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Home › Mazda › 2006 › Tribute s, 4WD › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle - Overhaul › Forward/Coast/Direct Clutches › Assembly

Forward/Coast/Direct Clutches: Assembly

  1. Soak the internal spline clutch plates in clean automatic transaxle fluid.
    Fig 1: Installing Forward Clutch Piston Inner Seal On Forward/Coast/Direct Clutch Cylinder Assembly
    G04321331Courtesy of MAZDA MOTORS CORP.
  2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.
    Fig 2: Installing Forward Clutch Piston Outer Lip Seal
    G04321332Courtesy of MAZDA MOTORS CORP.
  3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
    Fig 3: Installing Forward Clutch Piston Assembly
    G04321333Courtesy of MAZDA MOTORS CORP.
  4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
    Fig 4: Identifying Mark Of Adjacent Legs On Cylinder
    G04321334Courtesy of MAZDA MOTORS CORP.
  5. Mark the center of two adjacent legs on the top of the cylinder.
    Fig 5: Finding Center Between Marks
    G04321335Courtesy of MAZDA MOTORS CORP.
  6. Find the center between the marks (45 degrees from either leg) and mark the cylinder.
    Fig 6: Installing Coast Clutch Piston Assembly Onto Special Tool
    G04321336Courtesy of MAZDA MOTORS CORP.
  7. Install the coast clutch piston assembly onto the special tool.
    Fig 7: Installing Coast Clutch Piston Into Forward Clutch Piston Assembly
    G04321337Courtesy of MAZDA MOTORS CORP.
  8. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.
    Fig 8: Installing Forward/Coast Clutch Return Spring Assembly
    G04321338Courtesy of MAZDA MOTORS CORP.
  9. Install the forward/coast clutch return spring assembly.
    Fig 9: Compressing Return Spring Using Special Tool
    G04321339Courtesy of MAZDA MOTORS CORP.
    WARNING:
    • Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these Instructions can result in personal injury.
  10. Install the forward/coast clutch return spring retaining ring.
    1. Using the special tool, compress the return spring.
    2. Install the forward/coast clutch retaining ring.
      • Orient the gap between the piston legs.
        Fig 10: Installing Forward And Coast Clutch Plates In Sequence
        G04321340Courtesy of MAZDA MOTORS CORP.
  11. Install the forward and coast clutch plates in the sequence shown.
    1. coast clutch external spline clutch plates (steel)
    2. coast clutch internal spline clutch plates (friction)
    3. coast clutch pressure plate
    4. forward clutch wave spring
    5. forward clutch internal spline clutch plates (friction)
    6. forward clutch external spline clutch plates (steel)
    7. forward clutch pressure plate
      Fig 11: Installing Forward Clutch Pressure Plate Retaining Ring
      G04321341Courtesy of MAZDA MOTORS CORP.
  12. Install the forward clutch pressure plate retaining ring.
    • Center the select fit retaining ring on the 45 degree mark between the two adjacent legs.
      Fig 12: Measuring Clearance Between Forward Clutch Pressure Plate And Forward Clutch Pressure Plate
      G04321342Courtesy of MAZDA MOTORS CORP.
  13. Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring.
    • Take a second measurement on the opposite side.
    • Average the two measurements to get the clearance.
    • If the clearance is not within specification, select and install the correct thickness retaining ring to obtain the standard clearance.
    • Retaining ring sizes:
      • 1.43-1.53 mm (0.056-0.060 in)
      • 1.59-1.69 mm (0.062-0.066 in)
      • 1.75-1.85 mm (0.069-0.073 in)
      • 1.92-2.02 mm (0.075-0.079 in)
        Fig 13: Installing Direct Clutch Piston Inner Lip Seal On Direct Clutch Cylinder Assembly
        G04321343Courtesy of MAZDA MOTORS CORP.
  14. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.
    Fig 14: Installing Direct Clutch Piston Outer Seal On Direct Clutch Piston Assembly
    G04321344Courtesy of MAZDA MOTORS CORP.
  15. Install the direct clutch piston outer seal on the direct clutch piston assembly.
    Fig 15: Installing Direct Clutch Piston Assembly
    G04321345Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Position the lip seal facing down.
  16. Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
    Fig 16: Installing Direct Clutch Return Spring Assembly
    G04321346Courtesy of MAZDA MOTORS CORP.
  17. Install the direct clutch return spring assembly.
    Fig 17: Compressing Direct Clutch Return Springs Using Special Tool
    G04321347Courtesy of MAZDA MOTORS CORP.
    WARNING:
    • Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
    CAUTION:
    • Do not compress the direct clutch return springs completely.
  18. Install the direct clutch return spring retaining ring.
    1. Using the special tool, compress the direct clutch return springs.
    2. Install the direct clutch return spring retaining ring.
      Fig 18: Installing Direct Clutch Plates
      G04321348Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • Quantity of plates are model dependent.
  19. Install the direct clutch plates.
    1. Install the direct clutch external spline (steel) clutch plates.
    2. Install the direct clutch internal spline (friction) clutch plates.
    3. Install the direct clutch pressure plate.
      Fig 19: Installing Direct Clutch Pressure Plate Retaining Ring
      G04321349Courtesy of MAZDA MOTORS CORP.
  20. Install the direct clutch pressure plate retaining ring.
    Fig 20: Measuring Direct Clutch Clearance
    G04321350Courtesy of MAZDA MOTORS CORP.
  21. Measure the direct clutch clearance as follows:
    • Install the special tool.
    • Zero the dial on the direct clutch pressure plate.
    • Pull the direct clutch pressure plate upward, and record the reading.
      Fig 21: Measuring Clearance Using Special Tool
      G04321351Courtesy of MAZDA MOTORS CORP.
  22. Make a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within the specification, select and install, using the special tool, the correct thickness direct clutch pressure plate retainer snap ring to obtain the standard clearance.
    • Retaining ring sizes:
      • 1.28-1.38 mm (0.050-0.054 in)
      • 1.39-1.49 mm (0.054-0.058 in)
      • 1.52-1.62 mm (0.059-0.063 in)
      • 1.65-1.75 mm (0.064-0.069 in)
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