Input Shaft: Assembly

Fig 1: Inspecting Input Shaft

Courtesy of MAZDA MOTORS CORP.

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

Fig 2: Inspecting Synchronizer Rings For Damage
Courtesy of MAZDA MOTORS CORP.
Inspect the synchronizer rings for damage. Install new parts as necessary.

Fig 3: Measuring Clearance Between Synchronizer Ring And Gear Cone
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Limit value: 0.7 mm (0.02 in).

Press the synchronizer ring against the 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.

SYNCHRONIZER RING CLEARANCE

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	0.037-0.055

Fig 4: Installing Input Shaft Front Bearing Using Special Tool

Courtesy of MAZDA MOTORS CORP.

Using the special tools, install the input shaft front bearing.
Install the 3rd needle bearing.

Fig 5: Installing 3rd And 4th Gears Synchronizer Assembly
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Make sure the synchronizer side with 3 notches is facing the 3rd input gear and the synchronizer side with 4 notches is facing the 4th gear.
Install the 3rd and 4th gears synchronizer assembly.

Fig 6: Installing 4th Gear Bushing Using Special Tool
Courtesy of MAZDA MOTORS CORP.
Using the special tools, install the 4th gear bushing.
CAUTION:
- Only 1 thrust washer can be selected.

Fig 7: Measuring Distance

Courtesy of MAZDA MOTORS CORP.

Select the correct thickness thrust washer.

Measure the distance as shown.

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

THRUST WASHER 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

Fig 8: Installing Thrust Washer Using Special Tool

Courtesy of MAZDA MOTORS CORP.

Using the special tools, install the thrust washer.

Fig 9: Installing 5th Gear Bushing Using Special Tool
Courtesy of MAZDA MOTORS CORP.
Using the special tools, install the 5th gear bushing.

Fig 10: Installing 5th Gear Synchronizer Assembly
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Make sure the synchronizer side with the 3 notches is facing the 4th input gear.
Install the 5th gear synchronizer assembly.

Fig 11: Installing 5th Gear Stopper And Input Shaft Rear Bearing Spacer Using Special Tool
Courtesy of MAZDA MOTORS CORP.
Using the special tools, install the 5th gear stopper and input shaft rear bearing spacer together.

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

SNAP RING THICKNESS CHART

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

Fig 13: Installing Input Shaft Rear Bearing And Oil Channel Using Special Tool

Courtesy of MAZDA MOTORS CORP.

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