1994 MAZDA MX-5 Workshop Manual

TRANSMISSION J INSPECTION lnspect all parts and repair or replace as necessary. Each Gear and Main Drive Gear 1, lnspect synchronizer cones for wear. 2. lnspect individual gear teeth for damage, wear, and cracks. 3. lnspect synchronizer ring matching teeth for damage and wear. 4. lnspect main drive gear splines for damage and wear. MEASUREMENT POINTS 35UOJX-046 Mainshaft 1. Measure the mainshaft runout as shown. Maximum runout: 0.03mm (0.0012 in} 2. lnspect splines for damage or wear. 3. Measure the clearance between mainshaft and gear (or bushing). Maximum clearance: 0.15mm (0.006 in} Countershaft 1. lnspect gear teeth for damage, wear, and cracks. 2. lnspect splines for damage and wear. Clutch Hub Assembly 1. lnspect clutch hub sleeve and hub operation. 2. lnspect individual gear teeth for damage, wear, and cracks. 3. lnspect synchronizer keys for damage, wear, and cracks. Gartner Banana

J TRANSMISSION 4. Measure the clearance between the hub sleeve and shift fork. Standard clearance: 0.2--0.3mm (0.008--0.012 in) ii Maximum: 0.5mm (0.020 in) Synchronizer Ring (Ist, 3rd, 4th, 5th and Reverse) 1. lnspect individual synchronizer ring teeth for wear and cracks. 2. lnspect the tapered surface for wear and cracks. 3. Set the synchronizer ring squarely in the gear. 4. Measure the clearance between the synchronizer ring and flank surface of gear all around the circumference. Standard clearance: 1.5mm (0.059 in) Minimum: 0.8mm (0.032 in) Synchronizer Assembly (2nd) 1. lnspect individual synchronizer ring gear teeth for dam- age, wear, and cracks. Replace the synchronizer assembly if any such damage is found. 2. lnspect for wear and damage to the tapered surfaces of the inner cone, double cone, and synchronizer ring. Replace the synchronizer assembly if any such damage is found. Set the synchronizer ring squarely in the gear. Measure the clearance between the synchronizer ring and the flank surface of gear all around the circumfer- ence. Clearance: 1.5 mm (0.059 in) Minimum: 0.8 mm (0.031 in) Gartner Banana

TRANSMISSION J Bearing Inspect for damage and rough rotation. Reverse Idler Gear and Shaft 1. Inspect gear teeth for wear and cracks. 2. Measure the clearance between the reverse idler gear b~~shing and shaft. Standard clearance: 0.02-0.05mm {0.000&-0.0020 in) Maximum: 0.15mm (0.006 in) Springs Measure the free length of the springs. Standard free length Shift rod (Sth/Reverse) spring: 75mm (2.953 in) Detent ball spring (lst/2nd, 3rdI4th): 22.5mm (0.886 in) Detent ball spring (Sth/Reverse): 17.0mm (0.669 in) Intermediate housing Measure the intermediate housing pin height. Standard height: 9.0-10.0mm (0.354-0.394 in) Gartner Banana

J TRANSMISSION ASSEMBLY Precaution 1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit. 2. Before assembly, make sure all parts are completely clean. 4 3. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil. 35UOJX-053 (5TH) (REVERSE) (~RD, 4TH) (1 ST, 2ND) 45UOJX-029 Clutch hub For the synchronizer assemblies, align the synchronizer ring grooves and synchronizer keys. The synchronizer rings can be distinguished as shown in the figure. The inner diametes of the 2nd synchronizer ring is larger than the 1 st. When installing the gears and clutch hub assemblies in the following procedure, make sure that they are installed in the direction shown in the figure. Gartner Banana

TRANSMISSION J Extension Housing Parts Assemble in the order shown in the figure, referring to Assembly Note. 1. Oil seal 8. Control rod end Assembly Note .............. page 5-28 9. Roll pin 2. Oil passage Assembly Note .............. page J-28 3. Rod cover 10. Blind cover Assembly Note .............. page J-28 11. Plug, spring, and pushpin w 4. Change control case 12. Select-lock spindle, spring, and spring cap 5. Wave washer Assembly Note .............. page J-28 6. Change bushing 13. Steel ball, spring, and spring cap 7. Control rod Gartner Banana

J TRANSMISSION Assembly note Oil seal 1. Apply the specified oil to a new oil seal. 2. Install the new oil seal by using the SST. Rod cover 1. Apply transmission oil to the rubber bushings on the rod cover. 2. Install the rod cover with the mark facing forward. L I 35UOJX-058 Roll pin Install a new roll pin into the control rod end. The split in the roll pin must be facing in the direction shown in the figure. L I 45UOJX-031 Select-lock spindle, spring, and spring cap 1. Install the select-lock spindle, spring, and spring cap. Tightening torque: 7.9-10.7 Nm (80-11 0 kgfan, 70-95.4 in-lbf) 2. Push the select-lock spindle down by pushing on the control rod. This will ensure that the steel ball correctly engages the select-lock spindle. 45UOJX-032 Gartner Banana

TRANSMISSION J Bearing Housina Assemblv ~ssemble in t6e order sh6wn in the figure, referring to Assembly Note. 1. Bearing housing 6. Reverse idler gear shaft 2. Adjustment shim Assembly Note .............. page J-30 Assembly Note .............. page J-30 7. Washer 3. Countershaft center bearing 8. Reverse idler gear Assembly Note .................. below Assembly Note .............. page J-30 4. Adjustment shim 9. Washer Assembly Note .............. page J-30 10. Bearing cover 5. Mainshaft front bearing .. Assembly Note .............. page J-30 Assembly note Countershaft center bearing Press the countershaft center bearing into the bearing housing with a suitable pipe. Outer diameter of pipe: 50.0mm (1.97 in) 05UOJX-032 Gartner Banana

Bolt length (measured from below the head) @ : 28mm @I : 35mm Adjustment shim Measure the clearance between the countershaft center bearing and the bearing housing. If not within specification, adjust the clearance by instal- i, ling the correct adjustment shim(s). Standard clearance: 04.1 mm (0-4.004 in) Adjustment shim: O.lmm (0.004 in), 0.3mm (0.012 in) Mainshaft front bearing Press the mainshaft front bearing into the bearing hous- ing with a suitable pipe. Outer diameter of pipe: 70.0mm (2.76 in) Adjustment shim Measure the clearance between the mainshaft front bearing and the bearing housing. If not within specification, adjust the clearance by instal- ling the correct adjustment shim(s). Standard clearance: 0-4.1 mm (0--0.004 in) Adjustment shim: O.lmm (0.004 in), 0.15mm (0.006 in), 0.3mm (0.012 in) Reverse idler gear shaft 1. Press the reverse idler gear shaft into the bearing hous- ing. 2. Install and tighten the reverse idler gear shaft installation bolt. Tightening torque: 8.9-12.7 N.m (90-130 kgf.cm, 79-112 in4bf) Reverse idler gear 1. Install the reverse idler gear, end washer, and bearing cover. 2. Tighten the bearing cover installation bolts. Tightening torque @: 18-26 N.m (1.8-2.7 kgf-m, 14--19 ftlbf) @I: 37-53 N.m f3.7-5.5 kgf-m, 27-39 ft4bf) Gartner Banana