1994 MAZDA MX-5 transmission

J TRANSMISSION Thrust lock washer 1. lnstall the synchronizer ring and 5th gear. 2. Insert the steel ball and thrust lock washer. 3. lnstall only the two 3.0mm I0.118 in) thick C-washers in the front mainshaft groove. 4. Push the C-washers fully toward 5th gear and measure the clearance between the thrust lock washer and C-washers. If the clearance is not as specified, select the proper thrust lock washer. Standard play: 0.1 -4.3mm {O.OO4--O.Ol2 in) Thrust lock washer thickness: 6.2mm (0.244 in), 6.4mm (0.252 in}, 6.5mm (0.256 in), 6.6mm (0.260 in} 5. lnstall the retaining ring. Mainshaft rear bearing 1. lnstall the rnainshaft rear bearing by using the SST, and fully seat it against the front C-washers. 2. lnstall the original C-washers and hold them with the retaining ring. 3. lnstall the washer and new snap ring. u 4. If the C-washers do not fit into the rear mainshaft groove, select the proper thickness C-washers. 5. Verify that both C-washers at one position are the same thickness. 6. With points @ through 0 pressed tightly together, mea- sure the clearance between the washer and snap ring. If the clearance is not as specified, select the proper C- washers. Standard play: 0-0.lmm (0-4.004 in) C-washer thickness: 2.9mm (0.114 in), 3.0mm (0,118 in), 3.1 mm (0.1 22 in), 3.2mm (0.1 26 in) Countershaft rear bearing lnstall the countershaft rear bearing onto the counter- shaft by using the SST. Gartner Banana

TRANSMISSION J & BEARING HOUSING Locknut (Countershaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Connect the SST to the mainshaft and secure it in a vise. 3. Install a new locknut and tighten it. Tightening torque: 128-1 96 N.m (13-20 kgf-m, 95--144 ft-lbf) 4. Use a chisel to stake the locknut. Gartner Banana

J TRANSMISSION Shift Fork and Shift Rod Parts Assemble in the order shown in the figure, referring to Assembly Note. 1. Spring and ball 13. Cap plug .............. Assembly Note page J-39 14. Roll pin .............. 2. 5thlReverse shift fork Assembly Note page J-40 .............. Assembly Note page J-39 15. Spring 3. 5thlReverse shift rod Assembly Note .............. page J-40 Assembly Note .............. page J-39 16. Spacer .............. 4. Interlock pin Assembly Note page J-40 .............. Assembly Note page J-39 17. Clip 5. 1 stl2nd shift fork Assembly Note .............. page J-40 Assembly Note .............. page J-40 18. Clip 6. 3rdl4th shift fork Assembly Note .............. page J-40 .............. Assembly Note page J-40 19. Clip .............. 7. Interlock pin Assembly Note page J-40 8. 3rdl4th shift rod 20. Intermediate housing Assembly Note .............. page J-40 Assembly Note .............. page J-41 9. Interlock pin 21. SthlReverse shift rod end Assembly Note .............. page J-40 22. 3rdl4th shift rod end 10. 1 stl2nd shift rod 23. 1 stl2nd shift rod end d 11. Ball and spring 24. Roll pin 12. Washer Assembly Note .............. page J-41 Gartner Banana

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