Output Shaft Disassembly/Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

Position the reverse main gear on the mainshaft.
CAUTION:
- Be careful with the orientation of the reverse main gear or damage to the component may occur.
  
  Fig 1: Identifying Reverse Main Gear Position On Main-Shaft
  Courtesy of MAZDA MOTORS CORP.
Using the Spindle/Axle Shaft Installer, press on a new reverse main gear.

Fig 2: Pressing Reverse Main Gear
Courtesy of MAZDA MOTORS CORP.
Install the 1st main gear.
Using the Bearing/Oil Seal Plate and the 1st Gear Bushing Installer, press on the 1st main gear bushing.

Fig 3: Using Special Tool To Install 1st Main Gear
Courtesy of MAZDA MOTORS CORP.
Install the 1st gear needle bearing.
Install the 1st gear synchronizer ring.
Position a new 1st and 2nd gear synchronizer assembly on the mainshaft.
CAUTION:
- Make sure the synchronizer side with 3 notches is facing 1st gear and the synchronizer side with 4 notches is facing 2nd gear.
  
  Fig 4: Identifying 1st And 2nd Gear Synchronizer Assembly On Mainshaft
  Courtesy of MAZDA MOTORS CORP.
Using the Spindle/Axle Shaft Installer and the Bearing Puller, press on the 1st and 2nd gear synchronizer assembly.

Fig 5: Pressing 1st And 2nd Gear Synchronizer Assembly
Courtesy of MAZDA MOTORS CORP.
Install the 2nd gear synchronizer ring.

Fig 6: View Of Installing 2nd Gear Synchronizer Ring
Courtesy of MAZDA MOTORS CORP.
Using the Bearing Oil Seal late and the 2nd Gear Bushing Installer, install the 2nd gear bushing.

Fig 7: Using Special Tool To Install 2nd Gear Bushing
Courtesy of MAZDA MOTORS CORP.
Install the 2nd gear needle bearing.
Install the 2nd main gear.
Using the Spindle/Axle Shaft Installer and the Bearing Puller, press on a new 3rd main gear.
CAUTION:
- Be careful with the orientation of the 3rd main gear.
  
  Fig 8: Pressing 3rd Main Gear
  Courtesy of MAZDA MOTORS CORP.
Install the 3rd/4th main gear shaft spacer.

Fig 9: Identifying Reverse Main Gear Position On Main-Shaft
Courtesy of MAZDA MOTORS CORP.

Measure the mainshaft components as indicated to select the appropriate 4th main gear adjusting shim. See GEAR SPECIFICATION for shim thicknesses and install the 4th main gear adjusting shim.

CAUTION:

Only one adjusting shim can be installed.

Fig 10: Measuring Mainshaft Components Shim Thicknesses
Courtesy of MAZDA MOTORS CORP.

GEAR SPECIFICATION

mm	in
0.52	0.021
0.60	0.024
0.68	0.027
0.76	0.030
0.84	0.033
0.92	0.036
1.00	0.039
1.08	0.043

Using the Spindle/Axle Shaft Installer, press on a new 4th main gear.
CAUTION:
- Be careful with the orientation of the 4th main gear.
  
  Fig 11: Pressing 4th Main Gear
  Courtesy of MAZDA MOTORS CORP.
Using the Spindle/Axle Shaft Installer, press on a new 5th main gear.
CAUTION:
- Be careful with the orientation of the 5th main gear.
  
  Fig 12: Using Special Tool To Install 5th Main Gear
  Courtesy of MAZDA MOTORS CORP.

Measure the gap between the snap ring and the 5th main gear. The end play should be less than 0.1 mm (0.0039 in). See the chart to select the appropriate snap ring thickness and install a new snap ring.

Fig 13: Measuring Gap Between Snap Ring And 5th Main Gear

Courtesy of MAZDA MOTORS CORP.

GEAR SPECIFICATION

mm	in
1.85	0.073
1.90	0.075
1.95	0.077
2.00	0.079
2.05	0.081
2.10	0.083
2.15	0.085
2.20	0.087

Using the Spindle/Axle Shaft Installer, press on the mainshaft rear bearing.
CAUTION:
- Be careful with the orientation of the mainshaft rear bearing.
  
  Fig 14: Identifying Mainshaft Rear Bearing
  Courtesy of MAZDA MOTORS CORP.

Measure the gap between the mainshaft C-ring and the mainshaft rear bearing. See GEAR SPECIFICATION to select the appropriate C-ring thickness and install the C-ring.

Fig 15: Measuring Gap Between Mainshaft C-Ring And Mainshaft Rear Bearing

Courtesy of MAZDA MOTORS CORP.

GEAR SPECIFICATION

mm	in
2.535	0.0998
2.565	0.1010
2.595	0.1022
2.625	0.1033
2.655	0.1045
2.685	0.1057
2.715	0.1069
2.745	0.1081
2.775	0.1093
2.805	0.1104
2.835	0.1116
2.865	0.1128
2.895	0.1140
2.925	0.1152
2.955	0.1163
2.985	0.1175
3.015	0.1187
3.045	0.1199
3.075	0.1211

Install the C-ring holder.
Install a new snap ring.