MAZDA MX-5 1994 Workshop Manual

TRANSMISSION J Extension Housing Parts Assemble in the order shown in the figure, referring to Assembly Note. 1. Oil seal 8. Control rod end Assembly Note .............. page 5-28 9. Roll pin 2. Oil passage Assembly Note .............. page J-28 3. Rod cover 10. Blind cover Assembly Note .............. page J-28 11. Plug, spring, and pushpin w 4. Change control case 12. Select-lock spindle, spring, and spring cap 5. Wave washer Assembly Note .............. page J-28 6. Change bushing 13. Steel ball, spring, and spring cap 7. Control rod Gartner Banana

J TRANSMISSION Assembly note Oil seal 1. Apply the specified oil to a new oil seal. 2. Install the new oil seal by using the SST. Rod cover 1. Apply transmission oil to the rubber bushings on the rod cover. 2. Install the rod cover with the mark facing forward. L I 35UOJX-058 Roll pin Install a new roll pin into the control rod end. The split in the roll pin must be facing in the direction shown in the figure. L I 45UOJX-031 Select-lock spindle, spring, and spring cap 1. Install the select-lock spindle, spring, and spring cap. Tightening torque: 7.9-10.7 Nm (80-11 0 kgfan, 70-95.4 in-lbf) 2. Push the select-lock spindle down by pushing on the control rod. This will ensure that the steel ball correctly engages the select-lock spindle. 45UOJX-032 Gartner Banana

TRANSMISSION J Bearing Housina Assemblv ~ssemble in t6e order sh6wn in the figure, referring to Assembly Note. 1. Bearing housing 6. Reverse idler gear shaft 2. Adjustment shim Assembly Note .............. page J-30 Assembly Note .............. page J-30 7. Washer 3. Countershaft center bearing 8. Reverse idler gear Assembly Note .................. below Assembly Note .............. page J-30 4. Adjustment shim 9. Washer Assembly Note .............. page J-30 10. Bearing cover 5. Mainshaft front bearing .. Assembly Note .............. page J-30 Assembly note Countershaft center bearing Press the countershaft center bearing into the bearing housing with a suitable pipe. Outer diameter of pipe: 50.0mm (1.97 in) 05UOJX-032 Gartner Banana

Bolt length (measured from below the head) @ : 28mm @I : 35mm Adjustment shim Measure the clearance between the countershaft center bearing and the bearing housing. If not within specification, adjust the clearance by instal- i, ling the correct adjustment shim(s). Standard clearance: 04.1 mm (0-4.004 in) Adjustment shim: O.lmm (0.004 in), 0.3mm (0.012 in) Mainshaft front bearing Press the mainshaft front bearing into the bearing hous- ing with a suitable pipe. Outer diameter of pipe: 70.0mm (2.76 in) Adjustment shim Measure the clearance between the mainshaft front bearing and the bearing housing. If not within specification, adjust the clearance by instal- ling the correct adjustment shim(s). Standard clearance: 0-4.1 mm (0--0.004 in) Adjustment shim: O.lmm (0.004 in), 0.15mm (0.006 in), 0.3mm (0.012 in) Reverse idler gear shaft 1. Press the reverse idler gear shaft into the bearing hous- ing. 2. Install and tighten the reverse idler gear shaft installation bolt. Tightening torque: 8.9-12.7 N.m (90-130 kgf.cm, 79-112 in4bf) Reverse idler gear 1. Install the reverse idler gear, end washer, and bearing cover. 2. Tighten the bearing cover installation bolts. Tightening torque @: 18-26 N.m (1.8-2.7 kgf-m, 14--19 ftlbf) @I: 37-53 N.m f3.7-5.5 kgf-m, 27-39 ft4bf) Gartner Banana

TRANSMISSION J Mainshaft Parts Assemble in the order shown in the figure, referring to Assembly Note. WPPLY SPEwim OIL To IwiviDwL PmTs 45UOJX-034 Clutch hub Synchronizer key Clutch hub sleeve Synchronizer key springs Mainshaft 2nd gear Assembly Note .............. page J-32 2nd synchronizer ring Double cone Inner cone Synchronizer assembly (2nd) Clutch hub assembly (Istf2nd) Assembly Note .............. page J-32 3rd gear Assembly Note .............. page J-32 3rd synchronizer ring Clutch hub assembly (3rdl4th) Assembly Note .............. page J-32 Snap ring Assembly Note .............. page J-32 1 st synchronizer ring Bearing race Assembly Note .............. page J-32 Bearing Assembly Note .............. page J-32 1 st gear Assembly Note .............. page J-32 5-31 Gartner Banana

J TRANSMISSION Assembly note Clutch hub assembly 1. Set the 2nd gear, 2nd synchronizer ring, and 1stl2nd clutch hub assembly on the mainshaft, then press in the mainshaft. 2. Set the 3rd gear, 3rd synchronizer ring, and 3rdl4th clutch hub assembly on the mainshaft, then press them onto the mainshaft by using the SST. 3. Install a new snap ring on the front of the mainshaft. 4. Install the bearing race, bearing, and 1 st gear. Gartner Banana

TRANSMISSION J MEMO Gartner Banana

J TRANSMISSION Mainshaft and Countershaft Parts Assemble in the order shown in the figure, referring to Assembly Note. Gartner Banana

TRANSMISSION 1. Clutch hub 2. Synchronizer key 3. Clutch hub sleeve b 4. Synchronizer key springs 5. 4th synchronizer ring 6. Bearing 7. Main drive gear 8. Bearing housing assembly 9. Washer 10. Mainshaft gear assembly Assembly Note .................. below 1 1 . Spacer 12. Countershaft .................. Assembly Note below 13. Counter reverse gear 14. Washer 15. Bearing race 16. Bearing 17. Reverse gear 18. Reverse synchronizer ring 19. Clutch hub assembly (5thlReverse) 20. Locknut (Mainshaft) .................. Assembly Note below 21. 5th synchro-niter ring 22. 5th gear 23. Steel ball 24. Thrust lock washer .............. Assembly Note page J-36 25. C-washer .............. Assembly Note page J-36 26. Retaining ring .............. Assembly Note page J-36 27. Spacer 28. Counter 5th gear 29. Mainshaft rear bearing .............. Assembly Note page J-36 30. C-washer .............. Assembly Note page J-36 31. Retaining ring .............. Assembly Note page J-36 32. Washer .............. Assembly Note page J-36 33. Snap ring 34. Countershaft rear bearing .............. Assembly Note page J-36 35. Locknut (Countershaft) .............. Assembly Note page J-37 45UOJX437 Assembly note Mainshaft and countershaft 1. Place the mainshaft gear assembly and the countershaft on the bearing housing. 2. Use a suitable bar to press in the countershaft. Locknut (Mainshaft) 1. Secure the bearing housing assembly in a vise. 2. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 3. Install a new locknut and tighten it by using the SST. Tightening torque: 128-235 N.m (13-24 kgf.m, 95-173 ftdbf) 4. Use a chisel to stake the locknut. Gartner Banana

J TRANSMISSION Thrust lock washer 1. lnstall the synchronizer ring and 5th gear. 2. Insert the steel ball and thrust lock washer. 3. lnstall only the two 3.0mm I0.118 in) thick C-washers in the front mainshaft groove. 4. Push the C-washers fully toward 5th gear and measure the clearance between the thrust lock washer and C-washers. If the clearance is not as specified, select the proper thrust lock washer. Standard play: 0.1 -4.3mm {O.OO4--O.Ol2 in) Thrust lock washer thickness: 6.2mm (0.244 in), 6.4mm (0.252 in}, 6.5mm (0.256 in), 6.6mm (0.260 in} 5. lnstall the retaining ring. Mainshaft rear bearing 1. lnstall the rnainshaft rear bearing by using the SST, and fully seat it against the front C-washers. 2. lnstall the original C-washers and hold them with the retaining ring. 3. lnstall the washer and new snap ring. u 4. If the C-washers do not fit into the rear mainshaft groove, select the proper thickness C-washers. 5. Verify that both C-washers at one position are the same thickness. 6. With points @ through 0 pressed tightly together, mea- sure the clearance between the washer and snap ring. If the clearance is not as specified, select the proper C- washers. Standard play: 0-0.lmm (0-4.004 in) C-washer thickness: 2.9mm (0.114 in), 3.0mm (0,118 in), 3.1 mm (0.1 22 in), 3.2mm (0.1 26 in) Countershaft rear bearing lnstall the countershaft rear bearing onto the counter- shaft by using the SST. Gartner Banana