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Home >> Mazda >> 2009 >> Tribute s Sport, 4WD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle - Non-Hybrid >> Overdrive/Direct Clutch Assembly Disassembly/Assembly >> Assembly

Overdrive/Direct Clutch Assembly Disassembly/Assembly: Assembly

  1. Clean and inspect the O/D/direct clutch assembly for damage or excessive wear and install new components as necessary.
  2. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.
    Fig 1: Locating Direct (3, 5, R) Clutch Piston Seals
    G06158451Courtesy of MAZDA MOTORS CORP.
  3. Install the direct (3, 5, R) clutch wave spring.
    Fig 2: Locating Direct (3, 5, R) Clutch Wave Spring
    G06158452Courtesy of MAZDA MOTORS CORP.
  4. Soak the direct (3, 5, R) clutch pack in clean automatic transmission fluid.
    Fig 3: Identifying Direct (3, 5, R) Clutch Pack
    G06158453Courtesy of MAZDA MOTORS CORP.
  5. Install the direct (3, 5, R) clutch assembly and pressure plate.
    Fig 4: Locating Direct (3, 5, R) Clutch Assembly And Pressure Plate
    G06158449Courtesy of MAZDA MOTORS CORP.
  6. Install the direct (3, 5, R) clutch snap ring.
    1. Using a suitable tool, compress the snap ring.
    2. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.
    3. Release the tension on the snap ring.
      Fig 5: Compressing Snap Ring
      G06158455Courtesy of MAZDA MOTORS CORP.
  7. Install the direct (3, 5, R) clutch piston return spring.
    NOTE:
    • Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
      Fig 6: Locating Direct (3, 5, R) Clutch Piston Return Spring
      G06158447Courtesy of MAZDA MOTORS CORP.
  8. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.
    Fig 7: Locating Direct (3, 5, R) Clutch Piston
    G06158457Courtesy of MAZDA MOTORS CORP.
  9. Install the direct (3, 5, R) clutch cylinder.
    Fig 8: Locating Direct (3, 5, R) Clutch Cylinder
    G06158458Courtesy of MAZDA MOTORS CORP.
  10. Install Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
    CAUTION:
    • Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
      Fig 9: Compressing Direct (3, 5, R) Clutch Piston Return Spring
      G06158443Courtesy of MAZDA MOTORS CORP.
  11. Remove Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.
    Fig 10: View Of Removing Overdrive Clutch And Balance Piston Service Set And 2-6 Spring Compressor
    G06158444Courtesy of MAZDA MOTORS CORP.
  12. Install 2 new seals on the O/D (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
    Fig 11: Locating Seals On O/D (4, 5, 6) Clutch Piston
    G06158461Courtesy of MAZDA MOTORS CORP.
  13. Install a new O/D (4, 5, 6) clutch piston clutch piston inner seal and lubricate the seal with petroleum jelly.
    Fig 12: Locating O/D (4, 5, 6) Clutch Piston Clutch Piston Inner Seal
    G06158462Courtesy of MAZDA MOTORS CORP.
  14. Position the O/D (4, 5, 6) clutch piston in place.
    Fig 13: Positioning O/D (4, 5, 6) Clutch Piston
    G06158463Courtesy of MAZDA MOTORS CORP.
  15. Using Overdrive Clutch and Balance Piston Service Set, install the O/D (4, 5, 6) clutch piston into the O/D/direct clutch assembly by hand.
    Fig 14: Installing O/D (4, 5, 6) Clutch Piston Into O/D/Direct Clutch Assembly
    G06158464Courtesy of MAZDA MOTORS CORP.
  16. Install the O/D (4, 5, 6) clutch piston return spring.
    NOTE:
    • Holes face up on the O/D (4, 5, 6) clutch piston return spring.
      Fig 15: Identifying O/D (4, 5, 6) Clutch Piston Return Spring
      G06158434Courtesy of MAZDA MOTORS CORP.
  17. Lubricate the seals on a new balance piston and position the piston in place.
    Fig 16: Identifying Pistion Seals
    G06158466Courtesy of MAZDA MOTORS CORP.
  18. Install Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor on the balance piston.
    Fig 17: Using Special Tool To Install Overdrive Clutch And Balance Piston Service Set And 2-6 Spring Compressor On Balance Piston
    G06158430Courtesy of MAZDA MOTORS CORP.
  19. Using a press, compress the O/D (4, 5, 6) clutch return spring and install the snap ring.
    Fig 18: Compressing O/D (4, 5, 6) Clutch Return Spring
    G06158431Courtesy of MAZDA MOTORS CORP.
  20. Remove the Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.
    Fig 19: Identifying Overdrive Clutch And Balance Piston Service Set And 2-6 Spring Compressor
    G06158432Courtesy of MAZDA MOTORS CORP.
  21. Install the No. 2 thrust bearing.
    Fig 20: Locating No. 2 Thrust Bearing
    G06158470Courtesy of MAZDA MOTORS CORP.
  22. Install the O/D (4, 5, 6) clutch hub.
    Fig 21: Locating O/D (4, 5, 6) Clutch Hub
    G06158471Courtesy of MAZDA MOTORS CORP.
  23. Soak the O/D (4, 5, 6) clutch pack in clean automatic transaxle fluid.
    Fig 22: Identifying O/D (4, 5, 6) Clutch Pack
    G06158472Courtesy of MAZDA MOTORS CORP.
  24. Install the O/D (4, 5, 6) clutch pack.
    Fig 23: Locating O/D (4, 5, 6) Clutch Pack
    G06158473Courtesy of MAZDA MOTORS CORP.
  25. Install the O/D (4, 5, 6) clutch pressure plate.
    Fig 24: Locating O/D (4, 5, 6) Clutch Pressure Plate
    G06158474Courtesy of MAZDA MOTORS CORP.
  26. Install the O/D (4, 5, 6) clutch snap ring.
    Fig 25: Locating O/D (4, 5, 6) Clutch Snap Ring
    G06158475Courtesy of MAZDA MOTORS CORP.
  27. Install the input shaft.
    Fig 26: Locating Input Shaft
    G06158425Courtesy of MAZDA MOTORS CORP.
  28. While holding the input shaft in place, install the snap ring.
    Fig 27: Locating Snap Ring
    G06158424Courtesy of MAZDA MOTORS CORP.
  29. Position the O/D/direct clutch assembly in the transaxle case, install Dial Indicator Gauge With Holding Fixture or a suitable dial indicator and position the plunger on the O/D (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the O/D (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the O/D (4, 5, 6) clutch pack for correct installation. If the O/D (4, 5, 6) clutch pack is correctly installed, install a new O/D (4, 5, 6) clutch pack.
    Fig 28: Applying Of Air Pressure To O/D (4, 5, 6) Clutch Piston Port
    G06158478Courtesy of MAZDA MOTORS CORP.
  30. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator Gauge With Holding Fixture. The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.
    Fig 29: Positioning Plunger On One Of Top Direct (3, 5, R) Clutch Plate Tabs
    G06158479Courtesy of MAZDA MOTORS CORP.
  31. Remove Dial Indicator Gauge With Holding Fixture, O/D/direct clutch assembly and the No. 1 O/D/direct clutch assembly thrust bearing.
    Fig 30: Illustrating Removing O/D/Direct Clutch Assembly
    G06158480Courtesy of MAZDA MOTORS CORP.
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