FINAL ASSEMBLY Mazda Protege BJ

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 83) For outer diameter identification of bearings and races, see THRUST BEARING & RACE SPECIFICATIONS table. All bearings, except No. 1, are one-piece units.

Scheme 83

THRUST BEARING & RACE SPECIFICATIONS

1. Measure front sun gear bushing. (Scheme 84) Ensure bushing inner diameter is within specification. See «TRANSAXLE SPECIFICATIONS»(ref-143053-S33214900832002082200000). If not within specification, replace front sun gear.
2. Measure end cover bushing. (Scheme 85) Ensure bushing inner diameter is within specification. See «TRANSAXLE SPECIFICATIONS»(ref-143053-S33214900832002082200000). If not within specification, replace end cover.
3. Mount transaxle case in appropriate holding fixture. Install oil pipe. Install funnel bearing and race. Tighten Torx screws to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000). Install bearing race to transaxle case. Install locknut. Set primary gear in place. Install distance piece (spacer) and bearing. (Scheme 86) Install lock nut and hand tighten.
4. Secure primary gear with Holding Tool (49 B019 019). Using lock nut Socket (49 B019 021), tighten lock nut. Tighten the locknut from the end cover side to adjust the preload within specification. Preload: 4.42-7.96 INCH lbs. (0.50-0.90 N.m) is achieved. Stake lock nut. Remove SSTs.
5. Install front internal gear and one-way clutch. Apply petroleum jelly to the bearing and secure bearing to the front planetary gear. Install front planetary gear. Apply petroleum jelly to the bearing and secure to front sun gear. (Scheme 49)
6. Install front sun gear with thrust bearing. Install rear planetary gear. Rotate case so that the oil pan faces downward. Pull the front internal gear and one-way clutch a little until the groove for the snap ring appears. (Scheme 87) Install snap ring.
7. Rotate case so that the end cover faces upward, and verify that the snap ring is installed accurately. Install 2-4 brake band servo return spring, piston and seal lubricated with ATF into transaxle case. Install servo retainer (cover) and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
8. Install 2-4 brake band. Apply petroleum jelly to the bearing and install to 2-4 brake drum. Install 2-4 brake drum with thrust bearing. Install an alternate bolt in place of brake band strut. Bolt must be 2.36-2.75" (60-70 mm) in length. Tighten bolt to 43 INCH lbs. (4.9 N.m). Measure and record distance between case and head of bolt (dimension "A"). (Scheme 88)
9. Remove bolt. Measure and record total length of bolt from below head (dimension "B"). Calculate as follows: B - A = C (The middle of the under head length) C - 4 = D (The lower limit of under head length) C - 4.7 = E (The upper limit of under head length) Select a brake band strut whose length should be between "D" and "E". Available lengths are: 1.417" (36.0 mm) 1.437" (36.5 mm) 1.457" (37.0 mm) 1.476" (37.5 mm) 1.496" (38.0 mm) 1.516" (38.5 mm) 1.535" (39.0 mm) Install selected strut and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
10. Place.102" (2.6 mm) thrust bearing race (thickest) on end cover. Install end cover without gasket on 2-4 brake drum and case. Measure clearance between cover and transaxle case. (Scheme 89) Calculate according to the formula: A - 0.102 (2.6 mm) (Bearing thickness) = B B - 0.25 = C (The lower limit of bearing thickness) B - 0.50 = D (The upper limit of bearing thickness) Select an appropriate bearing race whose bearing thickness matches the calculated limits. Select a bearing race whose thickness is between "D" and "E". Bearing races are available in the following sizes: 0.071" (1.8 mm) 0.079" (2.0 mm) 0.087" (2.2 mm) 0.094" (2.4 mm) 0.102" (2.6 mm)
11. Select proper bearing race and install on end cover. (Scheme 89) Ensure tab on bearing race is installed in correct location. (Scheme 90) Install "O" rings coated with ATF in end cover. (Scheme 91) Seal ring inner diameter: A: 1.854" (47.1 mm) B: 2.197" (55.8 mm) Apply a light coat of silicone sealant to contact surfaces of the transaxle case and end cover. Apply ATF to the "O" ring and install to transfer case. Install end cover to transaxle case. Tighten bolts in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
12. Install parking pawl spring, parking pawl and shaft to transaxle case. (Scheme 48) Install support plate into transaxle case. Install actuator plate to transaxle case. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
13. Install secondary gear, and output gear and differential. Install forward clutch assembly. Apply light coating of silicone sealant to transaxle case and converter case. Install converter housing. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
14. Install differential side gear Holders (49 G030 455) into differential side gears. Install oil pump. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000). Install parking rod lever assembly. Apply ATF to "O" ring and install on manual shaft. Install manual shaft to manual plate and detent bracket. Install roll/knock pin.
15. Install accumulators. See «ACCUMULATORS»(ref-143053-S04649367562002082200000) under COMPONENT DISASSEMBLY & REASSEMBLY for identification.
16. Install coupler. Ensure that the head of the manual valve and the parking rod are assembled properly. If they are not, the ranges cannot be charged.
17. Install internal solenoid harness. Install valve body. Install valve body bolts in correct location. (Scheme 47) All bolts are same length except bolts with no markings: Bolt "B" - 1.575" (40 mm) No Mark - 2.756" (70 mm) Tighten bolts in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
18. Connect harness connectors to solenoids. Match the harness colors, then connect the solenoid connector and transaxle fluid temperature sensor. See «SOLENOID HARNESS CONNECTOR IDENTIFICATION»(ref-143053-S31782333882002082200000) table. (Scheme 92) SOLENOID HARNESS CONNECTOR IDENTIFICATION Shift Solenoid Connector Color A White B Blue C Green D White E Black Pressure Control Black
19. Connect ground. (Scheme 92) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
20. Apply a light coat of silicone to the contact surfaced of the oil pan and transaxle case. Install oil pan. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
21. Install oil pipe. Apply ATF to the "O" ring and install it to the vehicle speed sensor. Install vehicle speed sensor. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
22. Apply ATF to the new "O" ring and install it to the input/turbine speed sensor. Install the oil pressure switch. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
23. Install the input/turbine speed sensor. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
24. Install Transaxle Range (TR) switch. Rotate the manual shaft to the "N" position. Turn the protrusion till the resistance between TR switch connector terminals "B" and "C" becomes 750 ohms. (Scheme 93) Install the TR switch while aligning the protrusion and groove. Hand tighten the TR switch mounting bolts. (Scheme 94) Inspect resistance between TR switch terminals "B" and "C". (Scheme 93) Resistance should be 750 ohms. Adjust as necessary. Tighten TR switch mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000). CAUTION: Do NOT use an impact wrench. Hold the manual shaft lever when removing the manual shaft nut or the transaxle may be damaged. Install manual shaft lever and washer. Using an adjustable wrench, hold the manual shaft lever and tighten manual shaft nut to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
25. Apply ATF to NEW "O" ring and install on the oil filler tube. Install oil filler tube and dipstick to the transaxle. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-143053-S14020689702002082200000).
26. Align torque converter to oil pump and install torque converter. (Scheme 95) Check installed depth. (Scheme 96) Installed distance "A" depth: Mazda3 - 1.24" (31.4 mm) Mazda6 & Protege - 0.84" (21.4 mm)

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96