. For brass related metal (nonmagnetized), check for bushing wear. BOLT BOLT BOLT bsj6za emove the oil strainer from the control valve body component. 20. emove the O-ring from the oil strainer. BOLT bsj6za BOLT bsj6za

49 AUTOMATIC TANSMISSION 21. Disconnect the solenoid connectors from the solenoids. 22. Disconnect the coupler component from the clamps. SOLENOID CONNECTO CONNECT SOLENOID CONNECTO CLAMP SOLENOID CONNECTO TANSMISSION FLUID TEMPEATUE SWITCH 23. emove the lock plate from the control valve body component. bsj6za When installing the control valve body, make sure that it does not interfere with the coupler component. LOCK PLATE 24. Disconnect the transmission fluid temperature switch from the control valve body component. 25. Fix the coupler component with tape to the transmission case as shown in the figure. bsj6za TAPE 26. Disconnect the detent spring cover and detent spring from the control valve body component. bsj6za Do not drop the control valve body component. BOLT DETENT SPING bsj6za

50 27. emove the bolts from transmission case. AUTOMATIC TANSMISSION BOLT BOLT BOLT BOLT 28. Disconnect the manual valve link and remove the control valve body component. BOLT bsj6za MANUAL VALVE LINK 29. emove the check valve subcomponent and compression spring from transmission case. bsj6za emove the transmission case gasket and brake drum gasket from transmission case. bsj6za Be careful of the accumulator pistons A and B as they pop out. bsj6za

51 31. Blow compressed air from the oil passage shown in the figure and remove accumulator pistons A and B and the compression spring from the transmission case. AUTOMATIC TANSMISSION Using a flathead screwdriver, remove the snap ring from accumulator pistons A and B. 33. emove the compression spring from accumulator piston A and B. Do not damage the accumulator pistons. SNAP ING SPING ACCUMLATO PISTON A SNAP ING SPING ACCUMLATO PISTON B bsj6za Using a flathead screwdriver, remove the O-ring from accumulator piston A and B. Be careful of the accumulator pistons C as they pop out. O-ING ACCUMLATO PISTON A O-ING bsj6za ACCUMLOTO PISTON B 35. Blow compressed air from the oil passage shown in the figure and remove accumulator pistons C and the compression springs from the transmission case. 36. Using a flathead screwdriver, remove the O-ring from accumulator pistons C. 37. emove the accumulator valve and compression springs from the transmission case. O-ING O-ING bsj6za bsj6za

52 AUTOMATIC TANSMISSION 38. emove the bracket. 39. emove the parking rod from the manual valve lever. bsj6za Pull out the shaft parking pawl and spring. Be careful not to apply too much force to the torsion spring. 41. Using a flathead screwdriver, remove the driven plate from shaft parking pawl. 42. emove the parking pawl. PAKING PAWL DIVEN PLATE bsj6za SHAFT PAKING PAWL SPING 43. Using a flathead screwdriver and hammer, remove the manual shaft washer. Do not damage the manual valve component. bsj6za bsj6za

53 44. Using a hammer and pin punch, remove the pin. AUTOMATIC TANSMISSION Pull out the manual shaft and remove the manual valve component. MANUAL VALVE COMPONENT MANUAL SHAFT bsj6za Using a flathead screwdriver, remove the oil seal. Do not damage the transmission case component. bsj6za emove the bolts from the oil pump as shown in the figure. bsj6za Using a flathead screwdriver, remove the oil pump. Do not damage the oil pump. bsj6za bsj6za

54 AUTOMATIC TANSMISSION 49. emove the O-ring from the oil pump. 50. emove the thrust needle bearing and bearing race from oil pump. THUST NEEDLE BEAING BEAING ACE O-ING 51. emove the clutch drum component. CLUTCH DUM COMPONENT OIL PUMP bsj6za emove the thrust needle bearing and bearing race from the clutch drum component. CLUTCH DUM COMPONENT bsj6za emove the thrust washer and F2 one-way clutch component from the clutch drum component. THUST NEEDLE BEAING BEAING ACE THUST WASHE F2 ONE-WAY CLUTCH THUST WASHE bsj6za CLUTCH DUM COMPONENT 54. Using a flathead screwdriver, remove the snap ring from the transmission case component. bsj6za bsj6za

55 AUTOMATIC TANSMISSION 55. emove the retaining plates, drive and driven plates. DIVEN PLATE DIVE PLATE Inspect the lining of all drive plates. If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts. Note Before replacing with new drive plates, soak them at least 2 h in ATF. 57. emove the snap ring from transmission case using snap ring pliers. PINT bsj6za bsj6za emove the B2 brake piston component and F1 one-way clutch. bsj6za emove the bearing race and thrust washer from the F1 one-way clutch component. 60. emove the F1 one-way clutch component from the B3 brake piston component. F1 ONE-WAY CLUTCH BEAING ACE bsj6za THUST WASHE B3 BAKE PISTON COMPONENT bsj6za

56 AUTOMATIC TANSMISSION 61. emove the front planetary gear component and thrust washer. THUST WASHE 62. emove the front and middle ring gear component. 63. emove the bearing race and thrust needle bearing from front and middle ring gear component. FONT AND MIDDLE ING GEA COMPONENT FONT PLANETAY GEA COMPONENT bsj6za emove the retaining plates, drive and driven plates. THUST NEEDLE BEAING BEAING ACE DIVEN PLATE bsj6za ETANING PLATE DIVE PLATE 65. Inspect the lining of all drive plates. If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts. Note Before replacing with new drive plates, soak them at least 2 h in ATF. 66. emove the middle planetary gear component and sun gear. 67. emove the bearing race and thrust needle bearing from middle planetary gear component. PINT MIDDLE PLANETAY GEA COMPONENT SUN GEA bsj6za bsj6za BEAING ACE THUST NEEDLE BEAING bsj6za

57 68. Using a flathead screwdriver, remove the snap ring from transmission case component. AUTOMATIC TANSMISSION emove the piston return spring and B1brake piston component. B1 BEAK PISTON COMPONENT bsj6za PISTON ETUN SPING 70. Using a flathead screwdriver, remove the snap ring from transmission case. bsj6za emove the driven plate. bsj6za emove the retaining plates, drive and driven plates. DIVEN PLATE bsj6za DIVE PLATE bsj6za

58 73. emove the piston return spring. AUTOMATIC TANSMISSION 74. Inspect the lining of all drive plates If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts. Note Before replacing with new drive plates, soak them at least 2 h in ATF. 75. Blow compressed air into the oil passage as shown in the figure while pressing the B2 brake piston component by hand and remove the B2 brake piston component from the transmission case. Air pressure 392 kpa {4 kgf/cm 2, 57 psi} PINT bsj6za bsj6za emove the stopper spring from the transmission case. bsj6za emove the snap ring from the transmission case using snap ring pliers. bsj6za bsj6za

59 AUTOMATIC TANSMISSION 78. emove the following parts from the transmission case and disassemble in the order indicated below. (1) Inner race (2) F3 one-way clutch (3) ear ring gear component (4) Bearing race (5) Needle bearing (6) Bearing race (7) Intermediate shaft bsj6za INTEMEDIATE SHAFT EA ING GEA COMPONENT F3 ONE-WAY CLUTCH INNE ACE BEAING ACE NEEDLE BEAING BEAING ACE 79. emove the retaining plates, drive and driven plates. DIVEN PLATE bsj6za DIVEN PLATE DIVE PLATE ETAINING PLATE 80. Inspect the lining of all drive plates. If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts. Note Before replacing with new drive plates, soak them at least 2 h in ATF. PINT bsj6za bsj6za

60 AUTOMATIC TANSMISSION 81. emove the rear planetary gear component and bearing race and thrust needle bearing. THUST NEEDLE BEAING BEAING ACE EA PLANETAY GEA COMPONENT 82. emove the brake tube. bsj6za Make sure that the snap ring is not expanded excessively. 83. Compress the piston return spring using the SSTs and remove the snap ring. 49 G bsj6za T G emove the piston return spring. bsj6za Blow compressed air into the oil passage as shown in the figure while pressing the B4 brake piston component by hand and remove the B4 brake piston component from the transmission case. Air pressure 392 kpa {4 kgf/cm 2, 57 psi} bsj6za bsj6za

61 AUTOMATIC TANSMISSION 86. emove the inner brake piston and sleeve and B4 brake piston. INNE BAKE PISTON SLEEVE B4 BAKE PISTON emove the O-ring from the inner brake piston. O-ING O-ING bsj6za emove the O-ring from sleeve. O-ING INNE BAKE PISTON O-ING bsj6za emove the O-ring from B4 brake piston. End Of Sie AT: OIL PUMP SLEEVE B4 BAKE PISTON bsj6za O-ING bsj6za

62 AUTOMATIC TANSMISSION OIL PUMP DISASSEMBLY Components id bsj6za Pump housing 2 O-ring 3 Outer oil pump gear 4 Inner oil pump gear 5 Oil pump shaft 6 O-ring 7 Seal ring 8 Bearing race 9 Thrust needle bearing 10 Oil seal Disassembly 1. emove the O-ring from the oil pump component. 2. emove the seal ring from the oil pump shaft. bsj6za bsj6za

63 AUTOMATIC TANSMISSION 3. Put an installation mark on the pump housing and oil pump shaft. FITTING MAK emove the screw from the oil pump. bsj6za emove the oil pump shaft from the pump housing. bsj6za emove the O-ring from the pump housing. bsj6za emove the inner oil pump gear and outer oil pump gear from the pump housing. bsj6za bsj6za

64 8. Using a flathead screwdriver, remove the oil seal from the pump housing. Do not damage the bushing on the pump housing. End Of Sie AUTOMATIC TANSMISSION OIL PUMP INSPECTION 1. Using a dial gauge, measure the inner diameter of the pump housing component bushings. bsj6za id Pump housing bushing inner diameter mm { in} Measure at different places and take an average. If it exceeds the specification, replace the pump housing component with a new one. When the pump housing component is bsj6za replaced, inspect the contact surface opposed to the torque converter. If the surface of it is scratched or has changed color, replace the torque converter with a new one. 2. Using a dial gauge, measure the inner diameter of the oil pump shaft bushings. Oil pump shaft bushing inner diameter mm { in} Measure at different places and take an average. If it exceeds the specification, replace the oil pump shaft with a new one. When the oil pump shaft is replaced, inspect the contact surface opposed to the input shaft. If the surface of it is scratched or has changed color, replace the input shaft with a new one. 3. Press the gear oil pump towards the outer side of one side of the pump housing. Measure the clearance using a feeler gauge. Oil pump gear outer standard clearance mm { in} If it exceeds the specification, replace the pump housing with a new one. bsj6za bsj6za

65 4. Measure the clearance between the inner and outer oil pump gears using a feeler gauge. Oil pump gear inner standard clearance mm { in} If it exceeds the specification, replace the pump housing with a new one. AUTOMATIC TANSMISSION Measure the side clearance of both gears using a steel straight edge and feeler gauge. bsj6za Oil pump gear side standard clearance mm { in} Oil pump gear size (mm {in}) Identification mark Thickness bsj6za If the measurement exceeds the maximum specification, replace the inner oil pump gear and outer oil pump gear with a new one so that the side clearance is within the maximum specification. If the side clearance still exceeds the maximum specification, replace the oil pump with a new one. End Of Sie OIL PUMP ASSEMBLY Components id bsj6za Pump housing 2 O-ring 3 Outer oil pump gear 4 Inner oil pump gear 5 Oil pump shaft 6 O-ring 7 Seal ring 8 Bearing race 9 Thrust needle bearing 10 Oil seal

66 AUTOMATIC TANSMISSION Assembly Procedure 1. Apply ATF to the inner oil pump gear, outer oil pump gear and sliding surface of the pump housing. 2. Install the inner oil pump gear and outer oil pump gear to the pump housing as shown in the figure. 3. Apply ATF to the new O-ring. MAK 4. Install the O-ring to the pump housing. bsj6za Align the oil pump shaft with the mark on the pump housing, and install it. bsj6za FITTING MAK 6. Align the oil pump shaft with bolt hole on the pump housing, and temporarily tighten. 7. Tighten the bolts. bsj6za Tightening torque N m { kgf cm, in lbf} 8. Apply ATF to the sliding surface of the new seal ring and oil pump. Do not expand the seal ring too much. Be careful not to shorten the seal rings too much, when installing the seal rings. bsj6za