Transaxle Disassembly

NOTE: For References to 4 & 5-Speed Transmissions Gears and Shafts, See Fig 1 .

Fig 1: Exploded View of Mazda 4 and 5-Speed Transmission Gears and Shafts

Courtesy of MAZDA MOTORS CORP.

Clean exterior of transmission assembly. On GLC models, remove clutch cross-shaft bolt, cross-shaft, release lever, spring and throw-out bearing. On all other models, remove dust cover, throw-out bearing and clutch release fork. Remove front cover bolts (or nuts) and remove front cover, shim, gasket and oil seal. See Fig 2 .

Fig 2: Exploded View of Front Bearing Cover and Input Shaft Assembly
Courtesy of MAZDA MOTORS CORP.
Remove gearshift lever retainer and gasket from extension housing. Remove extension housing bolts and slide extension housing off mainshaft with control lever positioned to the left as far as possible. Remove control lever end attaching bolt and remove control lever end and control rod from housing.
Remove speedometer driven gear assembly, back-up light switch and overdrive switch from extension housing. Remove top switch from transmission case. On 4-speed models, remove speedometer drive gear snap ring from mainshaft and slide drive gear off mainshaft. Remove lock ball.
On all models, remove snap ring from input shaft and countershaft. Separate transmission case from bearing plate/intermediate housing using push tool or by tapping input shaft with plastic faced hammer. Remove input shaft bearing from transmission case. Using bearing puller tool, remove countershaft front bearing from countershaft.
On 5-speed models, remove speedometer drive gear snap ring from mainshaft and slide drive gear off mainshaft. Remove lock ball and drive gear positioning snap ring. On 4-speed models, remove 3 spring cap bolts and remove springs and shift locking balls.
On 5-speed models, remove shift rod end attaching bolts and remove shift rod ends. Separate bearing plate from intermediate housing by lightly tapping housing with plastic faced hammer.
On 4-speed models, remove reverse shift rod, shift fork assembly and reverse gear from bearing plate. Remove shift fork set screws. Remove shift rods and forks by pushing shift rods rearward through shift forks and bearing plate. Remove reverse shift rod locking ball, spring and interlock pins from bearing plate.
On 5-speed models, remove 3 spring cap bolts and remove springs and shift locking balls. Remove 3 shift rod snap rings. Remove shift fork attaching bolts, shift fork rods and shift forks. Remove lock ball, spring and interlock pins.
NOTE: On 5-speed, be careful not to lose lock ball when removing 5th-Reverse shift rod.
On 4-speed models, straighten lock washer tab and secure mainshaft with holding tool and loosen lock nut using wrench. Remove reverse gear and key from mainshaft. Remove countershaft snap ring and counter reverse gear.
Remove bearing cover and reverse idler gear shaft from bearing plate. Using plastic faced hammer, tap rear end of mainshaft and countershaft assemblies and remove from bearing plate, being careful not to damage shafts. Remove bearings from bearing plate.
On 5-speed models, remove mainshaft and countershaft snap rings and adjusting washers. Remove rear bearings using bearing removal tool.
From rear of mainshaft, remove snap ring, thrust washer, lock ball, 5th gear, synchronizer ring, counter 5th gear and spacer. Engage clutch sleeves into 1st and reverse gear to lock mainshaft assembly. Mount bearing plate in vise. Remove lock nut caulking using a chisel.
Remove and discard lock nut using wrench. Remove 5th-Reverse clutch hub assembly, reverse gear, needle bearing, inner race, thrust washer, counter reverse gear, snap ring, thrust washers and reverse idler gear.
Using plastic faced hammer, tap rear end of mainshaft and countershaft assemblies and remove from bearing plate. Remove bearing cover and bearings from bearing plate.