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Home >> Mazda >> 2005 >> MX-5 Miata Base, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - Overhaul >> Automatic Transmission >> Automatic Transmission Assembly >> Assembly Procedure

Assembly Procedure

  1. Apply ATF to the new oil seal.
  2. Install the oil seal to the transmission case using the SST  .
    Fig 1: Installing Oil Seal
    G03186941Courtesy of MAZDA MOTORS CORP.
    3. NOTE:
    • To protect transmission case against damage, spread cloth on stand.
    • A stand of such size as shown in figure will facilitate work.
    Fig 2: Preparing Transmission Stand
    G03186942Courtesy of MAZDA MOTORS CORP.
  3. Prepare a stand as shown. It is necessary because work will be done with transmission case set upright from this step on.
  4. Install thrust output shaft bearing and thrust bearing output shaft race after lubricating them with petroleum jelly.
    Fig 3: Installing Thrust Output Shaft Bearing & Thrust Bearing Output Shaft Race
    G03186943Courtesy of MAZDA MOTORS CORP.
  5. Install brake applying tube so that its lug A fits in B in transmission case. After installation, verify that 4 lugs along the underside of brake applying tube fit inside of reverse brake piston and leaf spring is installed properly.
    Fig 4: Installing Brake Applying Tube
    G03186944Courtesy of MAZDA MOTORS CORP.
  6. Remove reverse brake reaction plate of planetary gear component and align lugs of reverse brake plate, reverse brake disc and reverse brake packing plate. Install planetary gear component to transmission case so that aligned lugs fit in groove in transmission case.
    Fig 5: Installing Planetary Gear Component
    G03186945Courtesy of MAZDA MOTORS CORP.
  7. Measure clearance between reverse brake plate and lugs of transmission case.

    Standard Clearance 

    1. 0.61-1.93 mm {0.03-0.07 in} 

    Fig 6: Measuring Clearance Between Reverse Brake Plate & Lugs Of Transmission Case
    G03186946Courtesy of MAZDA MOTORS CORP.
  8. If measured value is less than standard range, it is possible that something is installed improperly or dust or fluid is on reverse brake disk, etc. If it exceeds standard range, replace reverse brake disc, reverse brake plate or reverse brake backing plate.
  9. Install reverse brake reaction plate so that its lug with dent comes to the same position as leaf spring.
    Fig 7: Installing Reverse Brake Reaction Plate
    G03186947Courtesy of MAZDA MOTORS CORP.
  10. Using screwdriver with vinyl tape or the like wound at its tip, install retaining reaction plate ring. After installation, verify that ring is in groove securely.
    Fig 8: Installing Retaining Reaction Plate Ring
    G03186948Courtesy of MAZDA MOTORS CORP.
    11. NOTE:
    • Unless retaining direct clutch ring of planetary sun gear is held, brake valve gets off center support and that will make it impossible to align fluid holes with bolt holes.
    Fig 9: Installing Center Support Component, Aligning Fluid Holes In Center Support & Transmission Case
    G03186949Courtesy of MAZDA MOTORS CORP.
  11. After confirming that lugs of all brake plates and brake discs are in grooves securely, hold retaining direct clutch ring of planetary sun gear, install center support component by aligning fluid holes in center support and transmission case.
  12. Tighten center support bolts by certain amount at a time till specified tightening torque is obtained.

    Tightening Torque 

    1. 24-27 N.m {2.4-2.8 kgf.m, 18-20 ft.lbf} 

    Fig 10: Tightening Center Support Bolts
    G03186950Courtesy of MAZDA MOTORS CORP.
    13. NOTE:
    • Ends of splines in direct clutch cylinder and planetary sun gear should come almost in alignment.
    Fig 11: Installing Direct Clutch Component
    G03186951Courtesy of MAZDA MOTORS CORP.
  13. Install direct clutch component by aligning splines in direct clutch cylinder with planetary sun gear.
  14. Apply petroleum jelly to forward clutch rear No. 1 race, thrust rear bearing, thrust bearing rear planetary ring race and install thrust bearing planetary ring race to direct clutch cylinder and forward clutch rear No. 1 race and thrust bearing to forward clutch hub.
    Fig 12: Installing Thrust Bearing Planetary Ring Race To Direct Clutch Cylinder & Forward Clutch Rear No. 1 Race & Thrust Bearing To Forward Clutch Hub
    G03186952Courtesy of MAZDA MOTORS CORP.
    15. NOTE:
    • Use care not to let forward clutch rear No. 1 race and thrust bearing installed to forward clutch hub fall off.
    Fig 13: Installing Forward Clutch Component
    G03186953Courtesy of MAZDA MOTORS CORP.
  15. Install forward clutch component by putting all lugs of direct clutch disc hub together and matching them with groove cut in direct clutch input hub, and at the same time aligning splines in forward clutch hub with inner shaft.
    16. NOTE:
    • If measured value is less than standard value, remove forward clutch component and install it again.
    Fig 14: Inspecting Height Difference Between Forward Clutch Input Shaft & Transmission Case
    G03186954Courtesy of MAZDA MOTORS CORP.
  16. When clutch disc and plate have been replaced, inspect height difference between forward clutch input shaft and transmission case by measuring as shown in figure.

    Standard Height Difference A 

    1. About 3.0 mm {about 0.1 in} 

  17. Apply petroleum jelly to thrust forward clutch bearing and install it to forward clutch input shaft. Also apply petroleum jelly to thrust rear race and install it to 4GR case.
    Fig 15: Installing Thrust Forward Clutch Bearing
    G03186955Courtesy of MAZDA MOTORS CORP.
  18. Install 4GR case by aligning cutouts in 4GR case and transmission case.
    Fig 16: Installing 4GR Case By Aligning Cutout Case By Aligning Cutouts
    G03186956Courtesy of MAZDA MOTORS CORP.
    19. NOTE:
    • Fit claws of thrust planetary rear washer and thrust planetary ring front race into holes securely.
    • Use care not to drop thrust planetary rear washer installed to 4GR planetary gear.
    Fig 17: Installing Thrust Planetary Rear Washer, Thrust Planetary Ring Front Race & 4GR Input Shaft Component
    G03186957Courtesy of MAZDA MOTORS CORP.
  19. Apply petroleum jelly to thrust planetary rear washer and install it to 4GR planetary gear. Also apply petroleum jelly to thrust planetary ring front race and install it to planetary ring gear and then install 4GR input shaft component to 4GR case.
  20. When clutch disc or plate has been replaced, inspect height difference between 4GR case and 4GR clutch cylinder by measuring it as shown in figure.

    Standard Height Difference A 

    1. About 2.0 mm {0.08 in} 

    Fig 18: Inspecting Height Difference Between 4GR Case & 4GR Clutch Cylinder
    G03186958Courtesy of MAZDA MOTORS CORP.
  21. Apply ATF to the new O-ring.
  22. Install the O-ring to the 4GR housing.
  23. Install the converter housing.

    Tightening Torque 

    1. A: 33.8 N.m {3.45 kgf.m, 25.0 ft.lbf} 
    2. B: 56.9 N.m {5.80 kgf.m, 42.0 ft.lbf} 

    Fig 19: Installing Converter Housing
    G03186959Courtesy of MAZDA MOTORS CORP.
  24. Apply petroleum jelly to bearing race.
  25. Install the bearing race to the 4GR clutch cylinder.
    Fig 20: Installing 4GR Clutch Cylinder Bearing Race
    G03186960Courtesy of MAZDA MOTORS CORP.
  26. Apply petroleum jelly to front bearing component.
  27. Install the front bearing component to the oil pump.
  28. Apply ATF to new O-ring.
  29. Install the O-ring to the oil pump component.
  30. Install the oil pump component aligning bolt holes in 4GR case with those in transmission case oil pump component.
  31. Apply seal packing to oil pump component bolts and tighten them by certain amount of torque each time one after another till specified torque is attained.

    Tightening Torque 

    1. 21.1 N.m {2.15 kgf.m, 15.6 ft.lbf} 

    Fig 21: Tightening Oil Pump Bolts
    G03186961Courtesy of MAZDA MOTORS CORP.
  32. Take down transmission from stand and measure clearance in shaft direction by applying dial gauge to output shaft as shown.

    Standard Clearance 

    1. 0.3-0.9 mm {0.012-0.035 in} 

    Fig 22: Measuring Clearance In Shaft Direction
    G03186962Courtesy of MAZDA MOTORS CORP.
  33. Inspect that inner shaft runs smoothly.
  34. Install the parking lock pawl, pawl pin, and pawl spring to the transmission case.
    Fig 23: Installing Parking Lock Pawl, Pawl Pin & Pawl Spring
    G03186963Courtesy of MAZDA MOTORS CORP.
  35. After installing new sleeve cover to manual shift lever, install manual shift shaft and manual shift lever to transmission case.
    Fig 24: Installing Manual Shift Shaft & Manual Shift Lever
    G03186964Courtesy of MAZDA MOTORS CORP.
  36. Align hole in manual shift shaft with that in manual shift lever and drive in new manual shift lever pin.
    Fig 25: Installing Manual Shift Lever Pin
    G03186965Courtesy of MAZDA MOTORS CORP.
  37. Align hole in sleeve cover with dent in manual shift lever and caulk securely with pin punch. Then verify that manual shift shaft turns smoothly.
    Fig 26: Denting & Caulking Manual Shift Lever
    G03186966Courtesy of MAZDA MOTORS CORP.
  38. With parking lock rod installed to manual shift lever, place parking lock rod on parking lock pawl as shown in figure. Then install pawl bracket and tighten bracket screw to specified torque.

    Tightening Torque 

    1. 5.9-8.8 N.m {60-90 kgf.cm, 53-78 in.lbf} 

    Fig 27: Installing Parking Lock Rod & Pawl Bracket
    G03186967Courtesy of MAZDA MOTORS CORP.
  39. Apply ATF to new O-ring.
  40. Install the O-ring to the throttle cable.
  41. Install the throttle cable to the transmission case.
    Fig 28: Installing Throttle Cable
    G03186968Courtesy of MAZDA MOTORS CORP.
  42. Apply ATF to new O-ring.
  43. Install the O-ring to the accumulator piston.
  44. Install the accumulator piston and spring to the transmission case.
    Fig 29: Installing Accumulator Pistons & Springs
    G03186969Courtesy of MAZDA MOTORS CORP.
    ACCUMULATOR SPRING SPECIFICATIONS

    Spring Outer Diameter - (mm {in}) Free Length - (mm {in})
    Upper Direct Clutch Accumulator 14.20 {0.560} 38.00 {1.496}
    Forward Clutch Accumulator 17.50 {0.689} 64.68 {2.546}
    Upper Second Brake Accumulator 18.79 {0.740} 56.40 {2.220}
    Low Second Brake Accumulator 12.80 {0.504} 17.50 {0.689}
    Lower Direct Clutch Accumulator 15.50 {0.610} 30.00 {1.181}
  45. Lift the valve body a little and install nipple of throttle cable to throttle valve cam.
    Fig 30: Installing Nipple Of Throttle Cable To Throttle Valve Cam
    G03186970Courtesy of MAZDA MOTORS CORP.
  46. After confirming that accumulator piston is pushed all the way down, match pin of manual shaft lever with groove in manual valve.
    Fig 31: Matching Pin Of Manual Shaft Lever With Groove In Manual Valve
    G03186971Courtesy of MAZDA MOTORS CORP.
  47. Fix valve body by using bolts with each nominal length as indicated in figure and tightening to specified torque.

    Tightening Torque 

    1. 7.9-11.7 N.m {80-120 kgf.cm, 70-104 in.lbf} 

    Fig 32: Locating Valve Body Bolts
    G03186972Courtesy of MAZDA MOTORS CORP.
  48. Install the new gaskets and oil strainer.
    1. Tightening Torque 
      1. 5.0-5.8 N.m {50-60 kgf.cm, 44-52 in.lbf} 
  49. Apply ATF to new O-ring.
  50. Install the O-ring to the transmission wire.
  51. Install the transmission wire to the transmission case.

    Tightening Torque 

    1. 5.4 N.m {55 kgf.cm, 48 in.lbf} 

  52. Connect the solenoid valve connectors.
  53. Install the tubes.
    Fig 33: Installing Tubes
    G03186973Courtesy of MAZDA MOTORS CORP.
  54. Install the gasket and oil pan.
  55. With wood rough key attached to output shaft, install rotor sensor by aligning its key groove with wood rough key and install retaining ring.
    Fig 34: Installing Rotor Sensor
    G03186974Courtesy of MAZDA MOTORS CORP.
  56. Install the new gasket and extension housing to the transmission case.

    Tightening Torque 

    1. 36.3 N.m {3.70 kgf.m, 26.8 ft.lbf} 

  57. Install the breather hose.
  58. Apply ATF to the O-ring.
  59. Install the new O-ring to the input/turbine speed sensor.
  60. Install the input/turbine speed sensor to the transmission case.

    Tightening Torque 

    1. 5.8-8.8 N.m {59-90 kgf.cm, 52-78 in.lbf} 

  61. Apply ATF to the O-ring.
  62. Install the O-ring to the output speed sensor.
  63. Install the output speed sensor to the transmission case.

    Tightening Torque 

    1. 4.0-6.8 N.m {40-70 kgf.cm, 35-60 in.lbf} 

  64. Apply ATF to the O-ring.
  65. Install the O-ring to the elbow.
  66. Install the elbow to the transmission case.
  67. Install the lock bolt.

    Tightening Torque 

    1. 25 N.m {2.5 kgf.m, 18 ft.lbf} 

  68. Install the transmission range switch.
  69. Hand-tighten the transmission range switch bolt.
    Fig 35: Installing Transmission Range Switch
    G03186975Courtesy of MAZDA MOTORS CORP.
  70. Install the new packing.
  71. Install the new lock washer.
    72. Fig 36: Installing Packing, Lock Washer & Nut
    G03186976Courtesy of MAZDA MOTORS CORP.
  72. Tighten the nut.

    Tightening Torque 

    1. 3.9 N.m {40 kgf.cm, 35 in.lbf} 

  73. Bend claws of lock washer.
  74. Rotate the manual shaft to the N position.
  75. With neutral reference line and cut groove in switch aligned.
    Fig 37: Aligning Neutral Reference Line & Cut Groove In Switch
    G03186977Courtesy of MAZDA MOTORS CORP.
  76. Tighten the transmission range switch mounting bolt.

    Tightening Torque 

    1. 4.0-6.8 N.m {40-70 kgf.cm, 35-60 in.lbf} 

  77. Install the transmission control lever.
    78. NOTE:
    • Step 78 is for throttle cable replacement only.
  78. With throttle cable installed to the throttle cam, bend near the center of throttle cable to a radius of 200 mm {7.87 in}.  Then, pull the throttle cable until there is no play or just before the throttle cam starts to move, and stake the adjustment mark at the position shown in the figure.
    79. Fig 38: Staking Throttle Cable Adjustment Mark
    G03186979Courtesy of MAZDA MOTORS CORP.
  79. Install the throttle cable cramp.
  80. Install the torque converter.
  81. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the face of the converter housing.

    Distance A 

    1. 22.7 mm {0.88 in} 

    82. Fig 39: Measuring Distance A Between End Of Torque Converter & Face Of Converter Housing
    G03186980Courtesy of MAZDA MOTORS CORP.
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