MAZDA MX-5 1994 Workshop Manual

H CLUTCH UNIT Removal Note Clutch cover and disc 1 . Install the SST. 2. Hold the flywheel by using the SST or equivalent. e 3. Loosen each bolt one turn at a time in a crisscross pat- tern until spring tension is released. Then remove the clutch cover and disc. Flywheel 1. Hold the flywheel by using the SST or equivalent. 2. Remove the flywheel. 3. Inspect for oil leakage from the crankshaft rear oil seal. If there is any such leakage or if the oil seal is damaged, refer to section B and replace the crankshaft oil seal. Pilot bearing Note The pilot bearing does not need to be removed unless you are replacing it. Remove the pilot bearing by using the SST. L' Installation Note Flywheel 1. Wipe the bolts clean, and apply sealant to the bolt threads. 2. Install the flywheel, and secure it by using the SST or equivalent. 3. Tighten the bolts in the pattern shown. Tightening torque: 97-1 02 N.m (9.8-1 0.5 kgf.m, 71-75.9 ft-lbf) Pilot bearing Install a new pilot bearing flush with the flywheel by using a suitable pipe. Gartner Banana

CLUTCH UNIT, CLUTCH RELEASE COLLAR, CLUTCH COVER, CLUTCH DlSC H Clutch disc 1. Clean the clutch disc splines and main drive gear splines, and apply Mori White TA No.2 or equivalent or- ganic molybdenum grease. 2. Hold the clutch disc in position by using the SST. Clutch cover 1. Hold the flywheel by using the SST or equivalent. 2. Align the dowel holes with the flywheel dowels. 3. Tighten the bolts evenly and gradually in the pattern shown. Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, 14--19 ft.lbf} CLUTCH RELEASE COLLAR INSPECTION Caution Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing. Turn the collar while applying force in the axial direction. If the collar sticks or has excessive resistance, replace it. CLUTCH COVER INSPECTION 1. lnspect the contact surface for scoring, cracks, and burning. Repair or replace as necessary. 2. Remove minor scoring or burning with emery paper. Repair if scoring or burning is major. Replace if cracked. 3. lnspect the tips of the diaphragm spring for wear and cracks. 4. If there is wear or cracks, replace the clutch cover. I I 45UOHX-027 CLUTCH DlSC INSPECTION 1. lnspect the lining surface for burning and oil contamina- tion. Repair with sandpaper if the trouble is minor. Re- place the clutch disc if it is badly burned or oil soaked. 2. lnspect for loose facing rivets or torsion dampers. Replace the clutch disc if any are loose. Gartner Banana

H CLUTCH DISC, PILOT BEARING, FLYWHEEL 3. Measure the thickness of the lining at a rivet head on both sides with vernier calipers. Replace the clutch disc if less than minimum. Minimum thickness: 0.3mm (0.012 in) 4. Measure the clutch disc runout with a dial indicator. Replace the clutch disc if runout is excessive. Maximum runout: 0.7mm (0.028 in) PILOT BEARING INSPECTION Turn the bearing while applying force in the axial direc- tion. If the bearing sticks or has excessive resistance, replace it. FLYWHEEL INSPECTION 1. lnspect the contact surface for scoring, cracks, and burning. 2. Remove minor scoring or burning with emery paper. Repair if scoring or burning is major. Replace if cracked. 3. lnspect the ring gear teeth for wear or damage. If neces- sary, replace the ring gear as follows: (1) Heat the ring gear with a blow torch. Tap around the gear to remove it from the flywheel. (2) Heat the new ring gear to 250--300°C (482--572°F); then fit it onto the flywheel. Gartner Banana

FLYWHEEL H 4. Measure the flywheel runout with a dial indicator. Replace the flywheel if runout is excessive. Maximum runout: 0.2mm (0.008 in) 9MUOHX-048 Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . MANUAL TRANSMISSION INDEX ....................................... J- 2 ..................................... OUTLINE J- 3 SPECIFICATIONS ........................... J- 3 ........................ STRUCTURAL VIEW J- 4 ............................. COMPONENTS J- 5 ............................. POWER FLOW J- 6 TROUBLESHOOTING GUIDE .................. J- 7 .......................... TRANSMISSION OIL J- 8 ............................... INSPECTION J- 8 ............................ REPLACEMENT J- 8 TRANSMISSION .............................. J- 9 ............................. PREPARATION J- 9 REMOVAL .................................. J-10 DISASSEMBLY ............................. J-13 ............................... INSPECTION 5-23 ASSEMBLY ................................. J-26 INSTALLATION ............................. J-45 25UOJX-011 Gartner Banana

J INDEX INDEX OIL SPECIFICATION API SERVICE GL-4 OR GL-5 ALL-SEASON TYPE: SAE 75W-90 ABOVE 10°C {50°F): SAE 80W-90 CAPACITY. 2.0 L {2.1 US qt, 1.8 Imp qt} 1. Transmission Removal . . . . . . . . . . . . . . . . . . . . page J-10 Disassembly . . . . . . . . . . . . . . . . page J-13 Inspection . . . . . . . . . . . . . . . . . . . page J-23 Assembly . . . . . . . . . . . . . . . . . . . page J-26 Installation . . . . . . . . . . . . . . . . . . page J-45 Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Transmission Item M15M-D Synchronization mechanism Forward: Synchromesh Reverse: Synchromesh Shift type Gear ratio I st 2nd 5-speed, floor shift 3.1 36 1.888 5th Reverse 0.81 4 3.758 API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 Grade ' Capacity L {US qt, Imp qt} Viscosity 2.0 12.1, 1.8) All-season Above 10°C {50°F) 45UOJX401 Gartner Banana

J OUTLINE STRUCTURAL VlEW 1. Main drive gear (4th gear) 2. 3rd gear 3. 2nd gear 4. 1 st gear 5. 5th gear 6. Countershaft VlEW &A 7. Counter 5th gear 8. Mainshaft 9. Reverse gear 10. Reverse idler gear 11. Counter reverse gear J-A Gartner Banana

OUTLINE J COMPONENTS 1. Front cover 6. 1 st12nd shift fork and rod 11. Countershaft 2. Transmission case 7. 3rdl4th shift fork and rod 12. 5th gear u 3. Intermediate housing 8. Mainshaft gear assembly 13. Reverse gear 4. Extension housing 9. Main drive gear 14. Counter 5th gear 5. 5thlReverse shift fork and 10. Bearing housing assembly 15. Counter reverse gear rod Gartner Banana

J OUTLINE POWER FLOW I REVERSE I Gartner Banana