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Transaxle Reassembly: Reassembly

Fig 1: Exploded View Of Transaxle & Torque Specifications
G03725659Courtesy of MAZDA MOTORS CORP.
Fig 2: Transaxle Components Index
G03725660Courtesy of MAZDA MOTORS CORP.
CAUTION:
  • Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.
CAUTION:
  • Assembly should only be carried out in a clean environment or damage to the transaxle may occur.
CAUTION:
  • Be careful not to scratch the sliding face or mating faces or damage to the transaxle may occur.
CAUTION:
  • Visually inspect all parts for any damage, deformation or abnormal wear. Replace any unsuitable parts with new parts only or damage to the transaxle may occur.
CAUTION:
  • Do not work on the transaxle with cotton gloves, cotton threads could become dislodged and damage to the transaxle may occur.
CAUTION:
  • Replace all retaining pins, oil seals and bearings with new parts or damage to the transaxle may occur.
CAUTION:
  • Make sure to clean the old sealant from the mating threads of any sealed bolt or damage to the transaxle may occur.
  1. Using the special tools, install a new input shaft oil seal.
    Fig 3: Installing New Input Shaft Oil Seal
    G03725661Courtesy of MAZDA MOTORS CORP.
  2. Using the special tools, install a new half shaft oil seal.
    Fig 4: Installing New Half Shaft Oil Seal
    G03725662Courtesy of MAZDA MOTORS CORP.
  3. Position the oil channel, make sure that the rib is correctly positioned.
    Fig 5: Positioning Oil Channel
    G03725663Courtesy of MAZDA MOTORS CORP.
  4. Install the mainshaft front bearing and retainer.
    1. Install the mainshaft front bearing.
      NOTE:
      • The stamping on the bearing retainer is installed facing away from the clutch housing.
    2. Position the retainer.
    3. Install the bolt.
      CAUTION:
      • Do not exceed 120°C (248°F) or damage to the clutch housing may occur.
      4. Fig 6: Illustration For Step 1-3 & Torque Specifications
      G03725664Courtesy of MAZDA MOTORS CORP.
  5. Heat the clutch housing to 100°C (212°F) and install the differential side bearing outer race.
  6. Install the differential.
    Fig 7: Installing Differential
    G03725665Courtesy of MAZDA MOTORS CORP.
    7. CAUTION:
    • Make sure to install the main shaft straight in. Failure to install the main shaft correctly may result in damage to the funnel on the clutch housing.
    Fig 8: Installing Input Shaft, Main Shaft And Reverse Gear Idler Shaft
    G03725666Courtesy of MAZDA MOTORS CORP.
  7. Install the input shaft, main shaft and reverse gear idler shaft as set.
  8. Position the 1st/2nd fork rod bracket on the 1st/2nd fork rod and install a new roll pin.
    Fig 9: Positioning 1st/2nd Fork Rod Bracket On 1st/2nd Fork Rod
    G03725667Courtesy of MAZDA MOTORS CORP.
  9. Install the 1st/2nd fork rod and the 1st/2nd shift fork and install a new roll pin.
    Fig 10: Installing New Roll Pin
    G03725668Courtesy of MAZDA MOTORS CORP.
  10. Install the 1st/2nd shift check sleeve.
    11. NOTE:
    • Apply vaseline to the interlock pin to hold it in place.
  11. Install a interlock pin into the 3rd/4th fork rod.
  12. Install the 3rd/4th bracket, 3rd/4th shift fork and the 3rd/4th fork rod.
  13. Install new circlips.
    Fig 11: Installing New Circlips
    G03725669Courtesy of MAZDA MOTORS CORP.
  14. Install a new roll pin.
    Fig 12: Installing New Roll Pin
    G03725670Courtesy of MAZDA MOTORS CORP.
    15. CAUTION:
    • Make sure that the check balls remain in the correct location or damage to the transaxle may occur.
  15. Install the two check balls.
  16. Install the 5th/reverse bracket, the 5th shift fork and the 5th/reverse fork rod.
  17. Install new circlips.
    Fig 13: Installing New Circlips
    G03725671Courtesy of MAZDA MOTORS CORP.
  18. Install a new roll pin.
    Fig 14: Installing New Roll Pin
    G03725672Courtesy of MAZDA MOTORS CORP.
  19. Install the reverse fork and the reverse fork rod.
  20. Install the shifter cap on the reverse lever cam then lift the reverse gear shift fork and insert the cam part of the 5th/reverse gear bracket into the reverse level bracket.
    Fig 15: Installing Shifter Cap On Reverse Lever Cam
    G03725673Courtesy of MAZDA MOTORS CORP.
  21. Install the shifter cap on the reverse lever cam then lift the reverse gear shift fork and insert the cam part of the 5th/reverse gear bracket into the reverse level bracket.
    Fig 16: Installing Check Ball & Torque Specifications
    G03725674Courtesy of MAZDA MOTORS CORP.
  22. Install a check ball, 5th/reverse shift check sleeve, 5th/reverse check spring and a new check ball plug.
  23. Install the magnet.
  24. Using a depth micrometer and a straight edge, measure and record the depth from the mating surface of the transaxle case to the differential side bearing adjustment shim mounting surface. Record this measurement as L1.
    Fig 17: Measuring Depth From Mating Surface Of Transaxle Case
    G03725675Courtesy of MAZDA MOTORS CORP.
  25. Using a depth micrometer and a straight edge, measure and record the depth from the mating surface of the clutch housing to the differential side bearing outer race outer surface. Record this measurement as L2.
    1. Install the differential side bearing outer race on the differential bearing.
    2. Holding the outer race in position using hand pressure, rotate the differential 5 times to seat the bearing races.
      Fig 18: Measuring Depth From Mating Surface Of Clutch Housing
      G03725676Courtesy of MAZDA MOTORS CORP.
    26. NOTE:
    • Do not use more than 2 shims to achieve the desired shim thickness.
    NOTE:
    • Shims are available in thicknesses from 0.48-0.92 mm (0.0189- 0.0366 in) in 0.04mm (0.00157 in) increments.
  26. Select the shims to allow a preload of 0.15-0.21 mm (0.0059- 0.0083 in) using the formula; shim thickness - (L1+L2) + Preload.
  27. Install the differential side bearing adjustment shim.
    28. CAUTION:
    • Do not exceed 120°C (248°F) or damage to the transaxle case may occur.
  28. Heat the transaxle case to 100°C (212°F) and install the differential side bearing outer race.
  29. Install the differential oil seal.
    NOTE:
    • Apply vaseline to the claw area to keep the baffle and oil gutter in place during case assembly.
  30. Install the oil gutter and oil baffle in the transaxle case.
  31. Temporarily install the main shaft, main shaft bearing and circlip.
  32. Temporarily assemble the transaxle case.
  33. Temporarily install and tighten the transaxle case bolts.
  34. Using the special tool, measure and record the depth of the transaxle case to the main shaft bearing surface when the circlip is expanded and main shaft is raised to contact the transaxle case.
    Fig 19: Measuring Depth Of Transaxle Case To Main Shaft Bearing Surface
    G03725677Courtesy of MAZDA MOTORS CORP.
  35. Release the circlip allow the main shaft to lower and engage the circlip, measure and record the depth of the transaxle case to the main shaft bearing surface.
    36. NOTE:
    • Do not use more than 1 shim to achieve the desired shim thickness.
    NOTE:
    • Shims are available in thicknesses from 0.44-1.08 mm (0.017-0.043 in) in 0.04 mm (0.00157 in) increments.
  36. Select the shim to allow an end play of 0.00-0.06mm (0.00-0.0024 in).
  37. Remove the transaxle case.
  38. Install the differential side bearing adjustment shim.
  39. Using a depth micrometer and a straight edge, measure and record the depth from the mating surface of the transaxle case to the input shaft adjustment shim mounting surface. Record this measurement as L1.
    Fig 20: Measuring Depth From Mating Surface Of Transaxle Case
    G03725678Courtesy of MAZDA MOTORS CORP.
  40. Using a depth micrometer and a straight edge, measure and record the depth from the mating surface of the clutch housing to the input shaft bearing outer race outer surface. Record this measurement as L2.
    Fig 21: Measuring Depth From Mating Surface Of Clutch Housing
    G03725679Courtesy of MAZDA MOTORS CORP.
    41. NOTE:
    • Do not use more than 1 shim to achieve the desired shim thickness.
    NOTE:
    • Shims are available in thicknesses from 0.40-1.72 mm (0.016-0.068 in) in 0.04 mm (0.00157 in) increments.
  41. Select the shims to allow an end play of 0.00-0.06 mm (0.00-0.0024 in) using the formula; shim thickness = (L1-L2)-endplay.
  42. Install the input shaft adjustment shim.
  43. Using a depth micrometer and a straight edge, measure and record the depth from the mating surface of the transaxle case to the reverse idler shaft adjustment shim mounting surface. Record this measurement as L1.
    Fig 22: Measuring Depth From Mating Surface Of Transaxle Case
    G03725680Courtesy of MAZDA MOTORS CORP.
  44. Using a depth micrometer and a straight edge, measure and record the depth from the mating surface of the clutch housing to the reverse idler shaft bearing surface. Record this measurement as L2.
    Fig 23: Measuring Depth From Mating Surface Of Clutch Housing
    G03725681Courtesy of MAZDA MOTORS CORP.
    45. NOTE:
    • Do not use more than 1 shim to achieve the desired shim thickness.
    NOTE:
    • Shims are available in thicknesses from 1.76-2.64 mm (0.069-0.104 in) in 0.04 mm (0.00157 in) increments.
  45. Select the shims to allow an end play of 0.04-0.14 mm (0.001-0.005 in) using the formula; shim thickness = (L1-L2)-endplay.
  46. Install the reverse idler shaft adjustment shim.
  47. Apply a continuous bead of silicone gasket and sealant.
    Fig 24: Applying Continuous Bead Of Silicone Gasket And Sealant
    G03725682Courtesy of MAZDA MOTORS CORP.
  48. Spread the circlip and install the transaxle case.
    49. NOTE:
    • The black colored bolt must be installed new, in the correct position and tightened to the higher specification.
    Fig 25: Installing Bolts & Torque Specifications
    G03725683Courtesy of MAZDA MOTORS CORP.
  49. Install the 20 bolts and tighten to specification in a cross pattern.
  50. Install the two check balls, springs and new plugs.
    Fig 26: Installing Two Check Balls, Springs And New Plugs & Torque Specifications
    G03725684Courtesy of MAZDA MOTORS CORP.
  51. Install a new O-ring on the control assembly.
  52. Install the control assembly.
  53. Shift the transaxle to 2nd gear, lift the mainshaft and fully seat the snap ring into the mainshaft bearing.
  54. Install a new shift rod plug and a new stopper bolt.
    Fig 27: Installing New Shift Rod Plug And New Stopper Bolt & Torque Specifications
    G03725685Courtesy of MAZDA MOTORS CORP.
  55. Install a new welch plug and a new bore plug.
  56. Install the reverse lamp switch.
    57. NOTE:
    • Install new gaskets on the drain and fill plugs.
  57. Install the fill and drain plugs. Tighten the plugs to 35 Nm (3.6 kgf-m, 26 lb-ft).
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