CONTENTS
Automatic
Title Section
Transaxle
General Information GI
Workshop
Mechanism and Operation K
Overhaul K1
Manual
Technical Data TD
Supplement
Special Tools ST
JA5AX-EL
© 2002 Mazda Motor Corporation
PRINTED IN THE NETHERLANDS, AUGUST 2002
1765 1E 02H
FOREWORD
This manual explains the changes and/or
additions relating to the disassembly,
inspection, repair, and reassembly
procedures for the above-indicated
automatic transaxle.
In order to do these procedures safety,
quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.
The information in this manual is current
up to August, 2002. Any changes that occur
after that time will not be reflected in this
particular manual. Therefore, the contents
of this manual may not exactly match
the mechanism that you are currently
serving.
Mazda Motor Corporation
HIROSHIMA, JAPAN
Note:
There is no description of the transfer in this
manual as the transfer cannot be
disassembled.
RELATED MATERIALS
Automatic Transaxle Workshop Manual JA5A EL . . . 1738 1* 02D
* : Indicates the printing location
E: Europe
0: Japan
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least to know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks
not normally encountered in a general technician's experience.
They should be followed to reduce the risk of injury and the risk that
improper service or repair may damage the vehicle or render it unsafe.
It is also important to understand that the "Warnings" and "Cautions"
are not exhaustive. It is impossible to warn of all the hazardous
consequences that might result from failure to follow the procedures.
The procedures recommended and described in this manual are
effective methods of performing service and repair. Some require tools
specifically designed for a specific purpose. Persons using procedures
and tools which are not recommended by Mazda Motor Corporation
must satisfy themselves thoroughly that neither personal safety nor
safety of the vehicle will be jeopardized.
The contents of this manual, including drawings and specifications, are
the latest available at the time of printing, and Mazda Motor Corporation
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.
Parts should be replaced with genuine Mazda replacement parts or
with parts which match the quality of genuine Mazda replacement
parts. Persons using replacement parts of lesser quality than that of
genuine Mazda replacement parts must satisfy themselves thoroughly
that neither personal safety nor safety of the vehicle will be
jeopardized.
Mazda Motor Corporation is not responsible for any problems which
may arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Mazda replacement parts, or not being aware of any revision
of this manual.
GIGENERAL INFORMATION
GI
HOW TO USE THIS MANUAL ............................. GI-2
RANGE OF TOPICS .......................................... GI-2
ABBREVIATIONS ................................................ GI-2
ABBREVIATIONS TABLE.................................. GI-2
GI 1
HOW TO USE THIS MANUAL, ABBREVIATIONS
HOW TO USE THIS MANUAL
RANGE OF TOPICS
A6E201000001305
" This manual indicates only changes/additions, as it is the supplemental for the related materials. Therefore it
may not contain the necessary reference service procedures to perform the services indicated in this manual.
End Of Sie
ABBREVIATIONS
ABBREVIATIONS TABLE
A6E203000011301
ATF Automatic transaxle fluid
SST Special service tool
End Of Sie
GI 2
KMECHANISM AND OPERATION
K
FEATURES
AUTOMATIC TRANSAXLE....................................K-2
AUTOMATIC TRANSAXLE OUTLINE .................K-2
AUTOMATIC TRANSAXLE SPECIFICATIONS...K-2
K 1
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE OUTLINE
A6E561401030301
" Adopted new JA5AX-EL automatic transaxle.
" The construction and operation of the JA5AX-EL type automatic transaxle is essentially carried over from that
of the current JA5A-EL type automatic transaxle. (See Automatic Transaxle Workshop Manual JA5A-EL 1738-
1*-02D.)
End Of Sie
AUTOMATIC TRANSAXLE SPECIFICATIONS
A6E561401030302
Transaxle type
Item
JA5AX-EL
1GR 3.801
2GR 2.131
3GR 1.364
Gear ratio
4GR 0.935
5GR (O/D) 0.685
Reverse 2.970
Final gear ratio 3.290
Type ATF M-III or equivalent (e.g. Dexron III)
ATF
Capacity (Approximate quantity)
8.3 {8.8, 7.3}
(L {US qt, Imp qt})
Torque converter stall torque ratio 1.86:1
Low clutch 6/6
2-4 brake 3/4
High clutch 5/5
Hydraulic system (Number of
drive/driven plates)
Direct clutch 3/5
Reverse clutch 2/2
Low and reverse brake 6/5
Reduction accumulator piston outer
49.66/57.64
Band servo (mm {in}) dia./reduction band servo piston outer
{1.955/2.269}
dia.
Ring gear 74
Number of front planetary gear
Sun gear 34
teeth
Pinion gear 20
Ring gear 75
Number of rear planetary gear
Sun gear 42
teeth
Pinion gear 17
Ring gear 85
Number of reduction planetary
Sun gear 31
gear teeth
Pinion gear 27
Number of output gear teeth 41
Number of idler gear teeth 47
Number of reduction gear teeth 22
Number of ring gear teeth 67
End Of Sie
K 2
K1OVERHAUL
K1
SERVICE
OUTLINE .............................................................. K1-2
SUPPLEMENTAL SERVICE INFORMATION ...K1-2
AUTOMATIC TRANSAXLE..................................K1-2
DIRECT CLUTCH DISASSEMBLY.................... K1-2
DIRECT CLUTCH ASSEMBLY.......................... K1-3
K1 1
OUTLINE, AUTOMATIC TRANSAXLE
OUTLINE
SUPPLEMENTAL SERVICE INFORMATION
A6E570201034301
" The following changes have been made since publication of the Automatic Transaxle Workshop Manual JA5A-
EL (1738-1*-02D.).
DIRECT CLUTCH DISASSEMBLY
" Number of drive/driven plates have been modified.
DIRECT CLUTCH ASSEMBLY
" Assembly procedure has been modified.
End Of Sie
AUTOMATIC TRANSAXLE
DIRECT CLUTCH DISASSEMBLY
A6E571419500310
1. Disassemble in the order indicated in the table.
SST
9
10
R
ATF
TF
R 11
ATF
TF
12
ATF
TF
13
14
15
4
3
2
1
ATF
TF
7
5
6
ATF
TF
8
A6E5614A902
.
1 Snap ring 9 Snap ring
(See K1 3 Snap Ring Disassembly Note)
2 Retainer
10 Spring retainer
3 One-way clutch
11 Return spring
4 Needle bearing
12 Direct piston
5 Snap ring
(See K1 3 Direct Piston Disassembly Note)
6 Retaining plate
13 O-ring
7 Drive plate
14 O-ring
8 Driven plate
15 Direct clutch drum
K1 2
AUTOMATIC TRANSAXLE
Snap Ring Disassembly Note
Caution
" Depress the spring retainer only enough to remove the snap ring. Overpressing will damage the
"
"
"
retainer component edges.
1. Install the SSTs in the clutch drum as shown.
2. Remove the snap ring. K1
49 G019 029
3. Remove the SSTs.
4. Remove the spring retainer.
49 JE01 032
5. Remove the return spring.
307-209
49 L019 001
49 G019 027
AMU0517A980
Direct Piston Disassembly Note
1. Assemble the clutch drum to the transaxle case.
Warning
" Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
"
"
"
Wear protective eye wear whenever using compressed air.
Caution
" Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will
"
"
"
damage the seal. Do not apply compressed air for more than the aforementioned time when
testing the system.
Note
" Regarding the position of the hole into which air is blown, refer to item Oil pressure circuit in this manual.
2. Remove the direct piston by applying
compressed air through the fluid passage.
3. Remove the O-ring from piston.
AMU0517A079
End Of Sie
DIRECT CLUTCH ASSEMBLY
A6E571419500312
Assembly Procedure
1. Apply a coat of ATF to new O-rings, then install
O-RING
them to the piston.
2. Apply a coat of ATF to inside of the clutch drum,
then install the piston while rotating it by hand.
Note
" After installing the drum, ensure that the
piston rotates smoothly by hand.
If not, the O-ring may be caught.
3. Install the return spring.
4. Position the spring retainer.
A6E56143002
Caution
" Depress the spring retainer only enough to remove the snap ring. Overpressing will damage the
"
"
"
retainer component edges.
K1 3
AUTOMATIC TRANSAXLE
5. Install the SSTs in the clutch drum as shown.
6. Install the snap ring.
49 G019 029
7. Remove the SSTs.
49 JE01 032
307-209
49 L019 001
49 G019 027
AMU0517A980
8. Install the drive plates and driven plates in the
order as shown in the figure.
9. Install the retaining plate. DRIVEN PLATE
10. Install the snap ring.
SNAP RING
RETAINING PLATE
DRIVE PLATE
A6EJ5714A901
11. Place the direct clutch upside down, then install
the one-way clutch and retainer.
SNAP RING
ONE-WAY CLUTCH
12. Install the snap ring.
RETAINER
A6E56143001
End Of Sie
K1 4
TDTECHNICAL DATA
TECHNICAL DATA ............................................. TD-2
AUTOMATIC TRANSAXLE............................... TD-2
TD
TD 1
TECHNICAL DATA
TECHNICAL DATA
AUTOMATIC TRANSAXLE
A6E931001030301
Item Transaxle type
JA5AX-EL
Oil pump Outer rotor and oil pump Standard
0.02 0.04 {0.0008 0.0015}
clearance(mm {in})
Inner rotor and oil pump Standard
0.02 0.05 {0.0008 0.0019}
clearance(mm {in})
Outer and inner rotor Standard
0.02 0.15 {0.0008 0.0059}
clearance(mm {in})
Reverse clutch Number of drive/driven plates 2/2
Drive plate thickness Minimum
1.7 {0.067}
(mm {in})
Clutch clearance (mm {in}) 0.5 0.8 {0.020 0.031}
Retaining plate size(mm {in}) 3.6 {0.142}, 3.8 {0.150}, 4.0 {0.157}, 4.2 {0.165}
Snap ring size(mm {in}) 2.0 {0.079}
High clutch Number of drive/driven plates 5/5
Drive plate thickness Minimum
1.7 {0.067}
(mm {in})
Clutch clearance (mm {in}) 0.8 1.1 {0.031 0.043}
Retaining plate size(mm {in}) 3.0 {0.118}, 3.2 {0.126}, 3.4 {0.134}, 3.6 {0.142}
Snap ring size(mm {in}) 2.0 {0.079}
Low clutch Number of drive/driven plates 6/6
Drive plate thickness Minimum
1.7 {0.067}
(mm {in})
Clutch clearance (mm {in}) 1.1 1.3 {0.044 0.051}
Retaining plate size(mm {in}) 3.8 {0.150}, 3.9 {0.154}, 4.0 {0.157}, 4.1 {0.161}, 4.2 {0.165}
4.3 {0.169}, 4.4 {0.173}, 4.5 {0.177}, 4.6 {0.181}
Snap ring size(mm {in}) 1.6 {0.063}
Direct clutch Number of drive/driven plates 3/5
Drive plate thickness Minimum
1.7 {0.067}
(mm {in})
Clutch clearance (mm {in}) 1.8 2.2 {0.07 0.09}
Retaining plate size(mm {in}) 4.0 {0.157}, 4.2 {0.165}, 4.4 {0.173}, 4.6 {0.181}, 4.8{0.189},
5.0 {0.197}
Snap ring size(mm {in}) 2.0 {0.079}
Low and reverse Number of drive/driven plates 6/5
brake
Drive plate thickness Minimum
1.7 {0.067}
(mm {in})
Clutch clearance (mm {in}) 0.8 1.1 {0.031 0.043}
Retaining plate size(mm {in}) 2.2 {0.087}, 2.4 {0.094}, 2.6 {0.102}, 2.8 {0.110}, 3.0 {0.118}
Snap ring size(mm {in}) 2.1 {0.083}, 2.2 {0.087}, 2.3 {0.091}
2-4 brake Number of drive/driven plates 3/4
Drive plate thickness Minimum
1.7 {0.067}
(mm {in})
Clutch clearance (mm {in}) 0.6 0.9 {0.02 0.04}
Retaining plate size(mm {in}) 3.0 {0.118}, 3.2 {0.126}, 3.4 {0.134}, 3.6 {0.142}, 3.8 {0.150},
4.0 {0.157}, 4.2 {0.165}
Snap ring size(mm {in}) 2.0 {0.079}
Total end play(mm {in}) 0.25 0.55 {0.01 0.02}
End play adjust race(mm {in}) 1.4 {0.055}, 1.6 {0.063}, 1.8 {0.071}, 2.0 {0.079}, 2.2{0.087}
Output gear bearing preload (N·m {kgf·cm, in·lbf}) 0.63 1.30 {6.4 13.3, 5.6 11.5}
Reduction gear bearing preload (N·m {kgf·cm, in·lbf}) 0.60 1.75 {6.1 17.8, 5.3 15.5}
TD 2
TECHNICAL DATA
Spring Item
Outer Free length No. of coils Wire Wire thickness
diameter (mm {in}) diameter x wire width
(mm {in}) (mm {in}) (mm {in})
2-4 brake accumulator 27.0 {1.06} 73.8 {2.91} 6.8 2.6 {0.10}
Large 27.0 {1.06} 54.6 {2.15} 5.2 2.5 {0.10}
Direct clutch accumulator
Small 20.0 {0.79} 54.5 {2.15} 7.5 1.9 {0.07}
1.1 x 6.0
Low clutch 108.8 {4.28} 24.4 {0.96} 9
{0.043 x 0.236}
TD
1.1 x 5.5
High clutch and reverse clutch 73.0 {2.87} 27.0 {1.06} 14
{0.043 x 0.217}
2-4 brake (Spring and retainer component) 8.0 {0.31} 21.4 {0.84} 6.6 1.0 {0.039}
1.3 x 5.2
Low and reverse brake 178.9 {7.04} 20.3 {0.79} 4
{0.05 x 0.20}
1.3 x 4.5
Direct clutch 66.9 {2.63} 33.2 {1.30} 9
{0.05 x 0.17}
End Of Sie
TD 3
STSPECIAL TOOLS
SPECIAL TOOLS .................................................ST-2
AUTOMATIC TRANSAXLE................................ST-2
ST
ST 1
SPECIAL TOOLS
SPECIAL TOOLS
AUTOMATIC TRANSAXLE
A6E941001024301
1: Mazda SST number
2: Global SST number
Example
1:49 UN30 3009
2:303-009
Crankshaft
damper
remover
1:49 JE01 032 1:49 G019 027 1:49 G019 029
2:307-209 2: 2:
Compressor Attachment A Nut
1:49 L019 001
2:
Bolt
End Of Sie
ST 2
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