Assembly Procedure

Reverse clutch drive plate thickness 

Standard: 1.60 mm {0.063 in} 

Minimum: 1.45 mm {0.057 in} 

3-4 clutch drive plate thickness 

Standard: 2.55 mm {0.100 in} 

Minimum: 2.40 mm {0.094 in} 

3-4 clutch driven plate thickness 

Standard: 2.55 mm {0.100 in} 

Minimum: 2.40 mm {0.094 in} 

• If not within the specification, replace the drive plates.

3-4 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.

Fig 1: Measuring Spring Free Length

Courtesy of MAZDA MOTORS CORP.

Air pressure 

392 kPa {4.0 kgf/cm ²  ,57 psi} max. 

Air pressure 

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

Rear sun gear bushing inner diameter 

Standard: 29.900-29.921 mm {1.17717-1.17799 in} 

Maximum: 29.941 mm {1.17878 in} 

• If not as specified, replace the rear sun gear plate.

Fig 4: Measuring Bushing Of Rear Sun Gear

Courtesy of MAZDA MOTORS CORP.

1. Apply ATF to the circumference of the reverse clutch piston seal, and install the piston into the 2-4 brake drum.
2. Install the piston return spring and reverse return stopper to the reverse piston.
   Fig 5: View Of Piston Return Spring, Reverse Return Stopper And Reverse Piston

   Courtesy of MAZDA MOTORS CORP.
3. Install the snap ring and the SSTs  to the 2-4 brake drum as shown.
   CAUTION:

   • Depress the piston return spring only enough to install the snap ring. Overpressing will damage the piston return spring assembly edges.
   Fig 6: Installing Snap Ring

   Courtesy of MAZDA MOTORS CORP.
4. Compress the piston return spring.
5. Install the snap ring.
6. Remove the SSTs. 
7. Install the dish plate.
8. Install the drive and driven plates in the following order.

   Driven-Drive-Driven-Drive

9. Install the retaining plate.

Fig 7: Measuring Reverse Clutch Clearance

Courtesy of MAZDA MOTORS CORP.

1. Install the reverse clutch into the end cover, and set the dial gauge.
2. Secure the reverse clutch by lightly pressing down with a press or similar tool.
   Fig 8: Securing Reverse Clutch

   Courtesy of MAZDA MOTORS CORP.
3. Apply compressed air to the part indicated in the figure and let the reverse clutch piston stroke three times.

   Air pressure 

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

4. Apply compressed air and operate the reverse clutch piston. Read the value when the indicator of the dial gauge stops.
   Fig 9: Identifying Reverse Clutch Fluid Passage

   Courtesy of MAZDA MOTORS CORP.
5. Release the compressed air and read the dial gauge when the reverse clutch piston is not operating.
6. Calculate the reverse clutch clearance according to the following formula:

   step (4) value - step (5) value = Reverse clutch clearance.

7. Measure the clearances at four locations (90° apart) by following the steps from (3) to (6). Verify that the average value is within the specification below.

   Reverse clutch clearance 

   Standard: 1.00-1.30 mm {0.039-0.051 in} 

   • If not within the specification, 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 10: Measuring Reverse Clutch Clearance

   Courtesy of MAZDA MOTORS CORP.

   Snap ring size for reverse clutch clearance 

   SNAP RING SIZE FOR REVERSE CLUTCH CLEARANCE SPECIFICATIONS
   
   

   Range mm {in}	Snap ring sizes mm {in}
   2.370-2.570 {0.094-0.101}	1.2 {0.047}
   2.570-2.770 {0.102-0.109}	1.4 {0.055}
   2.770-2.970 {0.110-0.116}	1.6 {0.063}
   2.970-3.170 {0.117-0.124}	1.8 {0.071}
   3.170-3.370 {0.125-0.132}	2.0 {0.079}
   3.370-3.570 {0.133-0.140}	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.

1. Install the 2-4 brake drum to the end cover.
2. Inspect the reverse clutch operation by applying compressed air as shown.

Air pressure 

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

Fig 11: Identifying Reverse Clutch Fluid Passage

Courtesy of MAZDA MOTORS CORP.

1. Apply ATF to the circumference of the 3-4 clutch piston seal, and install the piston in to the 3-4 clutch drum.
2. Install the spring and retainer.
3. Apply ATF to the 3-4 seal plate, and install it onto the 3-4 clutch drum.
   Fig 12: View Of 3-4 Clutch Drum

   Courtesy of MAZDA MOTORS CORP.
4. Install the SST  as shown.
   CAUTION:

   • Depress the 3-4 seal plate only enough to install the snap ring. Overpressing will damage the 3-4 seal plate assembly edges.
   Fig 13: Measuring Clearances Between Snap Ring And Retaining Plate

   Courtesy of MAZDA MOTORS CORP.
5. Compress the spring and retainer component and 3-4 seal plate.
6. Install the snap ring.
7. Remove the SST. 
8. Install the drive and driven plates in the following order.

   Driven-Drive-Driven-Drive-Driven-Drive

9. Install the retaining plate.

Fig 14: Measuring 3-4 Clutch Clearance

Courtesy of MAZDA MOTORS CORP.

1. Install the 3-4 clutch in the end cover, and set the dial gauge.
2. Secure the 3-4 clutch by lightly pressing down with a press or similar tool.
   Fig 15: Securing 3-4 Clutch

   Courtesy of MAZDA MOTORS CORP.
3. Apply compressed air to the part indicated in the figure and let the 3-4 clutch piston stroke three times.
   Fig 16: Identifying 3-4 Clutch Fluid Passage

   Courtesy of MAZDA MOTORS CORP.

   Air pressure 

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

4. Apply compressed air and operate the 3-4 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 3-4 clutch piston is not operating.
6. Calculate the 3-4 clutch clearance according to the following formula:

   step (4) value - step (5) value = 3-4 clutch clearance

7. Measure the clearances at four locations (90° apart) by following the steps from (3) to (6). Verify that the average value is within the specification below.

   3-4 clutch clearance 

   Standard: 1.10-1.40 mm {0.043-0.055 in} 

   Fig 17: Measuring Clutch Clearance

   Courtesy of MAZDA MOTORS CORP.
   • If not within the specification, 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.

   Snap ring size for 3-4 clutch clearance 

   SNAP RING SIZE SPECIFICATIONS
   
   

   Range mm {in}	Snap ring sizes mm {in}
   2.400-2.600 {0.095-0.102}	1.2 {0.047}
   2.600-2.800 {0.103-0.110}	1.4 {0.055}
   2.800-3.000 {0.111-0.118}	1.6 {0.063}
   3.000-3.200 {0.119-0.125}	1.8 {0.071}
   3.200-3.400 {0.126-0.133}	2.0 {0.079}
   3.400-3.600 {0.134-0.141}	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.

1. Install the 3-4 clutch drum to the end cover.
2. Inspect the 3-4 clutch operation by applying compressed air as shown.

Air pressure 

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