Mazda Transaxle A65M–R. Manual — part 6

MANUAL TRANSAXLE

J–5

J

Disassembly Procedure

1. Remove the drain plug and the filler cap.
2. Remove the neutral switch and reverse switch.
3. Remove the shift check bolt and stopper bolt.
4. Remove the shift control component.

5. Remove the check plugs, check springs, check

balls, and shift check sleeve as shown in the
figure.

6. Remove the transaxle case installation bolt.
7. Remove the bore plug using screwdriver.
8. Stretch the snap ring of the secondary shaft rear

bearing at the bore plug hole, and remove the
transaxle case.

9. Remove the baffle plate and the oil pass.

10. Remove the snap ring, secondary shaft adjust

shim, primary shaft rear bearing adjust shim from
the transaxle case.

11. Remove the differential side bearing outer race

(transaxle case side) using the SST, and remove
the adjust shim.

AME5112M098

AME5112M142

AME5112M007

AME5112M101

J–6

MANUAL TRANSAXLE

12. Remove the welt plug using a fit stick.
13. Remove the differential oil seal (transaxle case

side) using a screwdriver.

14. Remove the magnet from clutch housing.
15. Shift to 5th gear.

16. Remove the reverse lever component bracket

bolt.

17. Lift the reverse lever component, and remove it.
18. Remove the reverse fork rod.
19. Remove the reverse shift fork.

20. Shift 3rd/4th fork rod to the 3rd gear, and remove

the retaining pin of 5th shift fork using a pin
punch.

21. Remove the C ring of the 5th/reverse bracket.
22. Remove the 5th/reverse fork rod, and remove the

5th shift fork and 5th/reverse bracket.

23. Remove the check balls and the interlock pin from

the clutch housing.

24. Remove the retaining pin of 3rd/4th fork rod

bracket using a pin punch.

25. Remove the two C rings of the 3rd/4th shift fork.
26. Remove the 3rd/4th fork rod, and remove the 3rd/

4th shift fork and 3rd/4th bracket.

27. Remove the shift check sleeve from the clutch

housing.

AME5112M008

AME5112M009

AME5112M010

AME5112M011

AME5112M012

MANUAL TRANSAXLE

J–7

J

28. Remove the retaining pin of 1st/2nd shift fork

using a pin punch.

29. Remove the 1st/2nd fork rod and 1st/2nd bracket

at a time.

30. Remove the 1st/2nd shift fork.
31. Remove the retaining pin of the 1st/2nd bracket

using a pin punch, and remove the 1st/2nd
bracket from the 1st/2nd fork rod.

32. Remove each gear component.

(1) Tap the primary shaft using a plastic hammer.

Caution

••••

The oil channel in the clutch housing can
be damaged when removing the
secondary shaft component. Remove the
secondary shaft component to right
above.

(2) Remove the primary shaft component,

secondary shaft component, and reverse idler
gear component at the same time.

(3) Remove the differential.

33. Remove the secondary shaft bearing retainer.

Warning

••••

Using a heat gun can will cause the
clutch housing to heat up greatly. To
prevent burns wear gloves whenever
using a heat gun.

Caution

••••

The clutch housing will be damaged if
heated above 120

°°°°

C. Heat the clutch

housing below 120

°°°°

C.

Note

•

If the secondary shaft front bearing can’t be removed easily, heat the clutch housing to about 100

В°

C using

a heat gun and remove it.

34. Remove the secondary shaft front bearing using a

screwdriver.

35. Remove the oil channel of the secondary shaft.
36. Remove the differential oil seal (clutch housing

side) using a screwdriver.

Warning

••••

Using a heat gun will cause the clutch
housing to heat up greatly. To prevent
burns wear gloves whenever using a heat
gun.

Caution

••••

The clutch housing will be damaged if
heated above 120

°°°°

C. Heat the clutch housing below 120

°°°°

C.

Note

•

If the differential side bearing outer race can’t be removed easily, heat the clutch housing to about 100

В°

C

using a heat gun and remove it.

AME5112M013

AME5112M014

AME5112M015

AME5112M074

J–8

MANUAL TRANSAXLE

37. Remove the differential side bearing outer race

using the SST.

38. Remove the primary shaft oil seal using a

screwdriver.

End Of Sie

PRIMARY SHAFT COMPONENTS PREINSPECTION

AME511217201M01

3rd Gear Thrust Clearance

1. Measure the clearance between the 3rd gear and 2nd gear.

•

If not as specified, assemble the primary shaft component again.

Clearance

0.18—0.31 mm {0.0071—0.0122 in}

5th Gear Thrust Clearance

1. Measure the clearance between 4th thrust washer and the 5th gear.

•

If not as specified, assemble the primary shaft component again.

Clearance

0.06—0.16 mm {0.0024—0.0063 in}

4th Gear End Play

1. Remove the primary shaft rear bearing.
2. Set up the primary shaft component, and fix it.
3. Slide the 4th gear up and down, and measure the length of the movement.

•

If not as specified, assemble the primary shaft component again.

Length of the movement

0.20—0.30 mm {0.0078—0.0118 in}

AME5112M102

AME5112M016

AME5112M093