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Servicing - A/t: Other Mazda Millenia I

Automatic Trans 11 illustrations ~1513 words

Transmission

Park vehicle on level ground. Apply parking brake. Warm engine to normal operating temperature. Briefly place selector lever in all gears, and then return to "P" position. Clean dipstick and insert in tube. Remove dipstick. Level should be between "L" and "F" marks. Check fluid for discoloration and unusual smell. If necessary, add fluid. DO NOT overfill.

Transfer Case (B-Series 4WD)

Remove oil fill plug. If fluid is level with opening, install fill plug. If fluid is low, fill until fluid is level with fill plug opening. Install plug.

Transfer Case (MPV 4WD)

Remove fluid level check (lower) plug from right rear side of transfer case. If fluid is level with opening, install plug. If fluid is low, remove fill plug above and to left of level check plug opening. Fill until fluid is level with lower plug opening. Install plugs.

On B-Series, use Mercon V. For all other models, use Mercon III, Dexron-III or M-III ATF.

At temperatures greater than 50°F (10°C), use SAE 80W-90. For all season usage, use SAE 75W-90.

Transfer Case (B-Series)

Use Dexron III or M-III ATF.

B-Series, Miata & MPV

Disconnect negative battery cable. Loosen oil pan bolts to drain fluid. Remove oil pan and discard old gasket. Clean oil pan and install using NEW gasket. Tighten oil pan bolts to specification. See TORQUE SPECIFICATIONS . Connect negative battery cable. Add fluid and check level. DO NOT overfill.

Millenia, MX-6, Protege & 626

Remove drain plug from oil pan. If oil pan is removed, discard old oil pan gasket. Clean oil pan and install using NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Add fluid and check level. DO NOT overfill.

MPV

Loosen lock nut on band adjusting bolt. (Scheme 257) Tighten bolt to 35-53 INCH lbs. (4-6 N.m). Loosen band adjusting bolt 2 1/2 turns. Tighten lock nut to 24-31 ft. lbs. (32-42 N.m).

Scheme 257

Scheme 257: MPV
Scheme 257: MPV

Scheme 258

Scheme 258: Protege
Scheme 258: Protege
  1. Support engine. Raise and support vehicle. Remove drain plug and drain transaxle. Remove engine mounting member. Remove oil pan, gasket and valve body assembly. Remove snap ring and 2-4 band servo assembly. (Scheme 258)
  2. Install servo piston onto adapter. See «2-4 BAND ADJUSTMENT ADAPTER (PROTEGE)»(ref-2430-S32764150562000031800000) table. Remove "O" ring from servo retainer. Coat "O" ring with ATF and install ring onto adapter. Install 2-4 band servo assembly into transaxle case and secure using snap ring. Position dial indicator against piston stem. (Scheme 258) 2-4 BAND ADJUSTMENT ADAPTER (PROTEGE) Application Adapter No. 1.5L 49-G019-006 1.8L 49-G019-005
  3. Using a rubber-tipped air nozzle, apply compressed air through fluid passage and measure piston stem stroke. (Scheme 258) Piston stem stroke should be.040-.067" (1.00-1.70 mm) at 57 psi (4.0 kg/cm 2 ). If piston stem stroke is not as specified, replace piston stem.
  4. Piston stems (9) are available in.02" (.5 mm) increments ranging from 3.74" (95.0 mm) to 3.90" (99.1 mm). Remove 2-4 band servo assembly and adapter. Install servo retainer using NEW "O" ring.
  5. Install valve body assembly. Tighten bolts to specification. Install oil pan with NEW gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-2430-S03546018212000031800000). Install engine mounting member. Lower vehicle. Add fluid and check level. DO NOT overfill.

MX-6 & 626 (2.5L)

  1. Remove drain plug and drain transaxle. Remove oil pan and gasket. Loosen lock nut and tighten piston stem to 106-130 INCH lbs. (12-15 N.m). (Scheme 259) Loosen piston stem 1 1/2 turns.
  2. Hold piston stem and tighten lock nut to 18-29 ft. lbs. (24-39 N.m). Install oil pan using NEW gasket. Tighten oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-2430-S03546018212000031800000). Add fluid and check level. DO NOT overfill.

Scheme 259

Scheme 259
Scheme 259

OVERDRIVE BRAKE BAND

Note. Overdrive brake band is not adjustable on MPV.

Note. B-Series overdrive band adjustment procedure can also be used for intermediate band adjustment. see scheme 6

Scheme 260

Scheme 260: Miata
Scheme 260: Miata
  1. Remove overdrive band servo cover and gasket. (Scheme 260) Loosen overdrive adjustment screw lock nut while holding piston stem stationary. Tighten piston stem to 106-130 INCH lbs. (12-15 N.m).
  2. Back off piston stem 2 turns. While holding stem in this position, tighten lock nut to 11-30 ft. lbs. (15-40 N.m). Install overdrive band servo cover with NEW gasket. Tighten cover bolts to 44-62 INCH lbs. (5-7 N.m).

B-Series

See OVERDRIVE BRAKE BAND .

  1. Move gearshift lever to Park. Remove steering column covers. Pull gearshift lever rearward and insert a.20" (5.0 mm) diameter pin into gearshift rod assembly. (Scheme 261)
  2. Remove air intake pipe. Loosen shift lever bolts and top lever bolts. (Scheme 262) Place manual shaft in "P" position. Slide shift lever assembly until vertical clearance between shift lever bushing and lower bracket is zero. (Scheme 263)
  3. Tighten shift lever bolts to 12-17 ft. lbs. (16-23 N.m). Ensure detent ball is in center of "P" range detent. (Scheme 264) Loosen mounting bolts and rotate bracket to adjust detent ball placement. Tighten detent mounting bolts to 61-87 INCH lbs. (7-10 N.m).
  4. Rotate top lever until horizontal clearance between rear of shift lever bushing and lower bracket is zero. (Scheme 263) Tighten top lever bolts to 12-17 ft. lbs. (16-23 N.m). Remove pin from gear shift assembly. Install column covers. Check gearshift selector lever operation.

Scheme 261

Scheme 261
Scheme 261

Scheme 262

Scheme 262
Scheme 262

Scheme 263

Scheme 263
Scheme 263

Scheme 264

Scheme 264
Scheme 264

Millenia & Protege

  1. Remove battery, air cleaner assembly and battery tray. Place gearshift lever in Park. Loosen selector cable mounting nut at transaxle. Push selector cable toward cable bellows and hold in this position.
  2. Center nut on selector cable in a no-load position. Tighten selector cable mounting nut to 12-16 ft. lbs. (16-22 N.m). Ensure starter operates in Park and Neutral only. Ensure position of gearshift lever and indicator correspond with each other.
  3. Ensure lock button returns after button has been depressed. Ensure gearshift lever operates smoothly when engaged in all positions. Install center console.

MX-6 2.5L & 626 2.5L

  1. Remove front console. Place gearshift lever in Park. Remove indicator screws and lift up indicator panel. Slide lock cover forward. Disconnect set button from selector lever. Lock cover and set button are located forward and to left of selector lever. Push selector lever against "P" range and hold in this position.
  2. Connect set button and slide lock cover over set button. Ensure starter operates in Park and Neutral only. Ensure position of gearshift lever and indicator correspond with each other.
  3. Ensure lock button returns after button has been depressed. Ensure gearshift lever operates smoothly when engaged in all positions. Install center console.

THROTTLE CABLE

Note. Oil pressure gauge is needed to properly adjust throttle cable.

Protege

  1. Remove left splash shield, near left front tire. Remove the lower pressure port plug. Install oil pressure gauge to the port. (Scheme 265)
  2. Move gearshift lever to Park. Start engine and warm to normal operating temperature. Ensure engine is at normal idle speed. Ensure throttle pressure is 71 psi (5.0 kg/cm 2 ). If pressure is not within specification, adjust throttle cable.
  3. With engine running, loosen adjustment bolt/nut. Adjust throttle cable until pressure reading is within specification. (Scheme 266) Tighten throttle cable adjustment bolt/nut when pressure is within specification. Turn engine off. Remove oil pressure gauge. Install pressure port plug and tighten to 44-89 INCH lbs. (5-10 N.m). Install left splash shield.

Scheme 265

Scheme 265
Scheme 265

Scheme 266

Scheme 266
Scheme 266

TRANSMISSION RANGE SENSOR/SWITCH

Note. B-Series is equipped with a transmission range sensor. All other models are equipped with a transmission range switch.

626 & MX-6 2.0L

Loosen sensor bolts slightly. Place gearshift lever in Neutral. Ensure gearshift lever is adjusted correctly. Rotate manual lever to "N" position. Install Sensor Alignment Tool (49 UN01 086 ) or equivalent to align slots on sensor. Ensure manual lever is in "N" position. Tighten sensor bolts to 96-117 INCH lbs. (11-13 N.m).

Loosen sensor bolts slightly. Place gearshift lever in Neutral. Ensure gearshift lever is adjusted correctly. Rotate manual lever to "N" position. Install Sensor Alignment Tool (49 UN01 086 ) or equivalent to align 3 slots on sensor. Ensure manual lever is in "N" position. Tighten sensor bolts to 71-97 INCH lbs. (8-11 N.m).

  1. Disconnect negative battery cable. Remove battery, air cleaner assembly and battery tray. Disconnect selector cable. Place manual shaft in Neutral. Disconnect transmission range switch connector. Loosen transmission range switch mounting bolts at transmission and hand tighten.
  2. Connect ohmmeter between terminals "A" and "H". (Scheme 267) Adjust switch until continuity exists. Tighten transmission range switch mounting bolts to 71-97 INCH lbs. (8-11 N.m). Verify switch operation.

626 & MX-6 With 2.5L, Miata, Millenia & MPV

  1. Place gearshift lever in Neutral. Ensure gearshift lever is adjusted correctly. See «GEARSHIFT LEVER»(ref-2430-S17123826712000031800000) . Loosen transmission range switch mounting bolts at transmission. Remove screw from alignment pin hole at bottom of switch (if equipped).
  2. On Millenia 2.3L and MX-6/626 with 2.5L, place manual lever in Neutral. Line up neutral mark on switch with manual lever. On Millenia 2.5L and MPV, rotate switch and insert a 5/32" alignment pin (or drill bit) through alignment holes.
  3. On all models, tighten mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-2430-S03546018212000031800000) . Remove alignment pin. Install alignment pin hole screw (if equipped) and check switch operation. Vehicle should start only with gearshift in Park and Neutral.

Scheme 267

Scheme 267
Scheme 267

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