Automatic Transaxle - Overhaul [LJ4A-EL]: Other Mazda Millenia I рестайлинг

GEAR RATIOS

TRANSAXLE GEAR RATIOS

ON-VEHICLE SERVICE

See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.

LOW ONE-WAY CLUTCH

Inspect one-way clutch operation. Holding front planetary carrier, low one-way clutch should only rotate clockwise and lock when turned counterclockwise. (Scheme 190) Replace as needed.

Scheme 184

FORWARD ONE-WAY CLUTCH & REAR INTERNAL GEAR

Disassemble forward one-way clutch and rear internal gear. see scheme 59 Inspect all components for abnormal wear. Replace as needed. Reassemble in reverse order of disassembly. Apply petroleum jelly to thrust washer and install onto rear internal gear. Install tabs of the thrust washer into the alignment holes on each side of rear internal gear. Install rear internal gear in the forward clutch hub by turning it evenly and gradually. Inspect one-way clutch operation. Holding forward clutch hub, rear internal gear should only turn clockwise and lock counterclockwise. see scheme 60

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

1. Using appropriate return spring compressor, remove snap ring and retaining plate. Remove forward clutch drive and driven plates. see scheme 61 Remove dish plate. Remove snap ring securing overrunning clutch. Remove retaining plate, drive and driven plates. Remove dish plate.
2. Using appropriate compressor, compress return spring retainer and remove snap ring. Remove return spring retainer. Install forward clutch drum in transaxle case. Apply a maximum of 57 psi (4 kg/cm 2 ) of air pressure to oil passage to remove clutch pistons. see scheme 62
3. Remove overrunning clutch piston pistons from the forward clutch piston. Check for worn drive (friction) and driven plates. Drive plate minimum thickness for overrunning clutch is 0.055" (1.40 mm) or 0.071" (1.80 mm) for forward clutch. see scheme 37 Check snap rings for wear and cracks. Check for deformed or detached spring and retainer assembly. Check for broken or weak springs.
4. Check overrunning clutch piston. Verify there is no leakage when applying a maximum of 57 psi (4 kg/cm 2 ) of compressed air through the oil hole opposite the return spring. Verify there is air flow when applying 57 psi (4 kg/cm 2 ) compressed air through the oil hole on the return spring side. (Scheme 191) Replace overrunning clutch piston if damaged or malfunctioning.
5. Check forward drum. Verify there is no air leakage when applying 57 psi (4 kg/cm 2 ) compressed air through the oil hole opposite the low and reverse brake. Verify that there is air flow when applying 57 psi (4 kg/cm 2 ) compressed air through the oil hole on the low and reverse brake side. (Scheme 192) Replace forward clutch drum if damaged or malfunctioning.
6. Measure spring free length. Ensure spring free length is 0.841" (21.37 mm). see scheme 28 Check piston for damage or wear and seal contact area in transaxle case for damage.

DRUM SUPPORT

Disassemble drum support. (Scheme 197) Replace needle bearing as needed. Replace sealing rings using caution not to over expand seal rings during installation. Seal ring inner diameter should be 2.618" (66.5 mm). Apply petroleum jelly to thrust bearing.

Scheme 191

OUTPUT GEAR

Using appropriate puller, remove bearing as needed. Press on new bearing. Replace sealing rings. (Scheme 198) Apply petroleum jelly to thrust bearing.

Scheme 192

VALVE BODY

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

1. Remove Transmission Fluid Temperature (TFT) sensor from lower valve body. (Scheme 199) Remove lockup and pressure control solenoid valves from inter control valve body. Remove shift solenoid valve "A", shift solenoid "B" and overrunning clutch solenoid valve from the lower control valve body.
2. Remove 2 bolts with support plates. (Scheme 199) Unbolt and remove oil strainer. Unbolt and remove upper valve body with separator plate "A" as an assembly to prevent loss of steel balls. Turn over upper valve body and remove steel balls. Remove pilot filter from separator plate "A". (Scheme 199)and see scheme 72.
3. Remove steel ball from upper side of inter valve body. see scheme 73 Remove inter valve body with separator plate "B" as an assembly to prevent loss of steel balls. Turn over inter valve body and remove steel balls. see scheme 74
4. Remove orifice check valve and spring from lower control valve body. see scheme 75 Remove manual valve.

Scheme 198

Scheme 199

1. Disassemble upper valve body in numbered order. see scheme 76 Disassemble inter valve body in numbered order. see scheme 77 If a valve does not slide out under its own weight, place valve body open side down and tap lightly with plastic hammer.
2. Clean all components in solvent. Dry with compressed air and immediately coat with ATF. Ensure all valve body passages are clear. Inspect valve for scoring or roughness. Ensure valves slide freely in bores.
3. Inspect valve springs for damage, squareness and collapsed coils. Measure spring free length. see scheme 28 Replace spring if not within specification. See «VALVE BODY SPRING SPECIFICATIONS»(ref-171573-S17271096272005020800000) table. Reassemble in reverse order of disassembly. Ensure all valves snap in place when moved.

VALVE BODY SPRING SPECIFICATIONS

Setting Total End Play

1. Place NEW oil pump gaskets on transaxle case. Place straightedge across case. Using vernier caliper, measure and record distance from straightedge to bearing race on high clutch drum (measurement "A" less thickness of straightedge). see scheme 95
2. Measure and record distance from straightedge to oil pump gasket surface (measurement "B" less thickness of straightedge). Apply petroleum jelly to thrust bearing and install on oil pump support.
3. Place straightedge across pump support. see scheme 95 Measure and record distance from straightedge to gasket contact surface of oil pump (measurement "C" less thickness of straightedge).
4. With straightedge across pump support, measure and record distance from straightedge to thrust bearing surface (measurement "D" less thickness of straightedge).
5. Calculate total end play ("T1") using the equation: "T1" = "A" - "B" - ("C" - "D") - 0.0039" (0.100 mm). T1 Total end play. Specification: 0.010-0.022" (0.25-0.55 mm). A Distance between front of transaxle case and bearing race on the high clutch drum. B Distance between front of transaxle case and oil pump gasket. C Distance between upper surface of oil pump and oil pump gasket contact surface. D Distance between upper surface of oil pump and upper surface of oil pump bearing. 0.0039" (0.1 mm) Amount of compression of new oil pump gasket.
6. Total end play should be 0.010-0.022" (0.25-0.55 mm). If total end play is not within specification, select different high clutch bearing race. Races range in thickness from 0.031" (0.80 mm) to 0.079" (2.00 mm) in increments of 0.008" (0.20 mm).

Scheme 200

Scheme 201

1. Place straightedge across case. Using vernier caliper, measure and record distance from straightedge to bearing race on reverse clutch drum (measurement "E" less thickness of straightedge). see scheme 96
2. Measure and record distance from straightedge to oil pump gasket surface (measurement "B" less thickness of straightedge).
3. Place straightedge across pump support. see scheme 96 Measure and record distance from straightedge to gasket contact surface of oil pump (measurement "C" less thickness of straightedge).
4. With straightedge across pump support, measure and record distance from straightedge to reverse clutch contact surface (measurement "F" less thickness of straightedge).
5. Calculate reverse clutch end play ("T2") using the equation: "T2" = "E" - "B" - ("C" - "F") - 0.0039" (0.100 mm). T2 Reverse clutch end play. Specification: 0.022-0.035" (0.55-0.90 mm). B Distance between front of transaxle case and oil pump gasket. C Distance between upper surface of oil pump and oil pump gasket contact surface. E Distance between front of transaxle case and the reverse clutch drum. F Distance between reverse clutch contact surface of oil pump and upper surface of oil pump. 0.0039" (0.1 mm) Amount of compression of new oil pump gasket.
6. Reverse clutch end play should be 0.022-0.035" (0.55-0.90 mm). If reverse end play is not within specification, select different reverse clutch thrust washer. Thrust washers range in thickness from 0.031" (0.80 mm) to 0.079" (2.00 mm) in increments of 0.008" (0.20 mm).

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

1. Install oil pump on transaxle case. Tighten bolts in sequence to specification. See. see scheme 97. See «TORQUE SPECIFICATIONS»(ref-171573-S15654750062005020800000).
2. Install "O" rings to input shaft and differential lube hole.
3. Adjust brake band anchor end bolt. Tighten bolt to 35-52 INCH lbs. (4.0-5.8 N.m). see scheme 99 Loosen anchor end bolt 2.5 turns. Install lock nut and tighten to specification while holding anchor end bolt. See «TORQUE SPECIFICATIONS»(ref-171573-S15654750062005020800000).
4. Place differential assembly in transaxle case. Using Differential Side Gear Holder (49 G027 003) or equivalent. Install bearing race into converter housing using Bearing Installer (49 0500 330) or equivalent.
5. Apply light coat of sealant to contact surface of converter housing and transaxle case. Install transaxle case on converter housing. Tighten bolts evenly and gradually in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-171573-S15654750062005020800000).
6. Install low and reverse brake sleeve. see scheme 5 Install 2-3 accumulator return spring.
7. Align manual valve with pin on manual plate. Install valve body in transaxle case. Tighten bolts evenly and gradually in crisscross pattern to specification. see scheme 4 See «TORQUE SPECIFICATIONS»(ref-171573-S15654750062005020800000).
8. Ensure valve body electrical harness is fully seated in transaxle case. Install retaining clip. Install oil pan and tighten bolts evenly and gradually in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-171573-S15654750062005020800000).
9. Install and adjust transmission range sensor. Ensure manual shaft is in "L" position (fully forward). Install range sensor with new bolts. Turn manual shaft fully rearward. Return 2 notches to "N" position. Insert a 0.160" (4.00 mm) pin through holes of range sensor and manual shaft lever. see scheme 100 Tighten retaining bolts. Remove pin.
10. Install output gear with thrust bearing into back of transaxle case. Apply silicone sealant to contact surface of side cover and install cover. Tighten bolts evenly and gradually in crisscross pattern to specification.
11. Install NEW "O" Ring to output speed sensor. Install output speed sensor. see scheme 3 Install NEW "O" Ring to vehicle speed sensor. Install vehicle speed sensor.
12. Install shift control bracket onto transaxle case. Install control rod onto manual shaft. Fill torque converter with about 2.1 qts. (2.0L) of clean ATF. Install converter while rotating to align pump splines. Measure distance torque converter is set back from edge of converter housing (dimension "A") to verify converter installation. see scheme 101 Torque converter should be inset 0.551" (14.00 mm).