1994 MAZDA MX-5 Workshop Manual

TROUBLESHOOTING GUIDE J TROUBLESHOOTING GUIDE Problem ~bnormal noise lumps out of gear libration Possible Cause nsufficient oil leterioration of oil quality Norn bearing Norn contact surface of countershaft gear Norn contact surface of gears Excessive gear backlash larnaged gear teeth nsufficient oil leterioration of oil quality Worn synchronizer ring Worn synchronizer cone of gear Poor contact of synchronizer ring and gear cone Excessive longitudinal play of gears Worn bearing Improper disengagement of clutch Weak detent ball spring Worn shift fork Worn clutch hub Worn clutch hub sleeve Worn gears Excessive gear backlash Worn bearing Incorrect installation or looseness of power plant frame Action 4dd oil 3eplace with specified )il qeplace 4dd oil 3eplace with specified ~il Replace Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Replace Correct or tighten Page 5-8 J-8 J-9 J-16 5-1 6,19,20 J-16,19,20 J-16,19,20 J-8 J-8 J-16,19 J-16,19 J-16, 19 J-l6,19,20 J-9 section H J-15 J-15 J-16,19 J-16,19 J-16, 19,20 J-l6,19,20 J-9 J-45 35UOJX-O( 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

TRANSMISSION J TRANSMISSION 49 0839 425C Puller set, bearing For removal of bearing For installation of bearing Installer, bearing For removal of clutch hub assembly For holding mainshaft Puller, fan pulley boss Holder, mainshaft For removal of locknut 49 0862 350 Guide, shift fork / For installation of interlock pin Wrench, mainshaft locknut 49 HOl7 101 Hook For removal of bearing 49 071 0 520 Puller, bearing For removal of bearing For removal of transmission case For installation of bearing Pusher, main drive shaft \-4 I Installer, bearing 49 F401 330B Installer set, bearing For installation of bearing For installation of spring and ball Guide, interlock <-- pin For installation of clutch hub assembly 49 8025 OAO Installer, oil seal For installation of dust seal For installation of oil seal 49 6025 001 Body (Part of 49 6025 OAO) For installation of oil seal Handle (Part of 49 8025 OAO) 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 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