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Transaxle Reassembly: Reassembly

Fig 1: Exploded View Of Transaxle With Torque Specification
G04320959Courtesy of MAZDA MOTORS CORP.
Fig 2: Transaxle Components Reference Chart
G04320960Courtesy 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.
Fig 3: Installing Input Shaft Oil Seal
G04320961Courtesy of MAZDA MOTORS CORP.
  1. Using the special tools, install a new input shaft oil seal.
    Fig 4: Installing Halfshaft Oil Seal
    G04320962Courtesy of MAZDA MOTORS CORP.
  2. Using the special tools, install a new halfshaft oil seal.
    Fig 5: Identifying Oil Channel
    G04320963Courtesy of MAZDA MOTORS CORP.
  3. Position the oil channel. Make sure that the rib is correctly positioned.
    Fig 6: Installing Main Shaft Front Bearing And Retainer With Torque Specification
    G04320964Courtesy of MAZDA MOTORS CORP.
  4. Install the main shaft front bearing and retainer.
    1. Install the main shaft 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.
  5. Heat the clutch housing to 100°C (212°F) and install the differential side bearing outer race.
    Fig 7: Installing Differential
    G04320965Courtesy of MAZDA MOTORS CORP.
  6. Install the differential.
    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
    G04320966Courtesy of MAZDA MOTORS CORP.
  7. Install the input shaft, main shaft and reverse gear idler shaft as a set.
    Fig 9: Identifying Roll Pin
    G04320967Courtesy of MAZDA MOTORS CORP.
  8. Position the 1st/2nd fork rod bracket on the 1st/2nd fork rod and install a new roll pin.
    Fig 10: Installing 1st/2nd Fork Rod And 1st/2nd Shift Fork
    G04320968Courtesy of MAZDA MOTORS CORP.
  9. Install the 1st/2nd fork rod and the 1st/2nd shift fork and install a new roll pin.
  10. Install the 1st/2nd shift check sleeve.
    NOTE:
    • Apply petroleum jelly to the interlock pin to hold it in place.
  11. Install an interlock pin into the 3rd/4th fork rod.
  12. Install the 3rd/4th bracket, 3rd/4th shift fork and the 3rd/4th fork rod.
    Fig 11: Installing Circlips
    G04320969Courtesy of MAZDA MOTORS CORP.
  13. Install new circlips.
    Fig 12: Installing Roll Pin
    G04320970Courtesy of MAZDA MOTORS CORP.
  14. Install a new roll pin.
    CAUTION:
    • Make sure that the check balls remain in the correct location or damage to the transaxle may occur.
  15. Install the 2 check balls.
  16. Install the 5th/reverse bracket, the 5th shift fork and the 5th/reverse fork rod.
    Fig 13: Installing Circlips
    G04320971Courtesy of MAZDA MOTORS CORP.
  17. Install new circlips.
    Fig 14: Installing Reverse Fork And Reverse Fork Rod
    G04320972Courtesy of MAZDA MOTORS CORP.
  18. Install a new roll pin.
  19. Install the reverse fork and the reverse fork rod.
    Fig 15: Installing Shifter Cap
    G04320973Courtesy of MAZDA MOTORS CORP.
  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 16: Bracket Bolts With Torque Specification
    G04320974Courtesy 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.
  22. Install a check ball, 5th/reverse shift check sleeve, 5th/reverse check spring and a new check ball plug.
  23. Install the magnet.
    Fig 17: Measuring Depth From Mating Surface Of Transaxle Case To Differential Side Bearing Adjustment Shim Mounting Surface
    G04320975Courtesy of MAZDA MOTORS CORP.
  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 18: Checking Depth From Mating Surface Of Clutch Housing To Differential Side Bearing Outer Race Outer Surface
    G04320976Courtesy 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.
      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 0.04 mm (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.
    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 petroleum jelly 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.
    Fig 19: Measuring Depth Of Transaxle Case To Main Shaft Bearing Surface
    G04320977Courtesy of MAZDA MOTORS CORP.
  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 the main shaft is raised to contact the transaxle case.
  35. Release the circlip and 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.
    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 0.00-0.06 mm (0.00-0.0024 in).
  37. Remove the transaxle case.
  38. Install the differential side bearing adjustment shim.
    Fig 20: Measuring Depth From Mating Surface Of Transaxle Case To Input Shaft Adjustment Shim Mounting Surface
    G04320978Courtesy of MAZDA MOTORS CORP.
  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 21: Measuring Depth From Mating Surface Of Clutch Housing To Input Shaft Bearing Outer Race Outer Surface
    G04320979Courtesy 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.
    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) - end play.
  42. Install the input shaft adjustment shim.
    Fig 22: Measuring Depth From Mating Surface Of Transaxle Case To Reverse Idler Shaft Adjustment Shim Mounting Surface
    G04320980Courtesy of MAZDA MOTORS CORP.
  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 23: Measuring Depth From Mating Surface Of Clutch Housing To Reverse Idler Shaft Bearing Surface
    G04320981Courtesy 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.
    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) - end play.
  46. Install the reverse idler shaft adjustment shim.
    Fig 24: Identifying Sealant Application Area
    G04320982Courtesy of MAZDA MOTORS CORP.
  47. Apply a continuous bead of silicone gasket and sealant.
  48. Spread the circlip and install the transaxle case.
    Fig 25: Tightening Transaxle Case Bolts With Torque Specification
    G04320983Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The black colored bolt must be installed new in the correct position and tightened to the higher specification.
  49. Install the 20 bolts and tighten to specification in a cross pattern.
    Fig 26: Installing Check Balls, Springs And Plugs With Torque Specification
    G04320984Courtesy of MAZDA MOTORS CORP.
  50. Install the 2 check balls, springs and new plugs.
  51. Install a new O-ring on the control assembly.
  52. Install the control assembly.
  53. Shift the transaxle to 2nd gear, lift the main shaft and fully seat the snap ring into the main shaft bearing.
    Fig 27: Tightening Welch Plug With Torque Specification
    G04320985Courtesy of MAZDA MOTORS CORP.
  54. Install a new shift rod plug and a new stopper bolt.
  55. Install a new welch plug and a new bore plug.
  56. Install the reverse lamp switch.
    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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