1994 MAZDA MX-5 transmission

TRANSMISSION J Removal note Power plant frame (PPF) 1. Disconnect the wire harness from the PPF. 2. Support the transmission with a jack. 3. Remove the PPF bracket. DIFFERENTIAT MOUNTING SPACER BOLT BOLT (MI 4 x 1.5) d1 SLEEVE BLOCK 35UOJX-031 4. Remove the differential-side bolts, and pry out the spacer. 5. Remove the differential mounting spacer. 6. Screw a long bolt (MI 4 x 1.5) into the sleeve. 7. Twist and pull the bolt and sleeve downward. 8. Install a bolt (M6 x 1) into the hole in the block to keep the sleeve from turning, and unscrew the long bolt (MI4 x 1.5). 9. Remove the bolt (M6x 1). Gartner Banana

J TRANSMISSION Caution Removing the PPF spacers will reduce the perfor- mance of the PPF. If the spacers are removed, replace the PPF as an assembly. 10. Remove the transmission-side bolts, and remove the PPF. Transmission 1. Support the transmission with a transmission jack. 2. Loosen the transmission installation bolts. Caution Shaking the transmission could damage the crank angle sensor on the engine. When remov- ing the transmission, do not shake it up and down or side to side. 3. Remove the transmission. 45uOJx-007 Gartner Banana

TRANSMISSION J DISASSEMBLY Precaution : 1. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvent before disassembly. b Warning Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. 2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and check that there are no obstructions. Housing Components Note The front and rear oil seals do not need to be removed unless you are replacing them. Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Clutch release collar 2. Clutch release fork 3. Boot 4. Front cover 12. Extension housing Disassembly Note ............ page J-14 Disassembly ................ page J-22 13. Transmission case 5. Gasket Disassembly Note ............ pane J-14 6. Oil seal (front) lnspect for damage of oil seal lip. If necessary, replace it. 7. Adjustment shim 8. Snap ring 9. Speedometer driven gear 10. Neutral switch 11. Back-up light switch . - 14. Snap rings 15. Speedometer drive gear 16. Steel ball 17. Oil seal (rear) lnspect for damage of oil seal lip If necessary, replace it. On-vehicle replacement ....... page J-14 Gartner Banana

J TRANSMISSION Disassembly note Extension housing Turn the extension housing to remove it. Transmission case Remove the transmission case from the intermediate housing and gear assembly by using the SST. On-vehicle replacement Oil seal (rear) 1. Raise the vehicle and support it with safety stands. 2. Remove the propeller shaft. (Refer to section L.) 3. Remove the oil seal from the extension housing. 4. Apply the specified oil to a new oil seal. 5. Install the new oil seal by using the SST. 6. Install the propeller shaft. (Refer to section L.) 7. Inspect the oil level. (Refer to page J-8.) Gartner Banana

TRANSMISSION J Shift Fork and Shift Rod Parts Disassemble in the order shown in the figure, referring to Disassembly Note. I 'v 45uOJx-010 1. Roll pin 15. Interlock pin 2. 1 sV2nd shift rod end 16. 3rdl4th shift fork 3. 3rd14th shift rod end Inspection ................... page J-24 4. 5thlReverse shift rod end 17. 1 st12nd shift fork 5. Intermediate housing Inspection ................... page J-24 Inspection ................... page J-25 18. Interlock pin 6. Roll pin 19. Clip 7. Cap plug Disassembly Note ................ below 8. Washer 20. Spacer 9. Spring and ball 21. Spring Inspection ................... page J-25 Inspection ................... page J-25 10. Clip 22. 5thIReverse shift rod 11. 1 st/2nd shift rod 23. 5thiReverse shift fork 12. Interlock pin Inspection ................... page J-24 13. Clip 24. Spring and ball 14. 3rdl4th shift rod Inspection ................... page J-25 Disassembly note Clip Remove the clip, spacer, and spring from the 5th/ Reverse shift rod. Gartner Banana

J TRANSMISSION Mainshaft and Countershaft Parts Disassemble in the order shown in the figure, referring to Disassembly Note. Gartner Banana

TRANSMISSION 1. Snap ring 2. Washer 3. Retaining ring b 4. C-washer 5. Mainshaft rear bearing Disassembly Note . below Inspection ... page J-25 6. Retaining ring 7. C-washer 8. Thrust lock washer 9. Steel ball 10. Locknut (Countershaft) Disassembly Note ................ below 11. Countershaft rear bearing Disassembly Note ........... page J-18 Inspection ... page J-25 12. Counter 5th gear Inspection ... page J-23 13. Spacer 14. 5th gear 15. 5th synchronizer ring Inspection ... page J-24 16. Locknut (Mainshaft) Disassembly Note ........... page J-18 17. Clutch hub assembly (5thIReverse) Inspection ... page J-23 18. Reverse synchronizer ring Inspection ... page J-24 19. Reverse gear Inspection ... page J-23 20. Bearing Inspection ... page J-25 21. Bearing race 22. Washer 23. Counter reverse gear Inspection ... page J-23 24. Main drive gear bearing Disassembly Note ........... page J-18 Inspection ... page J-25 26. Countershaft front bearing Disassembly Note ........... page J-18 Inspection ... page J-25 27. Bearing housing assembly Disassembly Note ........... page J-18 Disassembly page J-20 28. Mainshaft gear assembly 29. Main drive gear Inspection ... page J-23 30. 4th synchronizer ring Inspection ... page J-24 31. Bearing Inspection ... page J-25 32. Washer 33. Countershaft Inspection ... page J-23 34. Spacer 35. Synchronizer key springs 36. Clutch hub sleeve 37. Synchronizer key . . Inspection ... page J-23 25. Snap ring 38. Clutch hub 45UOJX-012 Disassembly note Mainshaft rear bearing Remove the mainshaft rear bearing by using the SST. Locknut (Countershaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Use a suitable tool to uncrimp the tabs of the locknut. 3. Connect the SST to the mainshaft and secure it in a vise. 4. Remove the locknut. Gartner Banana

J TRANSMISSION Countershaft rear bearing Remove the countershaft rear bearing by using the SST. i/ Locknut (Mainshaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Use a suitable tool to uncrimp the tabs of the locknut. 3. Secure the bearing housing in a vise. 4. Remove the locknut by using the SST. Main drive gear bearing Remove the main drive gear bearing with a suitable pipe. u Outer diameter of pipe: 70.0mm (2.76 in) Countershaft front bearing Remove the countershaft front bearing by using the SST. Bearing housing assembly Remove the bearing housing by lightly tapping the coun- tershaft with a copper hammer. Gartner Banana