Input Shaft Disassembly/Assembly: Disassembly

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

Prior to disassembly of the input shaft, measure and record end play for the 3rd, 4th and 5th gears. See the following chart for standard values.

Fig 1: Measuring End Play For 3rd, 4th And 5th Gears

Courtesy of MAZDA MOTORS CORP.

GEAR SPECIFICATION

Gear	mm	in
3rd	0.18-0.31	0.007-0.0122
4th	0.20-0.30	0.0078-0.0118
5th	0.06-0.16	0.0024-0.0063

Remove the oil channel.
Using the Bearing Puller and a suitable press, remove the input shaft rear bearing.

Fig 2: Removing Input Shaft Rear Bearing Using Special Tool
Courtesy of MAZDA MOTORS CORP.
Remove and discard the snap ring.
NOTE:
- The snap ring is not reusable.
  
  Fig 3: View Of Snap Ring
  Courtesy of MAZDA MOTORS CORP.
Using the Bearing Puller and a suitable press, remove the input shaft spacer and the 5th gear stopper together.

Fig 4: Removing Input Shaft Spacer And 5th Gear Stopper Using Special Tool
Courtesy of MAZDA MOTORS CORP.
Using the Bearing Puller and a suitable press, remove the 5th gear synchronizer assembly, the 5th gear synchronizer ring and the 5th input gear together.
- Discard the 5th gear synchronizer ring and assembly.
  
  Fig 5: Removing 5th Gear Synchronizer Ring Assembly Using Special Tool
  Courtesy of MAZDA MOTORS CORP.
Remove the 5th needle bearing.
Using the Bearing Puller and a suitable press, remove the 5th gear bushing, thrust washer, 4th input gear, 4th gear needle bearing, 4th gear bushing, 4th gear synchronizer ring, 3rd and 4th gear synchronizer assembly, 3rd gear synchronizer ring and 3rd input gear together.
- Discard the 5th gear bushing.
- Discard the 3rd and 4th gear synchronizer assembly.
  
  Fig 6: Removing 3rd And 4th Gear Synchronizer Assembly Using Special Tool
  Courtesy of MAZDA MOTORS CORP.
Remove the 3rd gear needle bearing.
Using the Bearing Puller and a suitable press, remove the input shaft front bearing.

Fig 7: Removing Input Shaft Front Bearing Using Special Tool
Courtesy of MAZDA MOTORS CORP.
Inspect all input shaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.

Fig 8: Inspecting Input Shaft
Courtesy of MAZDA MOTORS CORP.
Inspect the synchronizer rings for damage. Install new parts as necessary.

Fig 9: Inspecting Synchronizer Rings For Damage
Courtesy of MAZDA MOTORS CORP.

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.

NOTE:

Limit value: 0.7 mm (0,02 in).

Fig 10: Identifying Clearance Between Synchronizer Ring And Gear Cone With Specifications
Courtesy of MAZDA MOTORS CORP.

GEAR SPECIFICATION

Gear	mm	in
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