Mazda Transaxle G35M–R. Manual — part 8
MANUAL TRANSAXLE
J–13
J
PRIMARY SHAFT COMPONENTS DISASSEMBLY
A6E511217201M02
1. Disassemble in the order shown in the figure.
.
Bearing (4th Gear End) Disassembly Note
1. Remove the bearing using the SST.
Z4F5112M023
1
Bearing (4th gear end)
(See
J–13 Bearing (4th Gear End) Disassembly
2
4th gear
3
4th synchronizer ring
4
Retaining ring
5
3rd/4th clutch hub component
(See
J–14 3rd/4th Clutch Hub Component, 3rd
Synchronizer Ring and 3rd Gear Disassembly Note
6
3rd synchronizer ring
(See
J–14 3rd/4th Clutch Hub Component, 3rd
Synchronizer Ring and 3rd Gear Disassembly Note
7
3rd gear
(See
J–14 3rd/4th Clutch Hub Component, 3rd
Synchronizer Ring and 3rd Gear Disassembly Note
8
Bearing (primary shaft end)
(See
J–14 Bearing (Primary Shaft End)
9
Primary shaft gear
10
Synchronizer key springs
11
3rd/4th clutch hub sleeve
12
Synchronizer keys
13
3rd/4th clutch hub
Z4F5112M024
J–14
MANUAL TRANSAXLE
3rd/4th Clutch Hub Component, 3rd Synchronizer Ring and 3rd Gear Disassembly Note
1. Remove the retaining ring.
2. Remove the 3rd/4th clutch hub component, 3rd
synchronizer ring, and 3rd gear using the SST.
Bearing (Primary Shaft End) Disassembly Note
1. Remove the bearing using the SST.
Caution
••••
Use protective plates in the vise to
prevent damage to the primary shaft
gear.
End Of Sie
PRIMARY SHAFT COMPONENTS INSPECTION
A6E511217201M03
4th Gear, 3rd 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.
4th Synchronizer Ring, 3rd 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}
Z4F5112M025
Z4F5112M026
A6E5112M027
MANUAL TRANSAXLE
J–15
J
3rd/4th 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 forks.
•
If the clearance exceeds the maximum,
replace the hub sleeve and shift fork as a set.
Standard
0.10—0.40 mm {0.004—0.015 in}
Maximum
0.90 mm {0.035 in}
Primary Shaft Gear Inspection
1. Inspect the gear contact surface for damage and wear.
•
If there is malfunction, replace the primary shaft.
2. Inspect the splines for damage and wear.
•
If there is malfunction, replace the primary shaft.
3. Inspect the gear teeth for damage, wear, and cracks.
•
If there is malfunction, replace the primary shaft.
4. Inspect the oil passage for clogging.
•
If there is malfunction, replace the primary shaft.
5. Measure the shaft gear runout.
•
If not as specified, replace the primary shaft.
Primary shaft runout
0.050 mm {0.0020 in} max.
6. Measure the clearance between the shaft gears
and the gears.
•
If not as specified, replace parts as
necessary.
End Of Sie
A6E5112M028
Gear
Shaft
(Outer dia.)
Gear
(Inner dia.)
Clearance
3rd
35.945—35.970
{1.415—1.416}
36.000—36.025
{1.417—1.418}
0.030—0.080
{0.001—0.003}
4th
30.945—30.970
{1.218—1.219}
31.000—31.025
{1.220—1.221}
Z4F5112M029
Z4F5112M030
J–16
MANUAL TRANSAXLE
PRIMARY SHAFT COMPONENTS ASSEMBLY
A6E511217201M04
1. Assemble in the order shown in the figure.
.
Z4F5112M031
1
3rd/4th clutch hub
(See
J–17 3rd/4th Clutch Hub Assembly Note
)
2
Synchronizer keys
3
3rd/4th clutch hub sleeve
4
Synchronizer key springs
5
Primary shaft gear
6
Bearing (primary shaft end)
(See
J–17 Bearing (Primary Shaft End) Assembly
7
3rd gear
(See
J–17 3rd Gear, 3rd Synchronizer Ring, and
3rd/4th Clutch Hub Component Assembly Note
8
3rd synchronizer ring
(See
J–17 3rd Gear, 3rd Synchronizer Ring, and
3rd/4th Clutch Hub Component Assembly Note
9
3rd/4th clutch hub component
(See
J–17 3rd Gear, 3rd Synchronizer Ring, and
3rd/4th Clutch Hub Component Assembly Note
10
Retaining ring
11
4th synchronizer ring
(See
J–18 4th Synchronizer Ring, 4th Gear, and
Bearing (4th Gear End) Assembly Note
)
12
4th gear
(See
J–18 4th Synchronizer Ring, 4th Gear, and
Bearing (4th Gear End) Assembly Note
)
13
Bearing (4th gear end)
(See
J–18 4th Synchronizer Ring, 4th Gear, and
Bearing (4th Gear End) Assembly Note
)
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