1994 MAZDA MX-5 Workshop Manual

H CLUTCH DISC, PILOT BEARING, FLYWHEEL 3. Measure the thickness of the lining at a rivet head on both sides with vernier calipers. Replace the clutch disc if less than minimum. Minimum thickness: 0.3mm (0.012 in) 4. Measure the clutch disc runout with a dial indicator. Replace the clutch disc if runout is excessive. Maximum runout: 0.7mm (0.028 in) PILOT BEARING INSPECTION Turn the bearing while applying force in the axial direc- tion. If the bearing sticks or has excessive resistance, replace it. FLYWHEEL INSPECTION 1. lnspect the contact surface for scoring, cracks, and burning. 2. Remove minor scoring or burning with emery paper. Repair if scoring or burning is major. Replace if cracked. 3. lnspect the ring gear teeth for wear or damage. If neces- sary, replace the ring gear as follows: (1) Heat the ring gear with a blow torch. Tap around the gear to remove it from the flywheel. (2) Heat the new ring gear to 250--300°C (482--572°F); then fit it onto the flywheel. Gartner Banana

FLYWHEEL H 4. Measure the flywheel runout with a dial indicator. Replace the flywheel if runout is excessive. Maximum runout: 0.2mm (0.008 in) 9MUOHX-048 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 OUTLINE STRUCTURAL VlEW 1. Main drive gear (4th gear) 2. 3rd gear 3. 2nd gear 4. 1 st gear 5. 5th gear 6. Countershaft VlEW &A 7. Counter 5th gear 8. Mainshaft 9. Reverse gear 10. Reverse idler gear 11. Counter reverse gear J-A Gartner Banana

OUTLINE J COMPONENTS 1. Front cover 6. 1 st12nd shift fork and rod 11. Countershaft 2. Transmission case 7. 3rdl4th shift fork and rod 12. 5th gear u 3. Intermediate housing 8. Mainshaft gear assembly 13. Reverse gear 4. Extension housing 9. Main drive gear 14. Counter 5th gear 5. 5thlReverse shift fork and 10. Bearing housing assembly 15. Counter reverse gear rod Gartner Banana

J OUTLINE POWER FLOW I REVERSE I Gartner Banana