1994 MAZDA MX-5 Workshop Manual

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

TRANSMISSION J Mainshaft Parts Disassemble in the order shown in the figure, referring to Disassembly Note. 1. 1st gear 10. Synchronizer assembly (2nd) Inspection ................... page J-23 lnspection ................... page J-24 2. Bearing 11. Inner cone Inspection ................... page J-25 12. Double cone 3. Bearing race 13. 2nd synchronizer ring 4. 1st synchronizer ring Inspection ................... page J-24 Inspection ................... page J-24 14. 2nd gear 5. Snap ring Inspection ................... page J-23 6. Clutch hub assembly (3rdl4th) 15. Mainshaft Disassembly Note ............ page J-20 Inspection ................... page J-23 Inspection ................... page J-23 16. Synchronizer key springs 7. 3rd synchronizer ring 17. Clutch hub sleeve Inspection ................... page J-24 18. Synchronizer key 8. 3rd gear 19. Clutch hub ................... u Inspection page J-23 9. Clutch hub assembly (1 stl2nd) Disassembly Note ............ page J-20 Inspection ................... page J-23 Gartner Banana

J TRANSMISSION Disassembly note 3rdl4th clutch hub assembly 1. Position the SST between 2nd and 3rd gears, and hold the mainshaft from underneath. 4 2. Press the mainshaft out of the clutch hub assembly (3rdl4th) and 3rd gear. 1 st12nd clutch hub assembly Hold the mainshaft, and press the lstJ2nd clutch hub assembly, 2nd synchronizer assembly, and 2nd gear from the mainshaft. Bearing Housing Assembly Disassemble in the order shown in the figure, referring to Disassembly Note. 1 . Bearing cover 6. Mainshaft front bearing 2. Washer Disassembly Note ............ page J-21 3. Reverse idler gear Inspection ................... page J-25 Inspection ................... page J-24 7. Adjustment shim 4. Washer 8. Countershaft center bearing 5. Reverse idler gear shaft Disassembly Note ............ page J-21 - Disassembly Note ............ page J-21 Inspection ................... page J-25 Inspection ................... page J-24 9. Adjustment shim 10. Bearing housing Gartner Banana

TRANSMISSION J Disassembly not Reverse idler gear shaft 1. Remove the reverse idler gear shaft installation bolt. 2. Support the reverse idler gear shaft, and press it from the bearing housing. Mainshaft front bearing Support the mainshaft front bearing, and press it out from the bearing housing by using a suitable pipe. Outer diameter of pipe: 70.0mm (2.76 in} Countershaft center bearing Note If countershaft center bearing is replaced, replace the spacer also. Support the countershaft center bearing, and press it out from the bearing housing by using a suitable pipe. Outer diameter of pipe: 50.0mm (1.97 in} Gartner Banana

J TRANSMISSION Extension Housing Parts Disassemble in the order shown in the figure. REPLACE 1. Steel ball, spring, and spring cap 8. Change bushing 2. Select-lock spindle, spring, and spring cap 9. Wave washer 3. Plug, spring, and pushpin 10. Change control case 4. Blind cover 11. Rod cover 5. Roll pin 12. Oil passage 6. Control rod 13. Oil seal 7. Control rod end Do not remove unless necessary Gartner Banana