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HOMESERVICE MANUALSMAZDA1991PROTEGE 4WD, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (OVERHAUL - F4A-EL & FA4A-EL)TRANSAXLE REASSEMBLYFINAL ASSEMBLY
1991 Mazda Protege 4WD, Automatic

Final Assembly

1991 Mazda Protege 4WD, AutomaticSECTION Final Assembly
WARNING: This page is about a different variant/trim than selected.
NOTE: Ensure all bearing preloads are set and appropriate shims are installed. See ADJUSTMENTS  .
  1. Install parking pawl. Assemble parking assist lever and actuator support, manual shaft and manual plate. See Figure . install detent ball, spring washer and plug. Manually check that parking pawl operates.
  2. Install output shell to output gear. Ensure thrust bearing is installed on output shell. Apply a thin coat of sealant to contact surfaces of converter housing and transmission case. Install oil passage "O" rings in converter housing. Install transaxle case to converter housing. Install bolts and tighten to specifications. See the TORQUE SPECIFICATIONS  table.
  3. Install holding support to hold turbine shaft. Place turbine shaft through 3-4 clutch assembly. Install thrust bearings on both sides of 3-4 clutch assembly and install 3-4 clutch assembly with turbine shaft into transaxle case. Install internal gear to 3-4 clutch drum and install snap ring. See Figure .
  4. Install bearing race in carrier hub and hold turbine shaft to prevent it from turning while installing carrier hub assembly with a rotating motion into 3-4 clutch drum.
  5. Install low-reverse drive and driven plates, retaining plate and snap ring. Measure clearance with a feeler gauge between retaining plate and snap ring. Clearance should be .083-.094" (2.10-2.40 mm). Adjust clearance by installing appropriate retaining plate or snap ring.
  6. Snap rings are available in sizes of .079-.118" (2.00-3.00 mm) in .008" (.20 mm) increments. Measure clearance with a feeler gauge between retaining plate and snap ring. Check low-reverse brake operation by applying air pressure to low-reverse oil passage. See Figure .
  7. Hold one-way clutch horizontally while installing. Rotate carrier hub assembly counterclockwise and install snap ring. Install servo spring, servo assembly and snap ring. Install anchor strut with groove upward. Install 2-4 brake band in transaxle case, interlocking brake band into anchor strut.
  8. Install bearing race on carrier hub and thrust bearing on small sun gear and one-way clutch. Install small sun gear and one-way clutch with rotating motion.
  9. Install forward, coasting and reverse clutch assembly. Ensure thrust bearings are on both sides of clutch assembly. Measure the height of reverse, coasting and forward drum above transaxle case. Height should be .035" (.90 mm). Install snap ring on turbine shaft bottom groove.
  10. Remove bearing race and gasket from oil pump (if installed). Select a .087" (2.20 mm) bearing race and place on oil pump. Install oil pump on transaxle case. Measure with a feeler gauge between oil pump and transaxle case. Use clearance measured to select bearing race. See the BEARING RACE SELECTION  table.
    BEARING RACE SELECTION

    Clearance Measured In. (mm) 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)
  11. Remove oil pump. Install selected bearing race and new gasket onto oil pump. Install oil pump onto reverse and forward drum. Install oil pipe. Tighten oil pump bolts to 14-19 ft. lbs. (19-26 N.m), in sequence. See Figure .
  12. Install throttle cable with new bracket "O" ring. Install valve body solenoid connector to transaxle case. Ensure manual valve is aligned with pin and install control valve body assembly into transaxle case. Tighten control valve body bolts to 70-95 INCH lbs. (7.9-10.7 N.m).
  13. Install oil filter and "O" ring to transaxle case. Install oil pan and new gasket. Tighten oil pan bolts to 74-95 INCH lbs. (8.4-10.7 N.m). Install remainder of electrical switches and sensors. Install control valve body cover with a new gasket. Tighten cover bolts to 74-95 INCH lbs. (8.4-10.7 N.m).
  14. Install dipstick tube with new "O" ring. Install oil pump shaft. Fill torque converter with ATF. Install new "O" ring on stator shaft and install torque converter. Measure distance from converter housing to torque converter. See the TORQUE CONVERTER SPECIFICATIONS  table.
TORQUE CONVERTER SPECIFICATIONS

Application Distance In. (mm)
FA4A-EL .54 (13.6)
F4A-EL .54 (13.6)
RENDER: 1.0x

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  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.