1994 MAZDA MX-5 Workshop Manual

TRANSMISSION J Assembly note Spring and ball 1. Insert the spring and ball (SthIReverse) into the bearing housing. 2. Press down the spring and ball (5thlReverse) by using the SST and a screwdriver, and install the shift rod. Shift fork and rod Install the SthIReverse shift fork and 5thJReverse shift rod into the bearing housing. Interlock pin 1. Position the interlock pin into the bearing housing by using the SST. 2. Verify that the interlock pin is correctly installed. Gartner Banana

J TRANSMISSION CLUTCH SLEEVE SYNCHRONIZER KEY Shift fork and rod, interlock pin 1. Set the 1 stf2nd shift fork onto the 1 sV2nd clutch hub assembly. 2. Install the 3rdI4th shift fork and 3rdl4th shift rod, and ii install the interlock pin into the bearing housing as shown in the interlock pin assembly note. (Refer to page J-39.) Roll pin Install a new roll pin into each shift fork. The roll pin must be installed with the split facing as shown. Spring, spacer, clip 1. Slide the spring and spacer onto the 5thlReverse shift rod. While pressing the spacer, install a new clip. 2. Install new clips to the 3rdl4th shift rod and 1 sV2nd shift rod. 3. Verify that the centers of the shift fork and clutch hub sleeve are aligned properly< If they are not, select the proper washer to install between 1st gear and the mainshaft front bearing, and between reverse gear and the mainshaft front bearing. Gartner Banana

TRANSMISSION J 4. The following washer thicknesses are available. The total thickness of the front and rear washers should be 5.9--6.0mm I0.232--0.236 in). Washer thickness: 2.2mm (0.087 in), 2.7mm 10.106 in) 3.0mm (0.118 in), 3.2mm (0.126 in) 3.7mm (0.146 in) Intermediate housing 1. Apply sealant to the contact surfaces of the intermediate housing and bearing housing. 2. Mount the intermediate housing to the bearing housing by tapping it lightly with a plastic hammer. Roll pin Install a new roll pin into each shift rod end. The roll pin must be installed with the split facing forward. Gartner Banana

J TRANSMISSION Housing Components 1. Assemble in the order shown in the figure, referring to Assembly Note. 2. Check the gearshift lever operation. - Gartner Banana

TRANSMISSION J 1. Oil seal Assembly Note .................. below 2. Snap ring u 3. Steel ball 4. Speedometer drive gear 5. Snap ring 6. Transmission case 7. Extension housing Assembly Note .................. below 8. Main drive gear bearing Assembly Note .................. below 9. Snap ring 10. Countershaft front bearing Assembly Note .............. page J-44 11. Snap ring 12. Adjustment shim Assembly Note .............. page J-44 13. Gasket 14. Front cover 15. Speedometer driven gear 16. Neutral switch 17. Back-up light switch 18. Boot 19. Clutch release fork Assembly Note .............. page J-44 20. Clutch release collar Assembly Note .............. page J-44 35UOJX-020 Assembly note Oil seal 1. Apply transmission oil to the outer periphery. 2. lnstall a new oil seal with the SST. Extension housing 1. Apply sealant to the contact surfaces of the bearing housing and transmission case. 2. Align the inner shift lever and shift rod end groove, and install the extension housing. 3. Apply sealant to the bolt threads, and install the bolts. Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, l4--19 ft4bf) Main drive gear bearing Install the main drive gear bearing by using the SST, and secure it with a new snap ring. Gartner Banana

J TRANSMISSION TRANSMISSION CASE SNAP RING Countershaft front bearing Install the countershaft front bearing by using the SST, and secure it with a new snap ring. d Adjustment shim After measuring dimensions (A) and (B) shown in the fig- ure, use an adjustment shim(s), as specified below, of the thickness corresponding to the value of (A) minus (B), so that bearing end play will be within specification. Bearing end play: 04.lmm (0-0.004 in) Adjustment shim thickness: 0.lOmm (0.004 in), 0.15mm (0.006 in), 0.30mm (0.012 in) Clutch release fork 1. Apply Mori White TA No.2 or equivalent organic rnolyb- denum grease to the shaded areas of the clutch release collar and release fork. 2. Install the clutch release collar and clutch release fork. Gartner Banana

TRANSMISSION J INSTALLATION 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Install in the order shown in the figure, referring to lnstallation Note. L 3. Add the specified amount of the specified transmission oil. (Refer to page J-8.) 4. Warm up the engine and transmission, and inspect for oil leakage and transmission problems. 1. Transmission 7. Exhaust pipe Installation Note ............. page J-46 8. Performance rod 2. Power plant frame (PPF) 9. Differential mounting pipe Installation Note ............. page J-46 10. Undercover 3. S~eedometer cable 11. Shift lever w 4. ~iarter Installation Note ............. page J-47 5. Clutch release cylinder 12. Rear console 6. Propeller shaft 13. Shift lever knob Service ...................... section L Gartner Banana

J TRANSMISSION -=DIFFERENTIAL MOUNTING SPACER 45UOJX-054 Installation note Transmission 1. Tilt the engine by pushing up on the front of the oil pan with a wooden block and a transmission jack. d 2. Support the transmission with a transmission jack. 3. Raise the transmission into place and install and tighten the installation bolts. Tightening torque: 64-89 N-m (6.5--9.1 kgf-m, 48-65 ft.lbf) Power plant frame (PPF) 1. Install the differential mounting spacer. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) 2. Support the transmission with a jack so that it is level. 3. Position the PPF and tighten the transmission-side bolts by hand. 4. Verify that the sleeve is installed into the block. 5. Install the spacer and reamer bolts in the forward hole, then hand tighten them. 6. Snugly install the power plant frame bracket. 7. Tighten the transmission-side bolts. Tightening torque: 104-123 N-m (10.S12.6 kgf.m, 76.7-91.1 ft.lbf) 8. Tighten the differential-side bolts. Tightening torque: 104-1 23 N-m (1 0.S12.6 kgf.m, 76.7-91.1 ft-lbf) Gartner Banana