Assembly Note

Soak the internal spline clutch plates in clean MERCON(R) Automatic Transaxle Fluid (ATF) for 30 minutes before assembly.
Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.

Fig 1: Installing Forward Clutch Piston Inner Seal On Forward/Coast/Direct Clutch Cylinder Assembly
Courtesy of MAZDA MOTORS CORP.
Install the forward clutch piston outer lip seal on the forward clutch piston assembly.

Fig 2: Installing Forward Clutch Piston Outer Lip Seal On Forward Clutch Piston Assembly
Courtesy of MAZDA MOTORS CORP.
Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.

Fig 3: Installing Forward Clutch Piston Assembly In Forward/Coast/Direct Clutch Cylinder Assembly
Courtesy of MAZDA MOTORS CORP.
Install the coast clutch piston assembly onto the special tool.

Fig 4: Installing Coast Clutch Piston Assembly Onto Special Tool
Courtesy of MAZDA MOTORS CORP.
Using the special tool, install the coast clutch piston into the forward clutch piston assembly.

Fig 5: Installing Coast Clutch Piston Into Forward Clutch Piston Assembly
Courtesy of MAZDA MOTORS CORP.
Install the forward/coast clutch return spring assembly.

Fig 6: Installing Forward/Coast Clutch Return Spring Assembly
Courtesy of MAZDA MOTORS CORP.
WARNING:
- Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
Install the forward/coast clutch return spring retaining ring.
1. Using the special tool, compress the return spring.
2. Install the forward/coast clutch retaining ring.
Fig 7: Installing Forward/Coast Clutch Return Spring Retaining Ring
Courtesy of MAZDA MOTORS CORP.
Install the forward and coast clutch plates in the sequence shown.
1. Coast clutch external spline clutch plates (steel).
2. Coast clutch internal spline clutch plates (friction).
3. Coast clutch pressure plate.
4. Forward clutch wave spring.
5. Forward clutch internal spline clutch plates (friction).
6. Forward clutch external spline clutch plates (steel).
7. Forward clutch pressure plate.
Fig 8: Installation Sequence Of Forward & Coast Clutch Plates
Courtesy of MAZDA MOTORS CORP.
Install the forward clutch pressure plate retaining ring.

Fig 9: Installing Forward Clutch Pressure Plate Retaining Ring
Courtesy of MAZDA MOTORS CORP.
Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring.
1. Take a second measurement on the opposite side.
2. Average the two measurements to get the clearance.
3. If the clearance is not within specification, select and install the proper thickness retaining ring to obtain the standard clearance.
4. Retaining ring sizes:
  1. 1.43-1.53 mm (0.056-0.060 in)
  2. 1.59-1.69 mm (0.062-0.066 in)
  3. 1.75-1.85 mm (0.069-0.073 in)
  4. 1.92-2.02 mm (0.75-0.079 in)
  Fig 10: Measuring Clearance Between Forward Clutch Pressure Plate & Forward Clutch Pressure Plate Retaining Ring
  Courtesy of MAZDA MOTORS CORP.
Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.

Fig 11: Installing Direct Clutch Piston Inner Lip Seal On Direct Clutch Cylinder Assembly
Courtesy of MAZDA MOTORS CORP.
Install the direct clutch piston outer seal on the direct clutch piston assembly.

Fig 12: Installing Direct Clutch Piston Outer Seal On Direct Clutch Piston Assembly
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Position the lip seal facing down.
Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.

Fig 13: Installing Direct Clutch Piston Assembly In Forward/Coast/Direct Clutch Cylinder Assembly
Courtesy of MAZDA MOTORS CORP.
Install the direct clutch return spring assembly.

Fig 14: Installing Direct Clutch Return Spring Assembly
Courtesy of MAZDA MOTORS CORP.
WARNING:
- Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
CAUTION:
- Do not compress the direct clutch return springs completely.
Install the direct clutch return spring retaining ring.
1. Using the special tool, compress the direct clutch return springs.
2. Install the direct clutch return spring retaining ring
Fig 15: Installing Direct Clutch Return Spring Retaining Ring
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Quantity of plates are model dependent.
Install the direct clutch plates.
1. Install the direct clutch external spline (steel) clutch plates.
2. Install the direct clutch internal spline (friction) clutch plates.
3. Install the direct clutch pressure plate.
Fig 16: Installing Direct Clutch Plates
Courtesy of MAZDA MOTORS CORP.
Install the direct clutch pressure plate retaining ring.

Fig 17: Installing Direct Clutch Pressure Plate Retaining Ring
Courtesy of MAZDA MOTORS CORP.
Measure the direct clutch clearance as follows:
1. Install the special tool.
2. Zero the dial on the direct clutch pressure plate.
3. Pull the direct clutch pressure plate upward, and record the reading.
Fig 18: Measuring Direct Clutch Clearance
Courtesy of MAZDA MOTORS CORP.
Make a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within the specification, select and install, using the special tool, the correct thickness direct clutch pressure plate retainer snap ring to obtain the standard clearance.
1. Retaining ring sizes:
  1. 1.28-1.38 mm (0.050-0.054 in)
  2. 1.39-1.49 mm (0.054-0.058 in)
  3. 1.52-1.62 mm (0.059-0.063 in)
  4. 1.65-1.75 mm (0.064-0.069 in)
  Fig 19: Installing Correct Direct Clutch Pressure Plate Retainer Snap Ring Thickness Using Special Tool
  Courtesy of MAZDA MOTORS CORP.