Attachment II

REPAIR PROCEDURE



Preparation

1. Check the EC-AT serial number and model type (turbo or non-turbo).

Subject EC-AT Serial Number Range: 035241 - 040898 This number is located on the ID tag as shown below.
Return the vehicle to the owner if it is out of the EC-AT serial number range as listed above. If the owner complains of trouble on an EC-AT which falls out of the subject serial number range, repair it on a normal warranty claim basis.

2. If the vehicle EC-AT serial number is within the range, ask the owner if there are any abnormal driving operations on the EC-AT.

If the owner complains about EC-AT trouble such as less power, late shift, no shift or erratic shift, test drive the car. If abnormal operation of EC-AT is found, except for normal harshness while up-and-down-shifting, replace the EC-AT assembly. If abnormal operation of EC-AT assembly is not found or the owner does not complain, replace the forward and reverse clutch assembly by using the forward and reverse clutch repair kit.


Part Order & Repair

A. Replacement of EC-AT Assembly

In case that EC-AT assembly replacement is necessary, take the following procedures.

A-1 Place your order for one applicable EC-AT assembly to the Quality Assurance Department of the nearest Mazda Regional Office. A-2 Ask the owner to leave his/her 626/MX-6 at the dealer until the replacement of EC-AT is completed, and taking the delivery date of new, EC-AT assembly into consideration, make a follow-up appointment with the owner.

NOTE:
If the owner demands a temporary vehicle, prepare a loaner car/rental car for the owner for a period not exceeding three working days.



A-3 After receiving a new EC-AT assembly, replace the damaged EC-AT with a new one by referring to the Workshop Manual.

NOTE:
Before installing the EC-AT assembly onto the vehicle. flush the cooling circuit line with compressed air as shown below.
A-4 Return the damaged EC-AT assembly to the Warranty Department of your Importer.


B. Replacement of Forward & Reverse Clutch Assembly

In case that only forward and reverse clutch assembly replacement is necessary, take the following procedures.

B-1 If the subject vehicle is 1988 626/MX-6 non-turbo model and you stock a pre-shipped forward and reverse clutch repair kit (8AG2 19 500), replace the forward and reverse clutch assembly with a kit according to the repair procedures described in page II-3.

B-2 If you don't stock any forward and reverse clutch repair kit, place your VOR order for an applicable forward and reverse clutch repair kit with your nearest Mazda Parts Warehouse.

B-3 Taking the delivery date of a forward and reverse clutch repair kit into consideration, make a follow-up appointment with the owner and return his/her 626/MX-6 to him/her.

B4 After receiving a forward and reverse clutch repair kit, replace the forward and reverse clutch assembly with a kit according to the repair procedures described in page 11-3. NOTE:

At the time of the owner's 2nd visit to the dealer in conjunction with this special service program, if the owner demands a temporary vehicle, prepare a loaner car/rental car for the owner for a period not exceeding one full working day.



Repair Procedures (Forward & Reverse Clutch Assembly Replacement)

1 Place vehicle on lift with transmission selector in Neutral position and disconnect the negative battery cable.

2. Remove air flow meter.



3. For non-turbo:
Disconnect the ignition coil and remove the resonance chamber and air hose.

For turbo:
Remove the intercooler pipe and hose, intercooler to throttle body and air cleaner to turbocharger.



4. Install engine support 49G0 17 5A0. CAUTION:
Make sure the engine support suspends the engine and transaxle securely.



5. Disconnect clips that secure the engine harness at the location shown. Remove the nut securing the bracket, then remove the 3 nuts to the engine mount No. 4 bracket.

6. Raise the vehicle on a hoist. Remove the left front wheel and splash shield.



7. Remove the drain plug and drain the ATF.

NOTE: Do not reuse the drain plug washer.



8. Loosen 2 nuts at the end of the left side sub frame. (DO NOT REMOVE).



9. Remove 4 bolts and 1 nut at the front of the left side subframe.



10. Remove through bolt from No. 2 engine mount.

11. Remove No. 2 engine mount bolt and nut.

12. Lower the engine and by turning the screw on the engine support tool.

NOTE:
Be careful to insure that nothing interferes with the downward travel of the engine/transaxle assembly.



13. Remove oil line to oil pump. Remove 10 bolts to the oil pump and remove the oil pump.




14. Remove the snap ring from the turbine shaft and carefully remove the reverse and forward clutch assembly.

NOTE:
Check that small sun gear/one-way clutch assembly and 24 brake band are still in place.

15. Apply petroleum jelly to the thrust bearing and install the bearing to the new clutch assembly.



CAUTION:
After removal of reverse/forward clutch assembly, be sure to remove thrust bearings and reinstall them with petroleum jelly into the new clutch assembly.

Thrust bearing outer diameter oil pump side:
86.0 mm (3.39 in.). Thrust bearing outer diameter small sun gear and one-way clutch side: 56.1 mm (2.21 in.)



16. Install the new forward and reverse clutch assembly. Rotate the clutch assembly until it is fully seated in the transaxle.

NOTE: The adjustment of the total end play is not necessary, since the end play will not be changed when the forward and reverse clutch assembly is replaced.



17. Pull the turbine shaft fully toward you and install the new snap ring to the groove of the turbine shaft.

CAUTION:
Make sure that the bearing race is correctly installed into the oil pump.



18. Place a new gasket and install the oil pump onto the clutch assembly.

Tightening Torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft.lbs.)

NOTE:
Make sure that there is no clearance between the transaxle case and oil pump.
19. Reinstall the engine and transaxle in the reverse order of disassembly.


20. Add ATF and check the fluid level according to the Workshop Manual.

21. Conduct a road test according to the Workshop Manual.

22. Check that there is no leakage from the transaxle.



23. Mark a white dot on the valve body cover upper end to indicate the repair has been completed.