LEMON Manuals: Even more car manuals for everyone
Home >> Mazda >> 2006 >> 6 s, 4D Wagon, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 32 (Automatic Transaxle - Overhaul (FS5A-El)) >> Forward Clutch Piston Disassembly Note >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Measure the facing thickness in three places, and calculate the average value.

    Forward clutch drive plate thickness 

    Standard: 1.60 mm {0.063 in} 

    Minimum: 1.45 mm {0.057 in} 

    • If not within the specification, replace the drive plates.
  2. Measure the spring free length.

    Forward clutch springs and retainer component free length 

    Standard: 17.2 mm {0.677 in} 

    Minimum: 15.2 mm {0.598 in} 

    • If not within the specification, replace the spring and retainer component.
    Fig 1: Measuring Spring Free Length
    G05118680Courtesy of MAZDA MOTORS CORP.
  3. Verify that there is airflow when applying compressed air through the fluid passage.

    Air pressure 

    392 kPa {4.0 kgf/cm 2  , 57 psi} max. 

  4. Replace the forward clutch drum and turbine shaft if damaged or malfunctioning.
    CAUTION:
    • Installing the forward clutch piston may damage its seal. Carefully install the forward clutch piston by pushing evenly around the circumference.
    Fig 2: Applying Compressed Air Through Fluid Passage
    G05118681Courtesy of MAZDA MOTORS CORP.
  5. Apply ATF to the circumference of the forward clutch piston seal, and install the piston into the forward clutch drum and turbine shaft.
  6. Install the spring and retainer component.
    Fig 3: View Of Forward Clutch Piston & Drum
    G05118682Courtesy of MAZDA MOTORS CORP.
  7. Apply ATF to the seal plate, and install it onto the forward clutch drum.
    Fig 4: Applying ATF To Seal Plate
    G05118683Courtesy of MAZDA MOTORS CORP.
  8. Install the SST  to the forward clutch drum and turbine shaft as shown.
    CAUTION:
    • Depress the seal plate only enough to remove the snap ring. Overpressing will damage the seal plate assembly edges.
  9. Compress the seal plate.
  10. Install the snap ring.
  11. Remove the SST  .
    Fig 5: Removing Seal Plate And Spring And Retainer Component
    G05118684Courtesy of MAZDA MOTORS CORP.
  12. Install the drive and driven plates in the following order.

    Driven-Drive-Driven-Drive-Driven-Drive- Driven-Drive

  13. Install the retaining plate.
  14. Install the snap ring.
    Fig 6: Measuring Forward Clutch Clearance
    G05118685Courtesy of MAZDA MOTORS CORP.
  15. Measure the forward clutch clearance.
    1. Install the forward clutch in the oil pump, and set the dial gauge.
    2. Secure the forward clutch by lightly pressing down with a press or similar tool.
      Fig 7: Securing Forward Clutch
      G05118686Courtesy of MAZDA MOTORS CORP.
    3. Apply compressed air to the part indicated in the figure and let the forward clutch piston stroke three times.

      Air pressure 

      392-441 kPa {4.0-4.5 kgf/cm 2  , 57-63 psi} 

      Fig 8: Identifying Forward Clutch Fluid Passage
      G05118687Courtesy of MAZDA MOTORS CORP.
    4. Apply compressed air and operate the forward clutch piston. Read the value when the indicator of the dial gauge stops.
    5. Release the compressed air and read the dial gauge when the forward clutch piston is not operating.
    6. Calculate the forward clutch clearance according to the following formula:

      Step (4) value-Step (5) value= Forward clutch clearance.

    7. Measure the clearances at four locations (90° apart) by following the steps (3) to (6).

      Verify that the average value is within the specification below:

      Forward clutch clearance 

      Standard: 1.50-1.80 mm {0.059-0.070 in} 

      • If not as specified, remove the snap ring and measure its thickness.
    8. Add the thickness to the average value calculated in step (7), and select the snap ring whose range includes the value.
      Fig 9: Measuring Forward Clutch Clearance
      G05118688Courtesy of MAZDA MOTORS CORP.

      Snap ring size for forward clutch clearance 

      SNAP RING SIZE FOR FORWARD CLUTCH CLEARANCE SPECIFICATIONS

      Range mm {in} Snap ring sizes mm {in}
      2.810-3.010 {0.111-0.118} 1.2 {0.047}
      3.010-3.210 {0.119-0.126} 1.4 {0.055}
      3.210-3.410 {0.127-0.134} 1.6 {0.063}
      3.410-3.610 {0.135-0.142} 1.8 {0.071}
      3.610-3.810 {0.143-0.150} 2.0 {0.079}
      3.810-4.010 {0.150-0.157} 2.2 {0.087}
    9. Install the selected snap ring and perform steps (2) to (7) again. Verify that the calculated value satisfies the clearance specification.
  16. Inspect the forward clutch operation.
    1. Install the forward clutch drum and turbine shaft to the oil pump.
    2. Inspect the forward clutch operation by applying compressed air as shown.

    Air pressure 

    392-441 kPa {4.0-4.5 kgf/cm 2  , 57-63 psi} 

    Fig 10: Identifying Forward Clutch Fluid Passage
    G05118689Courtesy of MAZDA MOTORS CORP.
  17. Install the forward clutch hub.
scientia non olet · About LEMON Manuals