Assembly procedure

WARNING: This page is about a different car, the 2008 Mazda RX-8, 2007 Mazda RX-8, 2006 Mazda RX-8, 2005 Mazda RX-8, and 2004 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.

Install new seal rings to the low one-way clutch inner race.

Fig 1: Installing Seal Rings To Low One-Way Clutch Inner Race
Courtesy of MAZDA MOTORS CORP.
Measure the clearance between the seal rings and the seal ring grooves.
- If the clearance is not within the specification, replace the low one-way clutch inner race.
Specification

0.10-0.25 mm {0.0040-0.0098 in}

Fig 2: Measuring Clearance Between Seal Rings And Seal Ring Grooves
Courtesy of MAZDA MOTORS CORP.
Set the SSTs in the order shown.

Fig 3: Installing SST To Transmission Case (Rear Side)
Courtesy of MAZDA MOTORS CORP.
Install the low one-way clutch inner race and the bearing.

Fig 4: Installing Low One-Way Clutch Inner Race And Bearing
Courtesy of MAZDA MOTORS CORP.
Set the SSTs in the order shown.

Fig 5: Installing SST To Transmission Case (Front Side)
Courtesy of MAZDA MOTORS CORP.
Hand tighten the bolts as shown in the figure.

Fig 6: Hand Tightening Bolts

Courtesy of MAZDA MOTORS CORP.

Remove the SSTs .
Tighten the bolts evenly and gradually.
Tightening torque

21-26 N.m {2.1-2.7 kgf.m, 16-19 ft.lbf}

Fig 7: Tightening Bolts To Transmission Case
Courtesy of MAZDA MOTORS CORP.
Install the carrier component.

Fig 8: Installing Carrier Component
Courtesy of MAZDA MOTORS CORP.
Verify that the top of the low clutch drum is lower than surface A (receiving surface of the 2-4 brake plate) of the transmission case.
NOTE:
- Install the thickest driven plate after the retaining plate.
Fig 9: Verifying Top Of The Low Clutch Drum Is Lower Than Surface Of Transmission Case
Courtesy of MAZDA MOTORS CORP.
Apply ATF to the retaining plate, driven plates, and the drive plates, and install them to the transmission case in the following order:
Retaining-Driven-Driven-Drive-Driven-Driven-Drive-Driven-Driven-Drive-Driven-Driven-Drive

Fig 10: Installing Retaining Plate, Driven Plates And Drive Plates And To Transmission Case
Courtesy of MAZDA MOTORS CORP.
Install the spring.
CAUTION:
- If the dished plate is not installed in the specified direction, it may be damaged or not operate properly. Install the plate exactly as shown in the figure.
Fig 11: Installing Spring
Courtesy of MAZDA MOTORS CORP.
Install the retaining plate and the dished plate.

Fig 12: Installing Retaining Plate And Dished Plate
Courtesy of MAZDA MOTORS CORP.
Install new seal rings to the 2-4 brake piston.

Fig 13: Installing Seal Rings To Brake Piston
Courtesy of MAZDA MOTORS CORP.
Install the 2-4 brake piston to the 2-4 brake retainer.

Fig 14: Installing Brake Piston To Brake Retainer
Courtesy of MAZDA MOTORS CORP.
Align the fluid passage and install the return spring, 2-4 brake retainer, and the snap ring.
CAUTION:
- Be sure to center the SSTs on the transmission case. Otherwise, the return spring can be damaged.
Fig 15: Installing Return Spring, Brake Retainer And Snap Ring
Courtesy of MAZDA MOTORS CORP.
Set the SSTs to the transmission case.
CAUTION:
- Do not compress the 2-4 brake retainer excessively. Doing so can damage the return spring.
Fig 16: Installing SST To Transmission Case
Courtesy of MAZDA MOTORS CORP.
Compress the 2-4 brake retainer using the SST .

Fig 17: Compressing Brake Retainer Using SST
Courtesy of MAZDA MOTORS CORP.
Install the snap ring.
Remove the SSTs .
Install the sleeve and a new seal ring.
CAUTION:
- Applying compressed air to the assembled clutch pack for more than 3 s at a time will damage the seal.
- Do not apply compressed air for more than the aforementioned time when testing the system.
Fig 18: Installing Sleeve And Seal Ring
Courtesy of MAZDA MOTORS CORP.
Apply compressed air to the part indicated in the figure and inspect the 2-4 brake operation.
- If there is any malfunction, inspect the seal rings.
Air pressure

390 kPa {4.0 kgf/cm ² , 57 psi} max.

Fig 19: Applying Compressed Air To 2-4 Brake Fluid Passage
Courtesy of MAZDA MOTORS CORP.

Measure the clearance between the 2-4 brake retainer and the snap ring.

If the clearance is not within the specification, adjust the clearance by installing the correct retaining plate.

Specification

1.0-1.4 mm {0.0394-0.0551 in}

Fig 20: Measuring Clearance Between Brake Retainer And Snap Ring

Courtesy of MAZDA MOTORS CORP.

Retaining plate sizes

mm {in}
5.2 {0.205}	5.4 {0.213}	5.6 {0.220}
5.8 {0.228}	6.0 {0.236}	6.2 {0.244}

Install the bearing race, front sun gear, and the bearing.

Fig 21: Installing Bearing Race, Front Sun Gear And Bearing
Courtesy of MAZDA MOTORS CORP.
Install the bearing race and the high clutch hub.

Fig 22: Installing Bearing Race And High Clutch Hub
Courtesy of MAZDA MOTORS CORP.
Install the bearing to the reverse and high clutch drum with the black surface facing rear side.

Fig 23: Installing Bearing To Reverse And High Clutch Drum With Black Surface Facing Rear Side
Courtesy of MAZDA MOTORS CORP.
Install the reverse and high clutch drum and the bearing.

Fig 24: Installing Reverse And High Clutch Drum And Bearing
Courtesy of MAZDA MOTORS CORP.

Use the following procedure to adjust the total end play.

Install the bearing race (oil pump installation race) to the reverse and high clutch drum and measure dimension A shown in the figure.

Fig 25: Measuring Dimension A
Courtesy of MAZDA MOTORS CORP.
Measure the dimension B shown in the figure.

Fig 26: Measuring Dimension B
Courtesy of MAZDA MOTORS CORP.
Calculate the total end play by using the formula below.
- If the total end play is not within the specification, adjust the total end play by selecting the correct bearing race (oil pump installation race).

Formula

Total end play= dimension A-dimension B

Specification

0.25-0.55 mm {0.0099-0.0216 in}

Bearing race sizes

mm {in}
1.4 {0.055}	1.6 {0.063}	1.8 {0.071}
2.0 {0.079}	2.2 {0.087}	2.4 {0.094}

Fig 27: Identifying Total End Play

Courtesy of MAZDA MOTORS CORP.

Install the input shaft.
NOTE:
- Install large seal rings to the front side and small seal rings to the rear side.
Fig 28: Installing Input Shaft
Courtesy of MAZDA MOTORS CORP.
Install new seal rings to the oil pump.

Fig 29: Installing Seal Rings To Oil Pump
Courtesy of MAZDA MOTORS CORP.
Measure the clearance between the seal rings and the seal ring grooves.
- If the clearance is not within the specification, replace the oil pump cover.
Specification

0.10-0.25 mm {0.0040-0.0098 in}

Fig 30: Measuring Clearance Between Seal Rings And Seal Ring Grooves
Courtesy of MAZDA MOTORS CORP.
Install a new O-ring to the oil pump.

Fig 31: Installing O-Ring To Oil Pump
Courtesy of MAZDA MOTORS CORP.
Install the bearing race to the oil pump.

Fig 32: Installing Bearing Race To Oil Pump
Courtesy of MAZDA MOTORS CORP.
Apply sealant to the oil pump installation bolts.
Apply ATF to the O-ring around the oil pump.
Install the oil pump.
Tightening torque

55-60 N.m {5.7-6.1 kgf.m, 42-44 ft.lbf}

Fig 33: Tightening Oil Pump Bolts
Courtesy of MAZDA MOTORS CORP.
Install a new O-ring to the input shaft.

Fig 34: Installing O-Ring To Input Shaft
Courtesy of MAZDA MOTORS CORP.
Install the torque converter housing.
Tightening torque

50-55 N.m {5.1-5.6 kgf.m, 37-40 ft.lbf}

Fig 35: Tightening Torque Converter Housing Bolts
Courtesy of MAZDA MOTORS CORP.
Install a new oil seal using the SST .

Fig 36: Installing Oil Seal Using SST
Courtesy of MAZDA MOTORS CORP.
Install the detent spring.
Tightening torque

6.4-8.3 N.m {66-84 kgf.cm, 58-72 in.lbf}

Fig 37: Installing Detent Spring
Courtesy of MAZDA MOTORS CORP.
Install the manual shaft, manual plate and parking rod as shown in the figure.

Fig 38: Installing Manual Shaft, Manual Plate And Parking Rod
Courtesy of MAZDA MOTORS CORP.
Rotate the manual plate until the detent spring catches on the indented part of the manual plate.
Install a new roll pin using a pin punch.
Apply ATF to a new O-ring, and install it to the harness component.

Fig 39: Installing Roll Pin Using Pin Punch
Courtesy of MAZDA MOTORS CORP.
Install the harness component.
Tightening torque

5.0-7.0 N.m {51-71 kgf.cm, 43-61 in.lbf}
NOTE:
- Do not move the manual valve in the direction of arrow to prevent the pin for the manual valve rotation prevention from falling from the control valve body.
Fig 40: Installing Harness Component
Courtesy of MAZDA MOTORS CORP.
Align the manual valve and the manual plate, and set the control valve body.

Fig 41: Identifying Manual Valve And Manual Plate
Courtesy of MAZDA MOTORS CORP.

Tighten the bolts evenly and gradually.

Bolt	Bolt length below the head (mm {in})
A	30 {1.181}
B	40 {1.575}

Tightening torque

6.9-8.8 N.m {71-89 kgf.cm, 62-77 in.lbf}

Fig 42: Tightening Control Valve Body Bolts

Courtesy of MAZDA MOTORS CORP.

Connect the connector.
NOTE:
- Do not reuse the oil pan installation bolts as they are coated.
Fig 43: Connecting Connector
Courtesy of MAZDA MOTORS CORP.
Install a new gasket and the oil pan with new bolts.
Tightening torque

7.0-9.0 N.m {72-91 kgf.cm, 63-78 in.lbf}
Install the actuator support.

Fig 44: Installing Actuator Support
Courtesy of MAZDA MOTORS CORP.
Install the parking pawl, shaft, spring, and the spacer.

Fig 45: Installing Parking Pawl, Shaft, Spring And Spacer
Courtesy of MAZDA MOTORS CORP.
Install new seal rings to the output shaft component.

Fig 46: Installing Seal Rings To Output Shaft
Courtesy of MAZDA MOTORS CORP.
Measure the clearance between the seal rings and seal ring grooves.
- If the clearance is not within the specification, replace the output shaft.
Specification

0.10-0.25 mm {0.0040-0.0098 in}
NOTE:
- Install the bearing to the transmission case with the black surface facing the rear side.
Fig 47: Measuring Clearance Between Seal Rings And Seal Ring Grooves
Courtesy of MAZDA MOTORS CORP.
Install the bearing and the output shaft component.

Fig 48: Installing Bearing And Output Shaft
Courtesy of MAZDA MOTORS CORP.
Apply ATF to a new oil seal.
NOTE:
- When installing the oil seal to the extension housing, tap the SSTs until the stopper on the oil seal circumference contacts the extension housing.
Install the oil seal to the extension housing using the SSTs .

Fig 49: Installing Oil Seal To Extension Housing Using SST
Courtesy of MAZDA MOTORS CORP.
Install the bearing to the extension housing.

Fig 50: Installing Bearing To Extension Housing
Courtesy of MAZDA MOTORS CORP.
Apply a light coat of sealant to the contact surfaces of the transmission case and the extension housing. (For the four locations indicated in the figure, apply sealant to the entire circumference of the bolt holes.)

Fig 51: Applying Of Sealant To Contact Surfaces Of Transmission Case
Courtesy of MAZDA MOTORS CORP.
Install the extension housing.
Tightening torque

50-55 N.m {5.1-5.6 kgf.m, 37-40 ft.lbf}

Fig 52: Tightening Extension Housing Bolts
Courtesy of MAZDA MOTORS CORP.
Install the TR switch, and hand-tighten the mounting bolts.
CAUTION:
- Improper adjustment of the TR switch will cause abnormal operation of the automatic transmission. Be sure to use the SST to adjust the TR switch correctly.
Fig 53: Installing TR Switch
Courtesy of MAZDA MOTORS CORP.
Using the SST and by turning the TR switch, adjust the positions of the manual shaft and the TR switch neutral hole.

Fig 54: Turning TR Switch Using SST

Courtesy of MAZDA MOTORS CORP.

Tighten the TR switch installation bolts.
Tightening torque

4.4-6.5 N.m {45-66 kgf.cm, 40-57 in.lbf}
Remove the SST .
Apply ATF to new O-rings and install them to the VSS and the turbine sensor.
Install the VSS and the turbine sensor.
Tightening torque

5.0-7.0 N.m {51-71 kgf.cm, 43-61 in.lbf}

Fig 55: Installing VSS And Turbine Sensor
Courtesy of MAZDA MOTORS CORP.
Pour ATF into the torque converter.
Shake the torque converter to clean the inside and pour out the solvent.
Pour ATF into the torque converter.
Install the torque converter.
To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing.
- If the distance is not within the specification, install the torque converter correctly.
Specification

50 mm {1.97 in} or more

Fig 56: Measuring Distance A Between End Of Torque Converter & Torque Converter Housing
Courtesy of MAZDA MOTORS CORP.