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Input Shaft Disassembly/Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Using the Input Bearing Installer and the Spindle/Axle Shaft Installer with the Bearing Puller, install the input shaft front bearing.
    Fig 1: Using Special Tool To Install Input Shaft Front Bearing
    G05460155Courtesy of MAZDA MOTORS CORP.
  2. Install the 3rd gear needle bearing.
  3. Install the 3rd input gear.
  4. Install the 3rd gear synchronizer ring.
  5. Install a new 3rd and 4th gear synchronizer assembly.
    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.
      Fig 2: Identifying 3rd And 4th Gear Synchronizer Assembly
      G05460156Courtesy of MAZDA MOTORS CORP.
  6. Install the 4th gear synchronizer ring.
  7. Using the Spindle/Axle Shaft Installer with the Bearing Puller, install the 4th gear bushing.
    Fig 3: Using Special Tool To Install 4th Gear Synchronizer Ring
    G05460157Courtesy of MAZDA MOTORS CORP.
  8. Install the 4th gear needle bearing.
  9. Install the 4th input gear.
  10. Select the correct thickness thrust washer.
    • Measure the distance as shown in figure.
    • If the measurement is not within 154.7-154.8 mm (6.090-6.094 in), select the correct thickness of shim from the chart.
      CAUTION:
      • Only one thrust washer can be selected.
        Fig 4: Locating 4th Gear Needle Bearing
        G05460158Courtesy of MAZDA MOTORS CORP.
      GEAR 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
  11. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on the thrust washer.
    Fig 5: Pressing On Thrust Washer
    G05460159Courtesy of MAZDA MOTORS CORP.
  12. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on a new 5th gear bushing.
    Fig 6: Pressing 5th Gear Bushing
    G05460160Courtesy of MAZDA MOTORS CORP.
  13. Install the 5th gear needle bearing.
  14. Install the 5th input gear.
  15. Install a new 5th gear synchronizer ring.
  16. Install a new 5th gear synchronizer assembly.
    CAUTION:
    • Make sure the synchronizer side with the 3 notches is facing the 4th input gear.
      Fig 7: Identifying 5th Gear Synchronizer Assembly
      G05460161Courtesy of MAZDA MOTORS CORP.
  17. Using the Spindle/Axle Shaft Installer with the Bearing Puller, install the 5th gear stopper and input shaft bearing spacer together.
    Fig 8: Using Special Tool To Install 5th Gear Stopper And Input Shaft Bearing Spacer
    G05460162Courtesy of MAZDA MOTORS CORP.
  18. Install the input shaft spacer.
  19. Install new snap ring. Measure the gap between the snap ring groove and the snap ring. The end play should be between 0-0.1 mm (0-0.0039 in). Refer to GEAR SPECIFICATION  for the correct snap ring thickness.
    Fig 9: Measuring Gap Between Snap Ring Groove And Snap Ring
    G05460163Courtesy of MAZDA MOTORS CORP.
    GEAR 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
  20. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on the input shaft rear bearing.
    Fig 10: Pressing Input Shaft Rear Bearing
    G05460164Courtesy of MAZDA MOTORS CORP.
  21. Install the oil channel.
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