Mazda Transaxle A65M–R. Manual — part 9
MANUAL TRANSAXLE
J–17
J
5th Clutch Hub Set Assembly Note
Note
•
Align the synchronizer ring grooves with the synchronizer key during assembly.
1. Install the 5th clutch hub set using the SSTs.
Primary Shaft Bearing Spacer Assembly Note
1. Install the primary shaft bearing spacer using the
SSTs.
Snap Ring Assembly Note
1. Install a new snap ring to the primary shaft.
2. Measure the clearance between the snap ring
and the primary shaft bearing spacer.
•
If it is not within the specification, adjust it by
selecting a proper snap ring from below.
Clearance
0.0—0.1 mm {0.0000—0.0039 in}
Snap ring size
AME5112M117
AME5112M118
Thickness (mm {in})
1.71 {0.067}
2.01 {0.079}
1.76 {0.069}
2.06 {0.081}
1.81 {0.071}
2.11 {0.083}
1.86 {0.073}
2.16 {0.085}
1.91 {0.075}
2.21 {0.087}
1.96 {0.077}
2.26 {0.089}
AME5112M053
J–18
MANUAL TRANSAXLE
Primary Shaft Rear Bearing Assembly Note
1. Place the primary shaft rear bearing with the brown side facing toward the 5th gear.
2. Install the primary shaft rear bearing using the
SSTs.
Primary Shaft Front Bearing Assembly Note
1. Install the primary shaft front bearing using the
SSTs.
2. Inspect the 3rd gear and 5th gear thrust
clearance and 4th gear end play. (See
PRIMARY SHAFT COMPONENTS
PREINSPECTION
.)
End Of Sie
SECONDARY SHAFT COMPONENTS PREINSPECTION
AME511217301M01
1st Gear End Play
1. Set up the secondary shaft component, and fix it.
2. Slide the 1st gear up and down, and measure the length of the movement.
•
If not as specified, assemble the secondary shaft component again.
Length of the movement
0.20—0.30 mm {0.0078—0.0118 in}
2nd Gear End Play
1. Set up the secondary shaft component, and fix it.
2. Slide the 2nd gear up and down, and measure the length of the movement.
•
If not as specified, assemble the secondary shaft component again.
Length of the movement
0.06—0.16 mm {0.0024—0.0063 in}
End Of Sie
AME5112M119
AME5112M120
AME5112M094
MANUAL TRANSAXLE
J–19
J
SECONDARY SHAFT COMPONENTS DISASSEMBLY
AME511217301M02
1. Disassemble in the order shown in the figure.
.
AME5112M096
1
Secondary shaft rear bearing adjust shim
2
Snap ring
3
Snap ring
4
C ring holder
5
Secondary shaft C ring
6
Secondary shaft rear bearing
(See
J–20 Secondary Shaft Rear Bearing
)
7
Snap ring
8
5th gear
(See
J–20 4th Gear and 5th Gear Disassembly
9
4th gear
10
4th gear adjustment shim
11
3rd/4th secondary shaft spacer
12
3rd gear
(See
J–20 3rd Gear, 2nd Gear, 2nd Needle Bearing,
13
2nd gear
14
2nd needle bearing
15
2nd bushing
16
2nd inner synchronizer component
17
1st/2nd clutch hub set
18
1st inner synchronizer component
19
1st needle bearing
20
1st bushing
21
1st gear
22
Reverse main gear
23
Secondary shaft
24
Synchronizer key spring
25
1st/2nd synchronizer key
26
1st/2nd clutch hub and sleeve
J–20
MANUAL TRANSAXLE
Secondary Shaft Rear Bearing Disassembly Note
1. Remove the secondary shaft rear bearing using
the SSTs.
4th Gear and 5th Gear Disassembly Note
1. Remove the 4th gear and 5th gear at the same
time using the SSTs.
3rd Gear, 2nd Gear, 2nd Needle Bearing, 2nd Bushing, 2nd Inner Synchronizer Component, 1st/2nd Clutch
Hub Set, 1st Inner Synchronizer Component, 1st Needle Bearing, 1st Bushing, 1st Gear and Reverse
Main Gear Disassembly Note
1. Remove the 3rd gear, 2nd gear, 2nd needle
bearing, 2nd bushing, 2nd inner synchronizer
component, 1st/2nd clutch hub set, 1st inner
synchronizer component, 1st needle bearing, 1st
bushing, 1st gear and reverse main gear at the
same time using the SST.
End Of Sie
SECONDARY SHAFT COMPONENTS INSPECTION
AME511217301M03
Secondary 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.
AME5112M113
AME5112M111
AME5112M112
AME5112M058
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