clutch MAZDA MX-5 1994 Repair Manual

TRANSMISSION 1. Snap ring 2. Washer 3. Retaining ring b 4. C-washer 5. Mainshaft rear bearing Disassembly Note . below Inspection ... page J-25 6. Retaining ring 7. C-washer 8. Thrust lock washer 9. Steel ball 10. Locknut (Countershaft) Disassembly Note ................ below 11. Countershaft rear bearing Disassembly Note ........... page J-18 Inspection ... page J-25 12. Counter 5th gear Inspection ... page J-23 13. Spacer 14. 5th gear 15. 5th synchronizer ring Inspection ... page J-24 16. Locknut (Mainshaft) Disassembly Note ........... page J-18 17. Clutch hub assembly (5thIReverse) Inspection ... page J-23 18. Reverse synchronizer ring Inspection ... page J-24 19. Reverse gear Inspection ... page J-23 20. Bearing Inspection ... page J-25 21. Bearing race 22. Washer 23. Counter reverse gear Inspection ... page J-23 24. Main drive gear bearing Disassembly Note ........... page J-18 Inspection ... page J-25 26. Countershaft front bearing Disassembly Note ........... page J-18 Inspection ... page J-25 27. Bearing housing assembly Disassembly Note ........... page J-18 Disassembly page J-20 28. Mainshaft gear assembly 29. Main drive gear Inspection ... page J-23 30. 4th synchronizer ring Inspection ... page J-24 31. Bearing Inspection ... page J-25 32. Washer 33. Countershaft Inspection ... page J-23 34. Spacer 35. Synchronizer key springs 36. Clutch hub sleeve 37. Synchronizer key . . Inspection ... page J-23 25. Snap ring 38. Clutch hub 45UOJX-012 Disassembly note Mainshaft rear bearing Remove the mainshaft rear bearing by using the SST. Locknut (Countershaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Use a suitable tool to uncrimp the tabs of the locknut. 3. Connect the SST to the mainshaft and secure it in a vise. 4. Remove the locknut. Gartner Banana

J TRANSMISSION Countershaft rear bearing Remove the countershaft rear bearing by using the SST. i/ Locknut (Mainshaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Use a suitable tool to uncrimp the tabs of the locknut. 3. Secure the bearing housing in a vise. 4. Remove the locknut by using the SST. Main drive gear bearing Remove the main drive gear bearing with a suitable pipe. u Outer diameter of pipe: 70.0mm (2.76 in) Countershaft front bearing Remove the countershaft front bearing by using the SST. Bearing housing assembly Remove the bearing housing by lightly tapping the coun- tershaft with a copper hammer. Gartner Banana

TRANSMISSION J Mainshaft Parts Disassemble in the order shown in the figure, referring to Disassembly Note. 1. 1st gear 10. Synchronizer assembly (2nd) Inspection ................... page J-23 lnspection ................... page J-24 2. Bearing 11. Inner cone Inspection ................... page J-25 12. Double cone 3. Bearing race 13. 2nd synchronizer ring 4. 1st synchronizer ring Inspection ................... page J-24 Inspection ................... page J-24 14. 2nd gear 5. Snap ring Inspection ................... page J-23 6. Clutch hub assembly (3rdl4th) 15. Mainshaft Disassembly Note ............ page J-20 Inspection ................... page J-23 Inspection ................... page J-23 16. Synchronizer key springs 7. 3rd synchronizer ring 17. Clutch hub sleeve Inspection ................... page J-24 18. Synchronizer key 8. 3rd gear 19. Clutch hub ................... u Inspection page J-23 9. Clutch hub assembly (1 stl2nd) Disassembly Note ............ page J-20 Inspection ................... page J-23 Gartner Banana

J TRANSMISSION Disassembly note 3rdl4th clutch hub assembly 1. Position the SST between 2nd and 3rd gears, and hold the mainshaft from underneath. 4 2. Press the mainshaft out of the clutch hub assembly (3rdl4th) and 3rd gear. 1 st12nd clutch hub assembly Hold the mainshaft, and press the lstJ2nd clutch hub assembly, 2nd synchronizer assembly, and 2nd gear from the mainshaft. Bearing Housing Assembly Disassemble in the order shown in the figure, referring to Disassembly Note. 1 . Bearing cover 6. Mainshaft front bearing 2. Washer Disassembly Note ............ page J-21 3. Reverse idler gear Inspection ................... page J-25 Inspection ................... page J-24 7. Adjustment shim 4. Washer 8. Countershaft center bearing 5. Reverse idler gear shaft Disassembly Note ............ page J-21 - Disassembly Note ............ page J-21 Inspection ................... page J-25 Inspection ................... page J-24 9. Adjustment shim 10. Bearing housing Gartner Banana

TRANSMISSION J INSPECTION lnspect all parts and repair or replace as necessary. Each Gear and Main Drive Gear 1, lnspect synchronizer cones for wear. 2. lnspect individual gear teeth for damage, wear, and cracks. 3. lnspect synchronizer ring matching teeth for damage and wear. 4. lnspect main drive gear splines for damage and wear. MEASUREMENT POINTS 35UOJX-046 Mainshaft 1. Measure the mainshaft runout as shown. Maximum runout: 0.03mm (0.0012 in} 2. lnspect splines for damage or wear. 3. Measure the clearance between mainshaft and gear (or bushing). Maximum clearance: 0.15mm (0.006 in} Countershaft 1. lnspect gear teeth for damage, wear, and cracks. 2. lnspect splines for damage and wear. Clutch Hub Assembly 1. lnspect clutch hub sleeve and hub operation. 2. lnspect individual gear teeth for damage, wear, and cracks. 3. lnspect synchronizer keys for damage, wear, and cracks. Gartner Banana

J TRANSMISSION ASSEMBLY Precaution 1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit. 2. Before assembly, make sure all parts are completely clean. 4 3. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil. 35UOJX-053 (5TH) (REVERSE) (~RD, 4TH) (1 ST, 2ND) 45UOJX-029 Clutch hub For the synchronizer assemblies, align the synchronizer ring grooves and synchronizer keys. The synchronizer rings can be distinguished as shown in the figure. The inner diametes of the 2nd synchronizer ring is larger than the 1 st. When installing the gears and clutch hub assemblies in the following procedure, make sure that they are installed in the direction shown in the figure. 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 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

TRANSMISSION J & BEARING HOUSING Locknut (Countershaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Connect the SST to the mainshaft and secure it in a vise. 3. Install a new locknut and tighten it. Tightening torque: 128-1 96 N.m (13-20 kgf-m, 95--144 ft-lbf) 4. Use a chisel to stake the locknut. Gartner Banana