Mazda Transaxle G35M–R. Manual — part 6
MANUAL TRANSAXLE
J–5
J
Locknut Disassembly Note
1. Assemble the SST.
2. Lift the transaxle and mount it on the SST.
3. Lock the primary shaft with the SST.
4. Shift to 1st gear to lock the rotation of the primary
shaft.
5. Bend back the caulking of locknuts using a chisel.
6. Remove the locknuts from the primary and
secondary shafts.
Shift Fork and Shift Rod Component Disassembly Note
1. Aligh the ends of the interlock sleeve and of the
control lever (arrow). Turn the shift rod
counterclockwise.
2. While holding the 1st/2nd shift fork with one hand
and the 3rd/4th shift fork with the other, raise
them both at the same time and shift each of the
clutch hub sleeves.
17
Reverse idler shaft
18
Reverse idler gear
19
5th/reverse shift rod
20
5th/reverse shift rod end
21
Pin
22
Crank lever shaft
23
Crank lever component
24
Shift fork and shift rod component
(See
J–5 Shift Fork and Shift Rod Component
)
25
Push pin
26
Primary shaft gear component
27
Secondary shaft gear component
28
Differential component
29
Clutch housing
30
Synchronizer key springs
31
Clutch hub sleeve
32
Clutch hub
33
3rd/4th shift fork
34
Interlock sleeve
35
Control lever
36
1st/2nd shift fork
37
Control end
38
Control rod
A6E5112M108
Z4F5112M004
Z4F5112M005
J–6
MANUAL TRANSAXLE
3. Lift the control end and remove the steel, and at
the same time, remove the control rod from the
clutch housing.
4. Separate the shift rod and shift fork component
from each of the clutch hub sleeves.
End Of Sie
5TH/REVERSE GEAR AND HOUSING PARTS INSPECTION
A6E511201029M04
5th and Reverse Gear Inspection
1. Inspect the synchronizer cones for wear.
•
If there is malfunction, replace parts as necessary.
2. Inspect the gear teeth for damage, wear, and cracks.
•
If there is malfunction, replace parts as necessary.
3. Inspect the synchronizer ring matching teeth for damage and wear.
•
If there is malfunction, replace the synchronizer ring.
Synchronizer Ring Inspection
1. Inspect the synchronizer ring teeth for damage, wear, and cracks.
•
If there is malfunction, replace parts as necessary.
2. Inspect the tapered surface for wear and cracks.
•
If there is malfunction, replace parts as necessary.
3. 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
1.50 mm {0.059 in}
Minimum
0.80 mm {0.031 in}
Clutch Hub Component Inspection
1. Inspect the clutch hub sleeve and hub operation.
•
If there is malfunction, replace parts as necessary.
2. Inspect the gear teeth for damage, wear, and cracks.
•
If there is malfunction, replace parts as necessary.
3. Inspect the synchronizer keys for damage, wear, and cracks.
•
If there is malfunction, replace parts as necessary.
4. Measure the clearance between the hub sleeve
and shift fork.
•
If the clearance exceeds the maximum,
replace the hub sleeve and shift fork as a set.
Standard clearance
0.10—0.36 mm {0.004—0.014 in}
Maximum clearance
0.86 mm {0.034 in}
A6E5112M006
A6E5112M118
A6E5112M008
MANUAL TRANSAXLE
J–7
J
Reverse Idle Gear and Reverse Lever Inspection
1. Inspect the gear teeth for damage, wear, and cracks.
•
If there is malfunction, replace the reverse idle gear.
2. Measure the clearance between the reverse idle
gear bushing and the reverse lever.
•
If not as specified, replace as necessary.
Standard clearance
0.10—0.35 mm {0.004—0.013 in}
Maximum Clearance
0.85 mm {0.033 in}
5th Gear and Sleeve Inspection
1. Measure the clearance between the 5th gear and
the Sleeve.
•
If not as specified, replace parts as
necessary.
5th gear inner diameter
34.000—34.025 mm {1.3386—1.3395 in}
Sleeve outer diameter
33.945—33.970 mm {1.3365—1.3373 in}
Clearance
0.030—0.080 mm {0.0012—0.0031 in}
End Of Sie
A6E5112M009
Z4F5112M010
J–8
MANUAL TRANSAXLE
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY
A6E511217010M01
1. Disassemble in the order shown in the figure.
.
A6E5112M113
1
Bearing race (primary shaft)
2
Oil seal (primary shaft)
(See
J–9 Oil Seal (Primary Shaft) Disassembly
3
Bearing race (secondary shaft)
(See
J–9 Bearing Race (Secondary Shaft)
)
4
Funnel
5
Guide plate component
6
Sealing cap
7
Roll pin
(See
J–9 Roll Pin Disassembly Note
8
Control rod
(See
J–9 Control Rod Disassembly Note
)
9
Selector
10
Change arm
11
Bleather cover component
12
Bleather
13
Hole cover
14
Oil seal (differential)
(See
J–10 Oil Seal (Differential) Disassembly Note
)
15
Bearing race (differential)
(See
J–11 Bearing Race (Differential) Disassembly
16
Reverse lever shaft
17
Reverse lever
18
Drain plug and washer
19
Bearing race (transaxle case)
(See
J–11 Bearing Race (Transaxle Case)
20
Adjustment shim(s)
21
Bearing race (differential)
(See
J–11 Bearing Race (Differential) Disassembly
)
22
Adjustment shim(s)
23
Oil seal (differential)
(See
J–10 Oil Seal (Differential) Disassembly Note
24
Dowel pin
25
O-ring
26
Crank lever shaft
27
Clank component lever
28
Roll pin
29
Shift lever component
30
Key
31
Control end
32
Spring and washer
33
shift lever shaft
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