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Overdrive/Direct Clutch Assembly Disassembly/Assembly: Disassembly

  1. Remove the input shaft snap ring.
    Fig 1: Locating Input Shaft Snap Ring
    G06158424Courtesy of MAZDA MOTORS CORP.
  2. Remove the input shaft.
    Fig 2: Locating Input Shaft
    G06158425Courtesy of MAZDA MOTORS CORP.
  3. Remove the O/D (4, 5, 6) clutch hub.
    Fig 3: Locating O/D (4, 5, 6) Clutch Hub
    G06158426Courtesy of MAZDA MOTORS CORP.
  4. Remove the O/D (4, 5, 6) clutch hub, No. 2 thrust bearing.
    Fig 4: Locating O/D (4, 5, 6) Clutch Hub, No. 2 Thrust Bearing
    G06158427Courtesy of MAZDA MOTORS CORP.
  5. Remove the O/D (4, 5, 6) clutch snap ring.
    Fig 5: Locating O/D (4, 5, 6) Clutch Snap Ring
    G06158428Courtesy of MAZDA MOTORS CORP.
  6. Remove the O/D (4, 5, 6) clutch pressure plate and clutch assembly.
    Fig 6: Identifying O/D (4, 5, 6) Clutch Pressure Plate And Clutch Assembly
    G06158429Courtesy of MAZDA MOTORS CORP.
  7. Install Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor on the balance piston.
    Fig 7: 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.
  8. Using a press, compress the O/D (4, 5, 6) clutch return spring and remove the snap ring.
    Fig 8: Compressing O/D (4, 5, 6) Clutch Return Spring
    G06158431Courtesy of MAZDA MOTORS CORP.
  9. Remove the Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.
    Fig 9: Identifying Overdrive Clutch And Balance Piston Service Set And 2-6 Spring Compressor
    G06158432Courtesy of MAZDA MOTORS CORP.
  10. Remove and discard the balance piston.
    Fig 10: Identifying Discard Balance Piston
    G06158433Courtesy of MAZDA MOTORS CORP.
  11. Remove the O/D (4, 5, 6) piston return spring.
    Fig 11: Identifying O/D (4, 5, 6) Piston Return Spring
    G06158434Courtesy of MAZDA MOTORS CORP.
  12. Install the clutch support tower and the 3 bolts.
    • Tighten to 12 N.m {1.2 kgf.m, 106 ft.lbf}.
      Fig 12: Locating Clutch Support Tower And Bolts
      G06158435Courtesy of MAZDA MOTORS CORP.
  13. Remove Input Shaft Support Seal Installer.
    Fig 13: Identifying Input Shaft Support Seal Installer
    G06158436Courtesy of MAZDA MOTORS CORP.
  14. Install the No. 1 O/D/direct clutch assembly thrust bearing.
    Fig 14: Locating No. 1 O/D/Direct Clutch Assembly Thrust Bearing
    G06158437Courtesy of MAZDA MOTORS CORP.
  15. Position the No. 1 O/D/direct clutch assembly in the transaxle case.
    Fig 15: Locating No. 1 O/D/Direct Clutch Assembly In Transaxle Case
    G06158438Courtesy of MAZDA MOTORS CORP.
  16. Apply compressed air to the O/D (4, 5, 6) clutch piston port and remove the O/D (4, 5, 6) clutch piston.
    Fig 16: Applying Compressed Air To O/D (4, 5, 6) Clutch Piston Port
    G06158439Courtesy of MAZDA MOTORS CORP.
  17. Remove the O/D/direct clutch assembly from the transaxle case.
    Fig 17: Locating O/D/Direct Clutch Assembly
    G06158440Courtesy of MAZDA MOTORS CORP.
  18. Remove the O/D (4, 5, 6) clutch piston seal from the O/D/direct clutch assembly.
    Fig 18: Illustrating Removing O/D (4, 5, 6) Clutch Piston Seal
    G06158441Courtesy of MAZDA MOTORS CORP.
  19. Remove the 2 seals from the O/D (4, 5, 6) clutch piston.
    Fig 19: Identifying O/D (4, 5, 6) Clutch Piston Seals
    G06158442Courtesy of MAZDA MOTORS CORP.
  20. 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 remove 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 20: Compressing Direct (3, 5, R) Clutch Piston Return Spring
      G06158443Courtesy of MAZDA MOTORS CORP.
  21. Remove Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.
    Fig 21: Illustrating Removing Overdrive Clutch And Balance Piston Service Set And 2-6 Spring Compressor
    G06158444Courtesy of MAZDA MOTORS CORP.
  22. Remove the direct (3, 5, R) clutch cylinder.
    Fig 22: Illustrating Removing Direct (3, 5, R) Clutch Cylinder
    G06158445Courtesy of MAZDA MOTORS CORP.
  23. Remove and discard the direct (3, 5, R) clutch piston.
    Fig 23: View Of Removing And Discarding Direct (3, 5, R) Clutch Piston
    G06158446Courtesy of MAZDA MOTORS CORP.
  24. Remove the direct (3, 5, R) clutch piston return spring.
    CAUTION:
    • Note the position of the return spring for assembly. The flat side faces down.
      Fig 24: Locating Direct (3, 5, R) Clutch Piston Return Spring
      G06158447Courtesy of MAZDA MOTORS CORP.
  25. Remove the direct (3, 5, R) clutch snap ring.
    1. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.
    2. Using a suitable tool, compress the snap ring.
    3. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.
    4. Remove the snap ring.
      Fig 25: View Of Removing Direct (3, 5, R) Clutch Snap Ring
      G06158448Courtesy of MAZDA MOTORS CORP.
  26. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.
    Fig 26: Locating Direct (3, 5, R) Clutch Pressure Plate, Clutch Pack And Wave Spring
    G06158449Courtesy of MAZDA MOTORS CORP.
  27. Remove and discard the 3 direct (3, 5, R) clutch piston seals.
    Fig 27: Locating Discard Direct (3, 5, R) Clutch Piston Seals
    G06158450Courtesy of MAZDA MOTORS CORP.
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