Automatic transmission workshop manual RC4A–EL

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 removalinstallation 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. Refer to this information when servicing the related part.

Automatic Transmission Workshop Manual RC4A–EL FOREWORD This manual explains the structure, operation, and service points for the above-indicated automatic transmission In order to these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully The information in this manual is current up to March, 2003 Any changes that occur after that time will not be reflected in this particular manual Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing Mazda Motor Corporation HIROSHIMA, JAPAN CONTENTS Title Section GENERAL INFORMATION 00 TRANSMISSION/TRANSAXLE 05 © 2003 Mazda Motor Corporation PRINTED IN U.S.A., MARCH 2003 Form No 1775–1U–03C Part No 9999–95–RC4A–EL GENERAL INFORMATION 00 SECTION Toc of SCT INFORMATION 00-00 GENERAL Toc of SCT 00–00 GENERAL INFORMATION HOW TO USE THIS MANUAL 00–00–1 Range of Topics 00–00–1 Service Procedure 00–00–2 Symbols 00–00–4 Advisory Messages 00–00–4 UNITS 00–00–5 Conversion to SI Units (Système International d'Unités) 00–00–5 Rounding Off 00–00–5 Upper and Lower Limits 00–00–5 FUNDAMENTAL PROCEDURES 00–00–6 Preparation of Tools and Measuring Equipment 00–00–6 Special Service Tools 00–00–6 Disassembly 00–00–6 Inspection During Removal, Disassembly Arrangement of Parts Cleaning of Parts Reassembly Adjustment Rubber Parts and Tubing Hose Clamps Torque Formulas Vise ELECTRICAL SYSTEM Connectors SAE STANDARDS ABBREVIATIONS 00–00–6 00–00–7 00–00–7 00–00–7 00–00–8 00–00–8 00–00–8 00–00–8 00–00–9 00–00–9 00–00–9 00–00–11 00–00–11 End of Toc HOW TO USE THIS MANUAL CHU000000001A01 Range of Topics • This manual contains procedures for performing all required service operations The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement — 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 00–00–1 00–00 GENERAL INFORMATION 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 PROCEDURE ORDER FOR SERVICE Fluid Pressure Inspection Assemble the SSTs as shown in the figure Tightening torque 39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf} 49 1232 670A 49 H002 671 49 H032 322 SHOWS TIGHTENING TORQUE SPECIFICATIONS Caution Connect the gauge set from under the vehicle to prevent contact with the drive belt and the cooling fan WGIWXX0009E 00–00–2 GENERAL INFORMATION Repair procedure 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 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 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 Refer to this information when servicing the related part YLU000WA0 00–00–3 00–00 GENERAL INFORMATION 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 Apply oil New appropriate engine oil or gear oil Apply brake fluid New appropriate brake fluid Apply automatic transaxle/ transmission fluid New appropriate automatic transaxle/ transmission fluid Apply grease Appropriate grease Apply sealant Appropriate sealant P Apply petroleum jelly Appropriate petroleum jelly R Replace part O-ring, gasket, etc SST Use SST or equivalent Appropriate tools OIL BRAKE FLUID ATF GREASE SEALANT Advisory Messages • You will find several Warnings, Cautions, 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 Caution • A Caution 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 00–00–4 GENERAL INFORMATION UNITS Electric current Electric power Electric resistance Electric voltage Length Negative pressure Positive pressure Number of revolutions Torque Volume Weight CHU000000002A01 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) 00–00 kgf/cm2 (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 Rounding 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 37.8 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/cm2 in the following specifications: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi} • The actual converted values for 2.7 kgf/cm2 are 264 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 00–00–5 GENERAL INFORMATION FUNDAMENTAL PROCEDURES CHU000000004A01 Preparation of Tools and Measuring Equipment • Be sure that all necessary tools and measuring equipment are available before starting any work CHU0014W003 Special Service Tools • Use special service tools or equivalent when they are required 49 SE01 310 WGIWXX0024E 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 WGIWXX0027E Inspection During Removal, Disassembly • When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems WGIWXX0028E 00–00–6 GENERAL INFORMATION 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 00–00 WGIWXX0029E 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 WGIWXX0030E Reassembly • Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts • If removed, the following parts should be replaced with new ones: — Oil seals — Gaskets — O-rings — Lock washers — Cotter pins — Nylon nuts WGIWXX0031E • 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 CHU0014W006 00–00–7 GENERAL INFORMATION Adjustment • Use suitable gauges and testers when making adjustments CHU0014W005 Rubber Parts and Tubing • Prevent gasoline or oil from getting on rubber parts or tubing WGIWXX0034E 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 WGIWXX0035E Torque Formulas • When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench Recalculate the torque by using the following formulas Choose the formula that applies to you SST 1 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 : The length of the SST past the torque wrench drive L : The length of the torque wrench 00–00–8 A L WGIWXX0036E GENERAL INFORMATION Vise • When using a vise, put protective plates in the jaws of the vise to prevent damage to parts End Of Sie 00–00 PROTECTIVE PLATES CHU0014W010 ELECTRICAL SYSTEM Connectors Disconnecting connectors • When disconnecting connector, grasp the connectors, not the wires CHU000000006A01 GOOD NO GOOD CHU0000W014 • Connectors can be disconnected by pressing or pulling the lock lever as shown WGIWXX0042E Locking connector • When locking connectors, listen for a click indicating they are securely locked WGIWXX0043E 00–00–9 AUTOMATIC TRANSMISSION 14 Install new seal rings to the 2-4 brake piston ATF TF AEA5610A150 15 Install the 2-4 brake piston to the 2-4 brake retainer ATF TF AEA5610A151 16 Align the fluid passage and install the return spring, 2-4 brake retainer, and the snap ring Caution • Be sure to center the SSTs on the transmission case Otherwise, the return spring can be damaged ATF TF AEA5610A152 17 Set the SSTs to the transmission case 49 S019 011 49 S019 010 Caution • Do not compress the 2-4 brake retainer excessively Doing so can damage the return spring 49 S019 009 AEA5610A153 18 Compress the 2-4 brake retainer using the SST 19 Install the snap ring 20 Remove the SSTs 49 S019 011 AEA5610A154 05–13Z–50 AUTOMATIC TRANSMISSION 21 Install the sleeve and a new seal ring Caution • Applying compressed air to the assembled clutch pack for more than s at a time will damage the seal • Do not apply compressed air for more than the aforementioned time when testing the system SEAL RING ATF TF 05–13Z SLEEVE ATF TF AEA5610A155 22 Apply compressed air to the part indicated in the figure and inspect the 2-4 brake operation • If there is any malfunction, inspect the seal rings Air pressure 390 kPa {4.0 kgf/cm2, 57 psi} max 2—4 BRAKE FLUID PASSAGE AEA5610A156 23 Measure the clearance between the 2-4 brake retainer and the snap ring • If the clearance is not within the specification, adjust the clearance by installing the correct retaining plate Specification 1.0—1.4 mm {0.0394—0.0551 in} SNAP RING RETAINING PLATE Retaining plate sizes mm {in} 5.2 {0.205} 5.8 {0.228} 5.4 {0.213} 6.0 {0.236} 5.6 {0.220} 6.2 {0.244} 24 Install the bearing race, front sun gear, and the bearing CHU0513A104 P ATF TF P AEA5610A158 05–13Z–51 AUTOMATIC TRANSMISSION 25 Install the bearing race and the high clutch hub ATF TF P AEA5610A159 26 Install the bearing to the reverse and high clutch drum with the black surface facing rear side P REAR FRONT AEA5610A160 27 Install the reverse and high clutch drum and the bearing 28 Use the following procedure to adjust the total end play P ATF TF AEA5610A161 (1) Install the bearing race (oil pump installation race) to the reverse and high clutch drum and measure dimension A shown in the figure BEARING RACE A CHU0513A117 (2) Measure the dimension B shown in the figure OIL PUMP B CHU0513A118 05–13Z–52 AUTOMATIC TRANSMISSION (3) Calculate the total end play by using the formula below • If the total end play is not within the specification, adjust the total end play by selecting the correct bearing race (oil pump installation race) Formula Total end play= dimension A–dimension B 05–13Z Specification 0.25—0.55 mm {0.0099—0.0216 in} Bearing race sizes mm {in} 1.4 {0.055} 2.0 {0.079} 1.6 {0.063} 2.2 {0.087} 1.8 {0.071} 2.4 {0.094} TOTAL END PLAY BEARING RACE BEARING CHU0513A119 29 Install the input shaft Note • Install large seal rings to the front side and small seal rings to the rear side ATF TF AEA5610A165 30 Install new seal rings to the oil pump P AEA5610A166 31 Measure the clearance between the seal rings and the seal ring grooves • If the clearance is not within the specification, replace the oil pump cover Specification 0.10—0.25 mm {0.0040—0.0098 in} AEA5610A167 05–13Z–53 AUTOMATIC TRANSMISSION 32 Install a new O-ring to the oil pump ATF TF AEA5610A168 33 Install the bearing race to the oil pump 34 Apply sealant to the oil pump installation bolts 35 Apply ATF to the O-ring around the oil pump P AEA5610A169 36 Install the oil pump Tightening torque 55—60 N·m {5.7—6.1 kgf·m, 42—44 ft·lbf} AEA5610A170 37 Install a new O-ring to the input shaft ATF TF AEA5610A171 38 Install the torque converter housing Tightening torque 50—55 N·m {5.1—5.6 kgf·m, 37—40 ft·lbf} AEA5610A172 05–13Z–54 AUTOMATIC TRANSMISSION 39 Install a new oil seal using the SST 05–13Z 49 B012 004 AEA5610A173 40 Install the detent spring Tightening torque 6.4—8.3 N·m {66—84 kgf·cm, 58—72 in·lbf} AEA5610A174 41 Install the manual shaft, manual plate and parking rod as shown in the figure 42 Rotate the manual plate until the detent spring catches on the indented part of the manual plate MANUAL PLATE PARKING ROD MANUAL SHAFT CHU0513A120 43 Install a new roll pin using a pin punch 44 Apply ATF to a new O-ring, and install it to the harness component ROLL PIN CHU0513A121 05–13Z–55 AUTOMATIC TRANSMISSION 45 Install the harness component Tightening torque 5.0—7.0 N·m {51—71 kgf·cm, 43—61 in·lbf} Note • Do not move the manual valve in the direction of arrow to prevent the pin for the manual valve rotation prevention from falling from the control valve body AEA5610A177 46 Align the manual valve and the manual plate, and set the control valve body MANUAL PLATE MANUAL VALVE AEA5610A178 47 Tighten the bolts evenly and gradually Bolt A B Bolt length below the head (mm {in}) 30 {1.181} 40 {1.575} A A Tightening torque 6.9—8.8 N·m {71—89 kgf·cm, 62—77 in·lbf} B A AEA5610A179 48 Connect the connector Note • Do not reuse the oil pan installation bolts as they are coated 49 Install a new gasket and the oil pan with new bolts Tightening torque 7.0—9.0 N·m {72—91 kgf·cm, 63—78 in·lbf} AEA5610A180 50 Install the actuator support ATF TF AEA5610A181 05–13Z–56 AUTOMATIC TRANSMISSION 51 Install the parking pawl, shaft, spring, and the spacer ATF TF 05–13Z AEA5610A182 52 Install new seal rings to the output shaft component ATF TF AEA5610A183 53 Measure the clearance between the seal rings and seal ring grooves • If the clearance is not within the specification, replace the output shaft Specification 0.10—0.25 mm {0.0040—0.0098 in} Note • Install the bearing to the transmission case with the black surface facing the rear side SEAL RING AEA5610A184 54 Install the bearing and the output shaft component 55 Apply ATF to a new oil seal Note • When installing the oil seal to the extension housing, tap the SSTs until the stopper on the oil seal circumference contacts the extension housing P AEA5610A185 56 Install the oil seal to the extension housing using the SSTs 49 G030 797 49 S231 627 BHJ0513A155 05–13Z–57 AUTOMATIC TRANSMISSION 57 Install the bearing to the extension housing P BHJ0513A163 58 Apply a light coat of sealant to the contact surfaces of the transmission case and the extension housing (For the four locations indicated in the figure, apply sealant to the entire circumference of the bolt holes.) SEALANT AEA5610A188 59 Install the extension housing Tightening torque 50—55 N·m {5.1—5.6 kgf·m, 37—40 ft·lbf} AEA5610A189 60 Install the TR switch, and hand-tighten the mounting bolts Caution • Improper adjustment of the TR switch will cause abnormal operation of the automatic transmission Be sure to use the SST to adjust the TR switch correctly NEUTRAL HOLE MANUAL SHAFT AEA5610A190 61 Using the SST and by turning the TR switch, adjust the positions of the manual shaft and the TR switch neutral hole 62 Tighten the TR switch installation bolts Tightening torque 4.4—6.5 N·m {45—66 kgf·cm, 40—57 in·lbf} 63 Remove the SST 64 Apply ATF to new O-rings and install them to the VSS and the turbine sensor 49 S019 007 AEA5610A191 05–13Z–58 AUTOMATIC TRANSMISSION 65 Install the VSS and the turbine sensor Tightening torque 5.0—7.0 N·m {51—71 kgf·cm, 43—61 in·lbf} 66 Pour ATF into the torque converter 67 Shake the torque converter to clean the inside and pour out the solvent 68 Pour ATF into the torque converter 69 Install the torque converter 05–13Z VSS TURBINE SENSOR AEA5610A192 70 To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing • If the distance is not within the specification, install the torque converter correctly DISTANCE A Specification 50 mm {1.97 in} or more End Of Sie CHU0513A122 05–13Z–59 TECHNICAL DATA 05–50 TECHNICAL DATA TECHNICAL DATA 05–50–1 End of Toc TECHNICAL DATA CHU055001026A01 Item Oil pump Reverse clutch High clutch Body clearance Tip clearance Seal ring and groove clearance Number of drive/driven plates Drive plate thickness Clutch clearance Retaining plate size Number of drive/driven plates Drive plate thickness Clutch clearance Retaining plate size (mm {in}) (mm {in}) 0.10—0.25 {0.0040—0.0098} (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) Number of drive/driven plates Drive plate thickness (mm {in}) Clutch clearance (mm {in}) Retaining plate size (mm {in}) Low clutch Number of drive/driven plates Drive plate thickness (mm {in}) Clutch clearance (mm {in}) Retaining plate size (mm {in}) Low and reverse Number of drive/driven plates brake Drive plate thickness (mm {in}) Clutch clearance (mm {in}) Retaining plate size (mm {in}) Output shaft Seal ring and groove clearance (mm {in}) Low one-way clutch Seal ring and groove inner race clearance (mm {in}) Total end play Total end play (mm {in}) Bearing race size (mm {in}) Distance between end of torque converter and face of converter housing (mm {in}) 2-4 brake Transmission type RC4A-EL 0.02—0.04 {0.0008—0.0015} 0.02—0.15 {0.0008—0.0059} 2/2 Minimum: 1.8 {0.071} 0.6—0.9 {0.0237—0.0354} 4.8 {0.191}, 5.0 {0.197}, 5.2 {0.205}, 5.4 {0.213} 6/6 Minimum: 1.8 {0.071} 1.2—1.4 {0.0473—0.0551} 4.6 {0.181}, 4.7 {0.185}, 4.8 {0.191}, 4.9 {0.193}, 5.0 {0.197}, 5.1 {0.201}, 5.2 {0.205}, 5.3 {0.209}, 5.4 {0.213} 4/8 Minimum: 1.8 {0.071} 1.0—1.4 {0.0394—0.0551} 5.2 {0.205}, 5.4 {0.213}, 5.6 {0.220}, 5.8 {0.228}, 6.0 {0.236}, 6.2 {0.244} 5/5 Minimum: 1.8 {0.071} 0.9—1.3 {0.036—0.051} 3.8 {0.150}, 4.0 {0.157}, 4.2 {0.165} 4.4 {0.173}, 4.6 {0.181}, 4.8 {0.189} 4/5 Minimum: 1.8 {0.071} 0.7—1.1 {0.028—0.043} 5.2 {0.205}, 5.4 {0.213}, 5.6 {0.220}, 5.8 {0.228}, 6.0 {0.236} 0.10—0.25 {0.0040—0.0098} 0.10—0.25 {0.0040—0.0098} 0.25—0.55 {0.0099—0.0216} 1.4 {0.055}, 1.6 {0.063}, 1.8 {0.071}, 2.0 {0.079}, 2.2 {0.087}, 2.4 {0.094} 50 {1.97} or more Spring High clutch return spring 2-4 brake return spring Low clutch return spring Low and reverse brake return spring Item Outer diameter (mm {in}) 8.0 {0.315} 6.9 {0.272} 9.7 {0.382} 11.2 {0.441} Free length (mm {in}) 27.1 {1.067} 22.5 {0.886} 36.4 {1.433} 22.3 {0.878} No of coils 10.2 10.0 9.9 4.8 Wire diameter (mm {in}) 1.1 {0.043} 0.9 {0.035} 1.2 {0.047} 1.1 {0.043} End Of Sie 05–50–1 05–50 SERVICE TOOLS 05–60 SERVICE TOOLS SPECIAL TOOLS 05–60–1 End of Toc SPECIAL TOOLS CHU056001026A01 49 0107 680A 49 U019 0A0A 49 0378 390 Engine stand Transmission hanger set Oil pump puller 49 S019 0A1 49 G030 795 49 W019 002 Spring compressor set Oil seal installer Body 49 T019 001 49 G019 027 49 G019 029 Attachment Attachment A Nut 49 T019 014 49 S019 0A2 49 B012 004 Body Inner race setting tool set Valve seal pusher 49 S019 007 49 S231 627 Set plate Attachment — End Of Sie 05–60–1 05–60 ... FRONT PLANETARY GEAR AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION CROSS-SECTIONAL VIEW CHU051301026A05 05–13Y CHU0513A002 End Of Sie 05–13Y–5 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION POWERTRAIN... SCT AUTOMATIC TRANSMISSION 05-13Y AUTOMATIC TRANSMISSION 05-13Z TECHNICAL DATA 05-50 SERVICE TOOLS 05-60 Toc of SCT 05–13Y AUTOMATIC TRANSMISSION AUTOMATIC. .. AUTOMATIC TRANSMISSION OUTLINE 05–13Y–2 AUTOMATIC TRANSMISSION FEATURES 05–13Y–2 AUTOMATIC TRANSMISSION SPECIFICATIONS 05–13Y–2 AUTOMATIC