Input Shaft: Assembly

Inspect all input shaft parts for damage, peeling, dents, uneven wear, bending, etc. Install new parts as necessary.

Fig 1: Identifying Parts Of Input Shaft
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Inspect the synchronizer rings for damage. Install new parts as necessary.

Fig 2: Inspecting Synchronizer Rings For Damage
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NOTE:

Limit value: 0.7 mm (0.02 in).

Fig 3: Measuring Clearance Between Synchronizer Ring And Gear Cone

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Press synchronizer ring against cone, and measure the clearance between the synchronizer ring and gear cone. Install a new synchronizer ring if the measurement is not within specification. See the following chart for correct synchronizer ring clearance.

GEAR CLEARANCE SPECIFICATION

Gear	mm	Inch
3rd	0.9 - 1.45	0.035 - 0.057
4th	0.9 - 1.45	0.035 - 0.057
5th	0.95 - 1.4	0.37 - 0.055

Using the special tools, install the input shaft front bearing.

Fig 4: Installing Input Shaft Front Bearing
Courtesy of MAZDA MOTORS CORP.
Install the 3rd needle bearing.

CAUTION:

Make sure the synchronizer side with 3 notches is facing 3rd input gear and the synchronizer side with 4 notches is facing 4th gear.

Fig 5: Installing 3rd And 4th Gears Synchronizer Assembly

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Install the 3rd and 4th gears synchronizer assembly.
Using the special tools, install the 4th gear bushing.

Fig 6: Installing 4th Gear Bushing & Torque Specifications
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CAUTION:

Only one thrust washer can be selected.

Fig 7: Measuring Distance

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Select the correct thickness thrust washer.

Measure distance as shown.
If the measurement is not within specification, select correct thickness of shim from the following chart.

SHIM THICKNESS SPECIFICATION

mm	in
3.84	0.151
3.90	0.153
3.96	0.155
4.02	0.158
4.08	0.16
4.14	0.162

Using the special tools, install the thrust washer.

Fig 8: Installing Thrust Washer
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Using the special tools, install the 5th gear bushing.

Fig 9: Installing 5th Gear Bushing
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CAUTION:

Make sure the synchronizer side with the 3 notches is facing the 4th input gear.

Fig 10: Installing 5th Gear Synchronizer Assembly

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Install the 5th gear synchronizer assembly.
Using the special tools, install the 5th gear stopper and input shaft rear bearing spacer together.

Fig 11: Installing 5th Gear Stopper And Input Shaft Rear Bearing Spacer
Courtesy of MAZDA MOTORS CORP.

Measure the gap between the snap ring groove and the snap ring. End play should be between 0 - 0.1 mm (0 - 0.0039 in). See the following chart for the correct snap ring thickness.

Fig 12: Measuring Gap Between Snap Ring Groove And Snap Ring

Courtesy of MAZDA MOTORS CORP.

SHIM THICKNESS SPECIFICATION

mm	inch
1.71	0.067
1.76	0.069
1.81	0.071
1.86	0.073
1.91	0.075
1.96	0.077
2.01	0.079
2.06	0.081
2.11	0.083
2.16	0.085
2.21	0.087
2.26	0.088

Using the special tools, install the input shaft rear bearing and oil channel

Fig 13: Installing Input Shaft Rear Bearing And Oil Channel
Courtesy of MAZDA MOTORS CORP.