Automatic Transaxle - Overhaul [GF4A-EL]: Overhaul Mazda Millenia I рестайлинг

Disassembly

1. Remove oil pump cover mounting bolts in sequence. (Scheme 214) Mark inner and outer rotors for reassembly reference. Remove flange, inner and outer rotors. (Scheme 215)
2. Remove plug, spring and spool. Remove selective bearing race, "O" rings and seal rings from cover.

Scheme 214

Scheme 215

Reassembly

Note. Ensure all components are coated with ATF during assembly.

1. Install spool and spring into oil pump body. Ensure spool moves freely. Install plug with NEW packing and tighten.
2. Align rotor reference marks and install rotors in oil pump housing. Install oil pump flange. Install oil pump cover on oil pump flange and tighten in sequence. (Scheme 214) See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000).
3. Install oil pump shaft and check for smooth operation. Install NEW seal rings. Apply petroleum jelly to selective bearing race and install on oil pump cover.

OIL PUMP SPECIFICATIONS

Disassembly (2-3 Accumulator)

Remove snap ring and stopper plug. Remove "O" ring from stopper plug. (Scheme 216) Remove accumulator spring and piston. Remove orifice check valve and spring.

Install "O" rings on accumulator using ATF. Install accumulator piston and spring. Install stopper plug and "O" ring. Install snap ring while applying pressure to stopper plug. For remainder of installation procedures, reverse disassembly procedures. Ensure snap ring is seated properly.

Scheme 216

Scheme 217

Scheme 218

1. Remove snap ring, retainer plate, drive and driven plates and dished plate from forward clutch, coasting clutch and reverse clutch. (Scheme 217)
2. Compress coasting clutch spring and remove snap ring. Remove spring and retainer assembly. Remove coasting clutch drum from reverse and forward drum. Using maximum 57 psi (4.0 kgf/cm 2 ) of air pressure, remove coasting clutch piston from coasting clutch drum. (Scheme 218)
3. Remove reverse clutch snap ring from reverse and forward drum. Place reverse and forward drum on oil pump. Use maximum 57 psi (4 kg/cm 2 ) of air pressure to remove reverse piston.
4. Check and repair or replace any faulty parts. Inspect piston check ball for leakage and sticking. Check for worn snap ring.
5. Check for broken or weak return springs. Check spring and retainer assembly for separation or deformation. Replace drive plates (friction discs) if thickness is less than 0.059" (1.50 mm). Measure spring and retainer free height. (Scheme 219) Height should be 1.242" (31.54 mm).

Scheme 219

Scheme 220

1. Apply ATF to all parts. Soak drive plates for at least 15 minutes. Install inner and outer seals on reverse piston. Install reverse piston into reverse clutch drum. Install piston return spring with tabs facing away from piston. Install return spring stop with step upward. Compress spring and retainer. Install snap ring.
2. Install reverse clutch dished plate with the dished side facing piston. Install drive and driven plates alternately beginning with a driven plate, retaining plate (step facing down) and snap rings. Measure clearance of reverse clutch between retaining plate and snap ring. (Scheme 220)
3. Clearance should be 0.059-0.071" (1.50-1.80 mm). Adjust clearance by installing selective snap ring. Snap rings are available in the following thicknesses: 0.079" (2.00 mm) 0.087" (2.20 mm) 0.094" (2.40 mm) 0.102" (2.60 mm) 0.110" (2.80 mm)
4. Install inner and outer seals on coasting drum. Install drum into forward and reverse drum. Install seal rings onto coasting clutch piston. Install coasting clutch piston into coasting clutch drum. Install spring and retainer. Compress spring and retainer, and install snap ring.
5. Install dished plate with dished side facing upward. Install drive (friction) and driven plates alternately beginning with a driven plate, retaining plate and snap ring. (Scheme 217) Ensure coasting clutch snap ring opening is opposite of piston snap ring. Measure coasting clutch clearance. (Scheme 220) Clearance should be 0.039-0.047" (1.00-1.20 mm).
6. Adjust clearance by installing selective snap ring. Selective snap rings are available in the following thicknesses: 0.059" (1.50 mm) 0.065" (1.65 mm) 0.071" (1.80 mm) 0.077" (1.95 mm) 0.083" (2.10 mm) 0.089" (2.25 mm)
7. Install forward clutch dished plate with dished side facing downward. Install drive (friction) and driven plates alternately beginning with a driven plate, retainer plate and snap ring. Check forward clutch clearance between retainer plate and snap ring. (Scheme 220) Clearance should be 0.038-0.047" (0.97-1.20 mm).
8. Adjust clearance by installing selective snap ring. Selective snap rings are available in the following thicknesses: 0.079" (2.00 mm) 0.085" (2.15 mm) 0.091" (2.30 mm) 0.096" (2.45 mm) 0.102" (2.60 mm) 0.108" (2.75 mm)
9. Check operation of clutches by setting clutch assembly onto oil pump. Apply maximum 57 psi (4 kg/cm 2 ) of air pressure to appropriate oil passage. (Scheme 218)

1. Remove snap ring, one-way clutch inner race, snap ring, needle bearing, one-way clutch, one-way clutch outer race, needle bearing and small sun gear. (Scheme 221)
2. Measure bushing inside diameters. Maximum inside diameter of sun gear drum is 1.316" (33.43 mm). Maximum inside diameter of sun gear is 0.945" (24.00 mm). Check sun gear drum and small sun gear, inner and outer race, clutch hub, gear and needle bearings for damage or wear.

Scheme 221

1. Apply petroleum jelly to needle bearing and install into one-way clutch inner race. Install one-way clutch into outer race. Ensure spring cage faces toward outer race.
2. Install one-way clutch inner race into one-way clutch by turning inner race counterclockwise. Ensure inner race turns counterclockwise only. (Scheme 222)
3. Install small sun gear into drum and install snap ring. Install one-way clutch races to sun gear drum. Ensure one-way clutch inner race and small gear clutch hub splines are aligned. Install snap ring.
4. Hold one-way clutch outer race with one-way clutch inner race facing upward. Inner race should turn smoothly in a counterclockwise direction and lock in clockwise direction. (Scheme 222) Apply petroleum jelly to needle bearing and install into sun gear drum.

Scheme 222

1. Remove one-way clutch No. 2, thrust washers and snap ring. (Scheme 223) Remove planetary carrier assembly from inner race. Place one-way clutch on inner race. Holding inner race, ensure one-way clutch rotates smoothly in clockwise direction. (Scheme 224)
2. Inspect for damaged or worn parts. Ensure clearance between planetary pinion gear and washer is 0.008-0.028" (0.20-0.70 mm). (Scheme 225)

Scheme 223

Scheme 224

Scheme 225

1. Assemble planetary gear to inner race. Install snap ring. Apply petroleum jelly to thrust washer and install on clutch and planetary carrier assembly.
2. Outer diameter of thrust washer for sun gear side of planetary is 2.835" (72.00 mm). Outer diameter of thrust washer for 3-4 clutch side is 2.209" (56.10 mm). Install one-way clutch. While holding inner race, ensure one-way clutch No. 2 rotates clockwise and locks counterclockwise. (Scheme 224)

1. Remove needle bearings and snap ring. Remove retaining plate and drive and driven plates. see scheme 19 Compress return spring and retainer. Remove snap ring.
2. Remove spring and retainer assembly. Remove piston, and inner and outer seals from piston.

1. Install seal rings. Coat 3-4 clutch piston with ATF and install into 3-4 clutch drum. Install and compress spring and retainer assembly. Install snap ring.
2. Install 3-4 clutch drive and driven plates. Install retaining plate and snap ring. Measure clearance between retaining plate and snap ring. Clearance should be 0.051-0.059" (1.30-1.50 mm). Adjust clearance by installing selective retaining plate. Retaining plates are available in the following thicknesses: 0.150" (3.80 mm) 0.154" (3.91 mm) 0.159" (4.04 mm) 0.164" (4.17 mm) 0.169" (4.30 mm) 0.174" (4.43 mm) 0.179" (4.56 mm) 0.184" (4.69 mm) 0.189" (4.80 mm)
3. Check clutch operation. Ensure clutch piston seal does not leak. Apply petroleum jelly to needle bearings and install on 3-4 clutch. Bearing outer diameter is 2.21" (56.1 mm) for carrier side and 2.84" (72.1 mm) for output shell side.

1. Install low-reverse brake piston. Install spring and retainer assembly. Compress spring and retainer assembly enough to install snap ring. Install clutch plates in alternate order, beginning with drive plate. Install retaining plate and snap ring.
2. Measure clearance between retaining plate and snap ring. (Scheme 226) Adjust clearance by selective snap rings or retainer plates. Clearance should be 0.059-0.071" (1.50-1.80 mm). Adjust clearance by installing selective retaining plate. Retaining plates are available in the following thicknesses: 0.276" (7.0 mm) 0.283" (7.2 mm) 0.291" (7.4 mm) 0.299" (7.6 mm) 0.268" (7.8 mm)

Scheme 226

Separate servo retainer from servo piston. see scheme 2 Remove "O" rings, "D" rings, spring and piston stem.

Install new "O" ring and "D" rings. Assemble servo piston to servo retainer. Install 2-4 brake band servo.

1. Remove side gears and thrust washers. Place gear assembly in a vise. Using a 0.07" (2.0 mm) punch into the roll pin hole from the ring gear side and remove the roll pin and pinion shaft. (Scheme 227) Remove pinion gears and rotate thrust washers out of differential housing.
2. Using appropriate bearing puller, remove side bearings. DO NOT remove speedometer drive gear unless damaged. Remove ring gear.

Install ring gear. Tighten bolts to specification in a crisscross pattern. See TORQUE SPECIFICATIONS . Install speedometer drive gear (if removed) and bearings. Apply ATF to thrust washers and pinion shaft. Install thrust washers, pinion gears and side gears. Install pinion shaft. Install and crimp roll pin.

Scheme 227

Disassembly & Reassembly

Remove seal rings. Using bearing puller, remove bearings. To reassemble, reverse disassembly procedure. (Scheme 228)

Scheme 228

Secure Idler Gear Shaft Holder (49 FT01 439) and idler gear in a vise. Remove lock nut from idler shaft. Remove both outer bearing races from idler gear. see scheme 25

1. Press both outer bearing races into idler gear. Assemble idler gear assembly. see scheme 25 Using holding device, mount idler gear shaft in vise. Tighten lock nut to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000).
2. Secure idle gear assembly in vise and measure bearing preload. (Scheme 229) Preload can be measured using a INCH-lb. torque wrench or pull scale. Using torque wrench, preload should be 0.27-7.8 INCH lbs. (0.03-0.90 N.m). Using pull scale, preload should be 0.066-1.98 lbs. (0.03-0.90 kg).
3. If specified preload cannot be obtained within specified torque, adjust preload by selecting different adjusting shims. Adjusting shims range in thickness from 0.179" (4.54 mm) to 0.209" (5.31 mm) in increments of 0.00137" (0.035 mm).

Scheme 229

VALVE BODY ASSEMBLY

1. Remove sensors, solenoid valves and "O" rings. Remove front valve body, pre-main separator plate and pre-main separator plate gaskets. Remove front/pre-main gaskets, pre-main separator plate and pre-main separator plate gaskets. (Scheme 230)and (Scheme 231).
2. Locate and remove rubber balls from front and pre-main valve body. Remove pre-main valve body, main separator plate and main separator plate gaskets.
3. Remove pre-main/main gaskets and main separator plate from pre-main valve body. Remove jet orifices and nuts from main separator plate. Locate and remove rubber balls and oil strainer from pre-main valve body.
4. Locate and remove rubber balls and oil strainer from main valve body. Turn assembly over and remove oil pipe, baffle and shift solenoids. Remove rear separator plate and rear separator plate gaskets from main valve body.
5. Remove main/rear gaskets and separator plate from rear valve body. Locate and remove rubber balls and oil strainer from rear valve body. Locate and remove rubber balls and oil strainer from main valve body.
6. Disassemble pre-main body, main body and rear body valve assemblies. (Scheme 232), (Scheme 233) and (Scheme 234).

1. Reassemble valve bodies. Install check balls, oil strainers and jet orifices in correct location. (Scheme 231)
2. During assembly of valve body, ensure bolts are installed in correct location. Ensure valve body gaskets are installed in correct location. (Scheme 235) Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000).

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

VALVE BODY SPRING FREE LENGTH SPECIFICATIONS

FINAL ASSEMBLY

Note. Ensure all bearing preloads are set and appropriate shims are installed. See ADJUSTMENTS .

Note. For location of thrust bearings and races, refer to illustration. (Scheme 236) For outer diameter specifications, see BEARING & RACE OUTER DIAMETER SPECIFICATIONS table.

Note. If drive plates or 2-4 brake band are replaced, soak new part in ATF for at least 2 hours before installation.

Scheme 236

BEARING & RACE OUTER DIAMETER SPECIFICATIONS

1. Align bearing cover with guide bolts. see scheme 34 Install and tighten mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000). Press bearing race into converter housing.
2. Assemble Transaxle Hanger (49 G019 0A0) and Engine Stand (49 0107 680A). Install idler gear and output gear by tapping with a plastic hammer. Install selected shims and bearing race into bearing housing. Install bearing housing on converter housing. Tighten bolts evenly and gradually to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000).
3. Align slot of idler shaft with mark on bearing housing. Using a punch and a hammer, tap in NEW roll pin. Install orifice check valve spring and orifice check valve. Apply ATF to NEW "O" rings. Install "O" rings into 2-3 accumulator. Install 2-3 accumulator piston. Install bearing race into converter housing.
4. Install differential. Install selected shims and bearing race into transaxle case. Install manual plate, spacer, washer and nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000). Install detent ball, spring, washer and plug. Move manual shaft and ensure parking pawl operates properly.
5. Install output shell to output gear. Install thrust bearing onto output shell. Apply a light coat of silicone sealant to contact surfaces of converter housing and transaxle case. Install NEW "O" rings into converter housing. Install transaxle case on converter housing. Tighten bolts evenly and gradually to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000).
6. Install Differential Side Gear Holder (49 G030 455) into differential side gears. Assemble turbine shaft and 3-4 clutch component. Ensure thrust bearing and race are properly installed. Install turbine shaft and 3-4 clutch component into transaxle case. Adjust Turbine Shaft Holder (49 G019 0A2) position so it contacts and holds turbine shaft. Install internal gear to output shell. Install snap ring.
7. Ensure turbine shaft thrust bearing and bearing race are installed in correct position. Hold turbine shaft with one hand to prevent shaft from rotating. Install carrier hub component into 3-4 clutch drum by rotating it. Install friction plate.
8. Hold one-way clutch No. 2 horizontally. Install clutch by turning carrier hub component counterclockwise. Install snap ring.
9. Install servo return spring and band servo. Using Return Spring Compressor Set (49-G019-0A7A), compress servo. Install snap ring. Remove return spring compressor set. Install piston stem. Loosely tighten piston stem by hand. Install anchor strut.
10. Install 2-4 brake band in transaxle case, and interlock band into anchor. Ensure small sun gear and one-way clutch No. 1 thrust bearing and bearing race are installed properly. Rotate sun gear and one-way clutch No. 1 component to install.
11. Measure height difference between reverse and forward drum and transaxle case. (Scheme 237) Height difference should be 0.028-0.075" (0.70-1.90 mm). If height is not within specification, repeat steps 7 - 11. Install NEW snap ring into bottom ring groove of turbine shaft.
12. Adjust total end play. Set thrust bearing onto clutch component. Remove bearing race and oil pump gasket. Set thickest bearing race, 0.084" (2.2 mm), onto oil pump. Set oil pump onto clutch component. Measure clearance between transaxle case and oil pump. (Scheme 238) Take several measurements and calculate average value. Select suitable bearing based on values. See «OIL PUMP BEARING RACE SELECTION»(ref-172033-S04870634112005021800000) table.
13. Remove oil pump. Place selected bearing race and NEW gasket onto oil pump. Install oil pump onto clutch component. Tighten bolts evenly and gradually to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000). Install oil pipe.
14. Adjust 2-4 brake band. Loosen lock nut. Tighten piston stem to 104-130 INCH lbs. (11.8-14.7 N.m). Install a dial indicator and magnetic base to oil pump. Set dial indicator against piston stem. While keeping 56-58 psi (3.9-4.1 kg/cm 2 ) of compressed air applied to 2-4 brake band engagement passage, set dial indicator to zero. Stop applying compressed air. Verify piston stroke. Stroke should be 0.0394-0.0472" (0.800-1.200 mm). Adjust piston stem and apply compressed air until stroke is within specification. Hold piston stem, and tighten lock nut to 19-28 ft. lbs. (26-38 N.m).
15. Install NEW "O" ring and oil strainer into transaxle. Install magnets inside oil pan. Apply a light coat of silicone sealant to contact surfaces of transaxle case and oil pan. Install oil pan to transaxle case. Align manual valve with pin on manual plate. Install control valve body into transaxle case. Tighten bolts evenly and gradually to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000).
16. Install NEW "O" ring to coupler component. Install coupler component. Match harness coupler, and connect solenoid connectors and TFT sensor connector. Apply a light coat of silicone sealant to contact surfaces of transaxle case and control valve body cover. Tighten bolts evenly and gradually to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000).
17. Install steel ball, spring, packing and oil pipe. Install bolt. Install input/turbine speed sensor and TR switch. Connect an ohmmeter between terminals No. "A" and "H" of TR switch. (Scheme 240) Rotate manual shaft full counterclockwise, then turn shaft two notches to "N" position. Adjust switch to point where there is no continuity between terminals No. "A" and "H". Tighten switch to 69.5-94.7 INCH lbs. (7.9-10.7 N.m).
18. Tighten manual shaft nut to specification. See «TORQUE SPECIFICATIONS»(ref-172033-S07950791182005021800000). Remove transaxle from transaxle hanger. Install oil dipstick, oil filler tube and NEW "O" ring to transaxle case. Install oil pump shaft. Install NEW "O" ring onto turbine shaft. If torque converter has been drained and washed, hold torque converter in an upright position and fill with NEW ATF.
19. Carefully install torque converter to torque converter housing. Rotate torque converter to align splines. To ensure torque converter is install accurately, measure distance "A" between end of torque converter and face of torque converter housing. (Scheme 239) Distance should be 0.605" (15.36 mm).

Scheme 237

OIL PUMP BEARING RACE SELECTION

Scheme 238

Scheme 239

Scheme 240