1994 MAZDA MX-5 service

CLUTCH UNIT H 97-1 02 {O&-10.5,71-75.9) 18--26 {I .6-2.7,14-19) (MORI WHITE TA No.2 OR EQUIVALENT ORGANIC MOLYBDENUM GREASE) 1. Clutch release cylinder 2. Transmission Service ..................... section J 3. Boot 4. Clutch release collar Inspection ................. page H-17 5. Clutch release fork 6. Clutch cover Removal Note ............. page H-16 Inspection ................. page H-17 Installation Note ........... page H-17 7. Clutch disc Removal Note ............. page H-16 Inspection ................. page H-17 Installation Note ........... page H-17 8. Pilot bearing Inspection ................. page H-18 Removal Note ............. page H-16 Installation Note ........... page H-16 9. Flywheel Removal Note ............. page H-16 Inspection ................. page H-18 Installation Note ........... page H-16 Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . MANUAL TRANSMISSION INDEX ....................................... J- 2 ..................................... OUTLINE J- 3 SPECIFICATIONS ........................... J- 3 ........................ STRUCTURAL VIEW J- 4 ............................. COMPONENTS J- 5 ............................. POWER FLOW J- 6 TROUBLESHOOTING GUIDE .................. J- 7 .......................... TRANSMISSION OIL J- 8 ............................... INSPECTION J- 8 ............................ REPLACEMENT J- 8 TRANSMISSION .............................. J- 9 ............................. PREPARATION J- 9 REMOVAL .................................. J-10 DISASSEMBLY ............................. J-13 ............................... INSPECTION 5-23 ASSEMBLY ................................. J-26 INSTALLATION ............................. J-45 25UOJX-011 Gartner Banana

J INDEX INDEX OIL SPECIFICATION API SERVICE GL-4 OR GL-5 ALL-SEASON TYPE: SAE 75W-90 ABOVE 10°C {50°F): SAE 80W-90 CAPACITY. 2.0 L {2.1 US qt, 1.8 Imp qt} 1. Transmission Removal . . . . . . . . . . . . . . . . . . . . page J-10 Disassembly . . . . . . . . . . . . . . . . page J-13 Inspection . . . . . . . . . . . . . . . . . . . page J-23 Assembly . . . . . . . . . . . . . . . . . . . page J-26 Installation . . . . . . . . . . . . . . . . . . page J-45 Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Transmission Item M15M-D Synchronization mechanism Forward: Synchromesh Reverse: Synchromesh Shift type Gear ratio I st 2nd 5-speed, floor shift 3.1 36 1.888 5th Reverse 0.81 4 3.758 API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 Grade ' Capacity L {US qt, Imp qt} Viscosity 2.0 12.1, 1.8) All-season Above 10°C {50°F) 45UOJX401 Gartner Banana

J TRANSMISSION OIL TRANSMISSION OIL INSPECTION 1. Remove check plug 0. u 2. Verify that the oil is at the bottom of the check plug hole. If it is low, add the specified oil from check plug @. 3. Wipe the plug clean and apply sealant to the plug threads before installing. Tightening torque @: 25--39 N.m (2.5--4.0 kgf.m, 19-28 ft4bf) REPLACEMENT 1. Remove plugs @I (with washer) and @. 2. Drain the oil into a suitable container. 3. Wipe all plugs clean. 4. Install drain plug @I (with new washer). Tightening torque @: 40-58 N.m (4.0-4.0 kgf.m, 2943 ftlbf) 5. Add the specified oil from check plug 0 port until the level reaches the bottom of check plug hole. Specified oil: API service GL-4 or GL-5 All-season: SAE 75W-90 Above 10°C (50°F): SAE 80W-90 Capacity: 2.0 L (2.1 US qt, 1.8 Imp qt) 6. Apply sealant to threads of plug 0. 7. lnstall plug @. Tightening torque @: 25--39 N.m (2.54.0 kgf.m, 19-28 ft-lbf) Gartner Banana

J TRANSMISSION REMOVAL 1. Obtain the code number and deactivate the audio antitheft system before disconnecting the battery. (Refer to section T.) 2. is connect the negative battery cable. 3. On level grand, jack up the vehicle and support it evenly on safety stands. 4. Drain the transmission oil into a suitable container. 5. Remove in the order shown in the figure, referring to Removal Note. I. Shift lever knob ?. Rear console 9. Clutch release cylinder 10. Starter I 1 3. Shift lever 11. speedometer cable 4. Undercover 12. Power plant frame (PPF) 5. Performance rod Removal Note ............... page J-1 1 6. Differential mounting pipe 13. Transmission 7. Exhaust pipe J Removal Note ............... page J-12 8. Propeller shaft Service ...................... section L Gartner Banana

TRANSMISSION J INSTALLATION 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Install in the order shown in the figure, referring to lnstallation Note. L 3. Add the specified amount of the specified transmission oil. (Refer to page J-8.) 4. Warm up the engine and transmission, and inspect for oil leakage and transmission problems. 1. Transmission 7. Exhaust pipe Installation Note ............. page J-46 8. Performance rod 2. Power plant frame (PPF) 9. Differential mounting pipe Installation Note ............. page J-46 10. Undercover 3. S~eedometer cable 11. Shift lever w 4. ~iarter Installation Note ............. page J-47 5. Clutch release cylinder 12. Rear console 6. Propeller shaft 13. Shift lever knob Service ...................... section L Gartner Banana

TRANSMISSION J 9. Install the power plant frame bracket. Tightening torque @ : lO4--123 N.m (1 0.6-1 2.6 kgf.m, 76.7-91.1 ft-lbf) @: 37-43 N.m (3.7-5.5 kgf-m, 27-39 ftlbf) 10. Remove the jack, and connect the wire harness. 11. Measure distance A with a straightedge and vernier cali- pers. Distance A: 66.0 2 5mm (2.60 a 0.197 in) 12. If the distance is not within specification, reposition the PPF to the transmission. FRONT Shift lever 1. Pour the specified amount of oil into the change control case. The change control case must also be filled with the specified amount of oil whenever the extension housing has been removed or the transmission has been overhauled. Specified oil Grade: API service GL-4 or GL-5 All season: SAE 75W-90 Above 10°C (50°F): SAE 80W-90 Specified amount: 80-95 cc (4.9-5.8 cu in) 2. Apply oil to the shift lever as shown. 3. Apply sealant to the contact surfaces of the boot panel and the change control case. Gartner Banana