lock MAZDA MX-5 1994 Manual PDF

CLUTCHPEDAL H Minimum disengagement height: 68mm (2.68 in) (With carpet) CLUTCHPEDAL ADJUSTMENT Height lnspection 1. Measure the distance from the upper surface of the ped- al pad to the carpet. Pedal height: 175--185mm (6.89-7.28 in) (With carpet) 2. If necessary, adjust the height. Adjustment 1. Disconnect the clutch switch connector. 2. Loosen locknut @ and turn clutch switch @I until the height is correct. I 3. Tighten locknut @. Tightening torque: l3.Cl7.6 N-m (1 4Gl8O kgf-cm, 122-1 56 in-IM) 4. After adjustment, inspect the free play. Free Play lnspection 1. Depress the clutch pedal by hand until clutch resistance is felt. Free play: 0.6-3.lmm (0.02-0.12 in) Total free play: S13mm (0.20-0.51 in) 2. If necessary, adjust the free play. Adjustment 1. Loosen locknut 0 and turn push rod 03 until free play is correct. 2. Verify that the disengagement height as measured from the upper surface of the pedal pad to the carpet is correct when the pedal is fully depressed. 3. Tighten locknut 0. Tightening torque: 11 .&l6.6 N.m (120-1 70 kgtcm, 105--147 in.lbf} 4. After adjustment, inspect the height. Gartner Banana

H CLUTCH PEDAL REMOVAL I INSPECTION I INSTALLATION 1. Remove in the order shown in the figure, referring to Removal Note. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to lnstallation Note. 45UOHX-00 1. Spring 7. Push rod Removal Note .............. page H-7 Inspect for damage and bending Installation Note ............ page H-7 8. Nut 2. Nut and lock washer 9. Clip 3. Bolt 1 0. Wave washer 4. Spacer 11. Pin 5. Clutch pedal 12. Spacer 6. Bushing 13. Stop 14. Pedal pad Gartner Banana

TRANSMISSION J TRANSMISSION 49 0839 425C Puller set, bearing For removal of bearing For installation of bearing Installer, bearing For removal of clutch hub assembly For holding mainshaft Puller, fan pulley boss Holder, mainshaft For removal of locknut 49 0862 350 Guide, shift fork / For installation of interlock pin Wrench, mainshaft locknut 49 HOl7 101 Hook For removal of bearing 49 071 0 520 Puller, bearing For removal of bearing For removal of transmission case For installation of bearing Pusher, main drive shaft \-4 I Installer, bearing 49 F401 330B Installer set, bearing For installation of bearing For installation of spring and ball Guide, interlock <-- pin For installation of clutch hub assembly 49 8025 OAO Installer, oil seal For installation of dust seal For installation of oil seal 49 6025 001 Body (Part of 49 6025 OAO) For installation of oil seal Handle (Part of 49 8025 OAO) Gartner Banana

TRANSMISSION J Removal note Power plant frame (PPF) 1. Disconnect the wire harness from the PPF. 2. Support the transmission with a jack. 3. Remove the PPF bracket. DIFFERENTIAT MOUNTING SPACER BOLT BOLT (MI 4 x 1.5) d1 SLEEVE BLOCK 35UOJX-031 4. Remove the differential-side bolts, and pry out the spacer. 5. Remove the differential mounting spacer. 6. Screw a long bolt (MI 4 x 1.5) into the sleeve. 7. Twist and pull the bolt and sleeve downward. 8. Install a bolt (M6 x 1) into the hole in the block to keep the sleeve from turning, and unscrew the long bolt (MI4 x 1.5). 9. Remove the bolt (M6x 1). Gartner Banana

TRANSMISSION J Shift Fork and Shift Rod Parts Disassemble in the order shown in the figure, referring to Disassembly Note. I 'v 45uOJx-010 1. Roll pin 15. Interlock pin 2. 1 sV2nd shift rod end 16. 3rdl4th shift fork 3. 3rd14th shift rod end Inspection ................... page J-24 4. 5thlReverse shift rod end 17. 1 st12nd shift fork 5. Intermediate housing Inspection ................... page J-24 Inspection ................... page J-25 18. Interlock pin 6. Roll pin 19. Clip 7. Cap plug Disassembly Note ................ below 8. Washer 20. Spacer 9. Spring and ball 21. Spring Inspection ................... page J-25 Inspection ................... page J-25 10. Clip 22. 5thIReverse shift rod 11. 1 st/2nd shift rod 23. 5thiReverse shift fork 12. Interlock pin Inspection ................... page J-24 13. Clip 24. Spring and ball 14. 3rdl4th shift rod Inspection ................... page J-25 Disassembly note Clip Remove the clip, spacer, and spring from the 5th/ Reverse shift rod. Gartner Banana

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

J TRANSMISSION Extension Housing Parts Disassemble in the order shown in the figure. REPLACE 1. Steel ball, spring, and spring cap 8. Change bushing 2. Select-lock spindle, spring, and spring cap 9. Wave washer 3. Plug, spring, and pushpin 10. Change control case 4. Blind cover 11. Rod cover 5. Roll pin 12. Oil passage 6. Control rod 13. Oil seal 7. Control rod end Do not remove unless necessary Gartner Banana

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