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Output Shaft Disassembly/Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Prior to disassembly of the main shaft, measure and record end play for 1st and 2nd gears.
    Fig 1: Measuring End Play For 1st And 2nd Gears
    G05460166Courtesy of MAZDA MOTORS CORP.
    GEAR SPECIFICATION

    Gear mm in
    1st 0.20-0.30 0.0078-0.0118
    2nd 0.06-0.16 0.0024-0.0063
  2. Remove and discard the snap ring.
  3. Remove the C-ring holder.
  4. Remove the mainshaft C-ring.
  5. Using the special tool, remove the mainshaft rear bearing.
    Fig 2: Using Special Tool To Remove Mainshaft Rear Bearing
    G05460167Courtesy of MAZDA MOTORS CORP.
  6. Remove and discard the snap ring.
  7. Using the Bearing Puller and a suitable press, remove the 5th main gear and the 4th main gear together.
    • Discard both gears.
      Fig 3: Using Special Tool To Remove Snap Ring
      G05460168Courtesy of MAZDA MOTORS CORP.
  8. Remove the 4th gear main adjusting shim.
  9. Remove the 3rd/4th gear shaft spacer.
  10. Remove the 3rd main gear, 2nd main gear, 2nd gear needle bearing, 2nd gear bushing, 1st and 2nd gear synchronizer assembly, 1st and 2nd gear synchronizer rings, 1st main gear, reverse main gear, 1st gear needle bearing and 1st gear bushing together.
    • Discard the 3rd main gear, the reverse main gear, and the 1st and 2nd gear synchronizer assembly.
      Fig 4: Illustrating Removing 3rd/4th Gear Shaft Spacer
      G05460169Courtesy of MAZDA MOTORS CORP.
  11. Inspect all mainshaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.
    Fig 5: Identifying Mainshaft Parts
    G05460170Courtesy of MAZDA MOTORS CORP.
  12. Inspect the synchronizer rings for damage. Install new parts as necessary.
    Fig 6: Locating Synchronizer Rings
    G05460153Courtesy of MAZDA MOTORS CORP.
  13. Check the clearances of the double cone synchronizer for 1st gear. If any of the clearances are beyond specification, install new parts as a set.
    NOTE:
    • The outer synchronizer ring, synchronizer cone and inner synchronizer ring have a set control clearance. If the measurement exceeds specification, install all 3 parts as a set.
      Fig 7: Identifying Clearances Of Double Cone Synchronizer For 1st Gear
      G06157724Courtesy of MAZDA MOTORS CORP.
  14. Using the Dial Indicator with Holding Fixture and the Bearing Puller, measure the clearance at 2 or more points diagonally between the synchronizer cone and the inner synchronizer ring. Install new parts if not within specification.
    NOTE:
    • If the difference in measurements is greater than 0.2 mm (0.078 in), install new parts.
      Fig 8: Measuring Clearance Between Synchronizer Cone And Inner Synchronizer Ring
      G05460173Courtesy of MAZDA MOTORS CORP.
  15. Measure the clearance between the outer synchronizer ring and the synchronizer cone at 2 or more points diagonally opposite and calculate the mean value. Install new parts if not within specification.
    NOTE:
    • If the difference in measurements is greater than 0.2 mm (0.078 in), install new parts.
      Fig 9: Measuring Clearance Between Outer Synchronizer Ring And Synchronizer Cone
      G05460174Courtesy of MAZDA MOTORS CORP.
  16. Check the clearances of the triple cone synchronizer for 2nd gear. If any of the clearances are beyond specification, install new parts as a set.
    CAUTION:
    • The outer synchronizer ring, synchronizer cone and inner synchronizer ring have a set control clearance. If the measurement exceeds specification, install all 3 parts new as a set.
  17. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.
    NOTE:
    • If the difference in measurements is greater than 0.3 mm (0.01 in), install new parts.
      Fig 10: Identifying Outer Synchronizer Ring Clearance
      G06157727Courtesy of MAZDA MOTORS CORP.
  18. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.
    NOTE:
    • If the difference in measurements is greater than 0.17 mm (0.007 in) install new parts.
      Fig 11: Identifying Synchronizer Ring Clearance
      G06157728Courtesy of MAZDA MOTORS CORP.
  19. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.
    NOTE:
    • If the difference in measurements is greater than 0.3 mm (0.01 in), install new parts.
      Fig 12: View Of Outer Synchronizer Ring And Parts
      G06157729Courtesy of MAZDA MOTORS CORP.
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