Automatic Transaxle - Overhaul [FN4A-EL]: Other Mazda 3 BK

OIL PUMP

Note. DO NOT place reference marks on oil pump rotors with a punch.

Front Internal Gear & One-Way Clutch Preinspection

1. Set front internal gear and one-way clutch component to the one-way clutch inner race. Verify that the one-way clutch rotates smoothly when turned counterclockwise and locks when turned clockwise. see scheme 24
2. If one-way clutch does not operate as specified, replace as necessary.

Secondary Gear Bearing Preload

1. Set primary gear into transaxle case. Remove bearing race and adjustment shim from converter housing using Bearing Removing Set (49 W032 2A0), or equivalent. Install plastic funnel and bearing race into transaxle case (if necessary). Place secondary gear and output gear into transaxle case. Install bearing race removed from converter housing onto bearing.
2. Mount shim selector gauge from Shim Selector Tool Set (49 B019 0A3) on primary gear and secondary gear and output gear assembly. (Scheme 56) Eliminate gap of selector gauge by turning collars "A" or "B" of selector gauge. (Scheme 57)
3. Mount converter housing on selector gauge. Mount 6 collars between converter housing and bearing housing. Tighten bolts to 14-19 ft. lbs. (19-25 N.m). (Scheme 58)
4. Turn selector in a direction which widens gap between "A" and "B" of selector gauge until it no longer turns. This will seat bearing race. Turn selector in opposite direction (reducing gap) until gap is eliminated. Insert joint through converter housing
5. Mount preload adapter to secondary gear and output gear. (Scheme 59) Measure preload (turning torque) with torque wrench. Widen gap on selector gauge to obtain 13-21 INCH lbs. (1.5-2.4 N.m) reading.
6. Measure clearance between "A" and "B" of selector gauge when specified preload is obtained. Measure clearance around entire circumference and select a shim equal to maximum clearance measured. The maximum allowable number of adjustment shim is one. Take the maximum reading and determine the shim to be used. Shims range in thickness of 0.020-0.051" (0.50-1.30 mm) in increments of 0.002" (0.05 mm).
7. Remove converter housing and selector gauge. Install required shim(s), press bearing race into converter housing and install onto transaxle housing. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000). Check secondary gear and output gear bearing preload (turning torque). Preload should be 13-21 INCH lbs. (1.5-2.4 N.m).

Scheme 56

Scheme 57

Scheme 58

Scheme 59

GENERAL PRECAUTION NOTES

1. Select the adjustment shims. See «ADJUSTMENTS»(ref-143053-S38859604102002082200000) .
2. If the drive plates or 2-4 brake band are replaced with new ones, soak the new part in ATF for at least 2 hours before installation.
3. Before assembly, apply ATF to all seal rings, rotating parts, "O" rings and sliding parts.
4. All "O" rings, seals and gaskets must be replaced with NEW ones included in the overhaul kit.
5. Use petroleum Jelly, not grease, when assembling.
6. When necessary to replace a bushing, replace the subassembly that includes that bushing.
7. Assemble the housing within 10 minutes after applying sealant, and allow it to cure for at least 30 minutes after assembly before filling the transaxle with ATF.