Mazda Transaxle A65M–R. Manual — part 7

MANUAL TRANSAXLE

J–9

J

End Of Sie

PRIMARY SHAFT COMPONENTS DISASSEMBLY

AME511217201M02

1. Disassemble in the order shown in the figure.

.

AME5112M095

1

Primary shaft rear bearing adjust shim

2

Oil channel

3

Primary shaft rear bearing
(See

J–10 Primary Shaft Rear Bearing Disassembly

Note

)

4

Snap ring

5

Primary shaft bearing spacer
(See

J–10 Primary Shaft Bearing Spacer and 5th

Gear Stopper Disassembly Note

)

6

5th gear stopper

7

5th clutch hub set
(See

J–10 5th Clutch Hub Set, 5th Synchronizer

Ring and 5th Gear Disassembly Note

)

8

5th synchronizer ring

9

5th gear

10

5th needle bearing

11

5th bushing
(See

J–10 5th Bushing, Thrust Washer, 4th Gear,

4th Needle Bearing, 4th Bushing, 4th Synchronizer
Ring, 3rd/4th Clutch Hub Set, 3rd Synchronizer Ring
and 3rd Gear Disassembly Note

)

12

Thrust washer

13

4th gear

14

4th needle bearing

15

4th bushing

16

4th synchronizer ring

17

3rd/4th clutch hub set

18

3rd synchronizer ring

19

3rd gear

20

3rd needle bearing

21

Primary shaft

22

Primary shaft front bearing
(See

J–11 Primary Shaft Front Bearing Disassembly

Note

)

23

Synchronizer key spring (5th)

24

5th synchronizer key

25

5th clutch hub and sleeve

26

3rd/4th synchronizer key

27

3rd/4th clutch hub and sleeve

28

Synchronizer key spring (3rd/4th)

J–10

MANUAL TRANSAXLE

Primary Shaft Rear Bearing Disassembly Note

1. Remove the bearing using the SSTs.

Primary Shaft Bearing Spacer and 5th Gear Stopper Disassembly Note

1. Remove the primary shaft bearing spacer and 5th

gear stopper at the same time using the SSTs.

5th Clutch Hub Set, 5th Synchronizer Ring and 5th Gear Disassembly Note

1. Remove the 5th clutch hub set, 5th synchronizer

ring and 5th gear at the same time using the
SSTs.

5th Bushing, Thrust Washer, 4th Gear, 4th Needle Bearing, 4th Bushing, 4th Synchronizer Ring, 3rd/4th

Clutch Hub Set, 3rd Synchronizer Ring and 3rd Gear Disassembly Note

1. Remove the 5th bushing, thrust washer, 4th gear,

4th needle bearing, 4th bushing, 4th synchronizer
ring, 3rd/4th clutch hub set, 3rd synchronizer ring
and 3rd gear at the same time using the SSTs.

AME5112M103

AME5112M106

AME5112M108

AME5112M109

MANUAL TRANSAXLE

J–11

J

Primary Shaft Front Bearing Disassembly Note

1. Remove the primary shaft front bearing using the

SST.

End Of Sie

PRIMARY SHAFT COMPONENTS INSPECTION

AME511217201M03

Primary Shaft and Gear Inspection

1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.

•

If there is malfunction, replace the shaft.

2. Inspect the gears for damage, abnormal wear,

dents, flaking, or bending.

•

If there is malfunction, replace the gear.

3. Inspect the oil passage for clogging.

•

If there is malfunction, replace the shaft.

Synchronizer Ring and Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve, clutch hub, and

synchronizer key contact surface for damage and
abnormal wear.

•

If there is malfunction, replace the part where
necessary.

2. Verify that the clutch hub sleeve and clutch hub

for move smoothly.

•

If there is malfunction, replace parts as
necessary.

3. Inspect the synchronizer ring teeth and grooves

for damage, abnormal wear, and cracks.

•

If there is malfunction, replace the
synchronizer ring.

4. Inspect the tapered surface for abnormal wear

and cracks.

•

If there is malfunction, replace parts as
necessary.

AME5112M107

AME5112M044

AME5112M045

AME5112M046

J–12

MANUAL TRANSAXLE

5. Measure the clearance between the synchronizer

ring and the flank surface of the gear.

•

If not as specified, replace the synchronizer
ring.

Note

•

Set the synchronizer ring squarely in the
gear; then measure around the
circumference.

Standard clearance

3rd: 0.90—1.45 mm {0.035—0.057 in}
4th: 0.90—1.45 mm {0.035—0.057 in}
5th: 0.95—1.40 mm {0.037—0.055 in}

Minimum clearance

0.70 mm {0.028 in}

Bearing Inspection

1. Inspect the ball and the ball contact surface for damage and abnormal wear.

•

If there is malfunction, replace the bearing.

2. Verify that the bearing to rotates smoothly.

•

If there is malfunction, replace the bearing.

End Of Sie

AME5112M070

AME5112M072