Assembly Note
Assembly Note1. Thoroughly clean all parts in solvent and blow dry with moisture free compressed air.
2. Clean and lubricate the outer surface with clean transmission fluid.
Caution: If there is evidence of clutch plate burning, replace the forward clutch cushion.
Note: This step only needs to be carried out if the bearing was removed.
3. Install the forward clutch bearing with the rectangular hole facing up.
Note:
^ This step only needs to be carried out if the bearing was removed.
^ The rectangular hole in the inside of the forward clutch bearing must face up (away from the forward clutch drum).
4. Using Mazda Driver Handle SST 49 F027 003, install the forward clutch bearing.
Note: This step only needs to be carried out if the bearing was removed.
5. Inspect that the bearing is properly seated on the drum. Inspect the top portion of the drum to ensure that it was not damaged, and check that the bearing rotates freely.
Note: This step only needs to be carried out if the bearing was removed.
6. Install new forward clutch piston seals.
1) Install the forward clutch piston inner seal.
2) Install the forward clutch piston outer seal.
3) Install the forward clutch piston spring.
7. Install lip seal protector tools on the forward clutch piston.
1) Install Lip Seal Protector SST 49 UN01 018 to the forward clutch piston outer seal.
2) Install Lip Seal Protector SST 49 UN01 072 to the forward clutch piston inner seal.
Note: Lubricate the forward clutch piston inner and outer seal with clean ATF
Caution: Care must betaken to prevent damage to the seals.
8. Install the forward clutch piston into the forward clutch cylinder. Remove Lip Seal Protector SSTs 49 UN01 01 Band 49 UN01 072.
9. Install the 15 forward clutch piston springs and the forward clutch piston spring retainer.
1) Install the 15 forward clutch piston springs.
2) Install the forward clutch piston spring retainer.
Caution: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
10. Use Clutch Spring Compressor SST 49 G019 025 to install the forward clutch piston spring snap ring.
1) Install Clutch Spring Compressor SST 49 G01 9 025 and compress the forward clutch springs.
2) Install the forward clutch piston spring snap ring.
Caution:
^ The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise (I.D. to O.D.) and the word "TOP". facing up.
^ If new plates are used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.
11. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed counterclockwise. Install the forward clutch disc pack.
12. Install the five (4R44E) or six (5R55E) steel clutch plates and five (4R44E) or six (5R55E) friction clutch plates in alternating order starting with a steel clutch plate.
Caution: The snap ring is a select fit.
13. Install the forward clutch pressure plate and the original selective snap ring.
1) Install the forward clutch pressure plate.
2) Install the forward clutch snap ring.
Warning: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the drum is facing down as shown.
14. Air check the forward clutch piston.
1) Place the forward clutch cylinder with forward clutch piston facing down.
2) Install the transmission center support on the forward clutch cylinder.
3) Apply air pressure to the left port of the center support.
15. Check forward clutch disc pack free play.
1) Press down on forward clutch disc pack.
2) Using a feeler gauge, check the gap between the forward clutch snap ring and the forward clutch pressure plate.
3) If the clearance is not within specifications, install the correct size snap ring.
