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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. See Fig 1 . 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.
Fig 1: Locating Thrust Bearings & Races
G00050376Courtesy of MAZDA MOTORS CORP.
BEARING & RACE OUTER DIAMETER SPECIFICATIONS

Application In. (mm)
No. 1 Bearing 3.39 (86.1)
No. 1 Race 3.46 (88.0)
No. 2 Bearing 2.21 (56.1)
No. 3 Bearing 2.44 (62.1)
No. 4 Bearing 2.44 (62.1)
No. 5 Bearing 2.83 (72.0)
No. 5 Race 2.83 (72.0)
No. 6 Bearing 2.21 (56.1)
No. 6 Race 2.24 (57.0)
No. 7 Bearing 2.80 (71.0)
No. 7 Race 2.83 (72.0)
  1. Align bearing cover with guide bolts. Install and tighten mounting bolts to specification. See TORQUE SPECIFICATIONS  . Press bearing race into converter housing. 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  .
  2. 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. Install baffle plate.
  3. 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  . Install detent spring. Move manual shaft and ensure parking pawl operates properly.
  4. 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  .
  5. 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.
  6. 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.
  7. Hold one-way clutch No. 2 horizontally. Install clutch by turning carrier hub component counterclockwise. Install snap ring. 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.
  8. 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.
  9. Measure height difference between reverse and forward drum and transaxle case. See Fig 2 . Height difference should be .028-.075" (.70-1.90 mm). If height is not within specification, repeat steps  6 -  9 . Install NEW snap ring into bottom ring groove of turbine shaft.
  10. Adjust total end play. Set thrust bearing onto clutch component. Remove bearing race and oil pump gasket. Set thickest bearing race, .084" (2.2 mm), onto oil pump. Set oil pump onto clutch component. Measure clearance between transaxle case and oil pump. See Fig 3 . Take several measurements and calculate average value. Select suitable bearing based on values. See OIL PUMP BEARING RACE SELECTION  table. 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  . Install oil pipe.
  11. 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/cm2 ) 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 .0394-.0472" (.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).
  12. 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  .
  13. 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  .
  14. 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. See Fig 5 . 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).
    15. CAUTION: Do not use an impact wrench or tighten manual shaft nut without holding manual shaft lever, as transaxle may be damaged.
  15. Tighten manual shaft nut to specification. See TORQUE SPECIFICATIONS  . 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.
  16. 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. See Fig 4 . Distance should be .5496" (13.960 mm).
Fig 2: Checking Reverse, Coasting & Forward Drum Installation
G96F04996Courtesy of MAZDA MOTORS CORP.
OIL PUMP BEARING RACE SELECTION

Clearance Measured ("A") - In. (mm) Bearing Race Selection - In. (mm)
.036-.043 (.91-1.10) .047 (1.20)
.028-.035 (.71-.90) .055 (1.40)
.020-.027 (.51-.70) .063 (1.60)
.012-.020 (.31-.51) .071 (1.80)
.004-.012 (.11-.30) .079 (2.00)
.000-.004 (.00-.10) .087 (2.20)
Fig 3: Determining Total End Play
G96H04997Courtesy of MAZDA MOTORS CORP.
Fig 4: Measuring Torque Converter Installed Depth
G96J04998Courtesy of MAZDA MOTORS CORP.
Fig 5: Adjusting TR Switch
G00050377Courtesy of MAZDA MOTORS CORP.
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