1994 MAZDA MX-5 key

ON-VEHICLE MAINTENANCE B Steps After Installation 1. Connect the neaative batterv cable. Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. Installation Note Oil seal 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly with a pipe and a hammer until it is flush with the edge of the oil pump body. Note Oil seal outer diameter: 50.5mm (1.99 in} Oil seal inner diameter: 36.5mm (1.44 in} Timing belt pulley 1. Install the timing belt pulley. 2. Install the pulley woodruff key with the tapered side to- ward the oil pump body. 2. Start the enginsand check, and if necessary, adjust the ignition timing. 3. Connect the negative battery cable. 4. Start the engine and check follows: (1) Engine coolant leakage (2) Ignition timing (Refer to page B-9.) 5. Recheck the engine coolant levels. Gartner Banana

B ASSEMBLY TIMING MARK Timing Belt Pulley 1. lnstall the timing belt pulley. 2. lnstall the pulley woodruff key with the tapered side to- ward the oil pump body. d Idler lnstall the idler. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ftlbf) Tensioner and Tensioner Spring 1. lnstall the tensioner and the tensioner spring. 2. Temporarily secure the tensioner with the spring fully ex- tended. Timing Belt 1, Turn the crankshaft and align the timing belt pulley mark with the timing mark. Do not turn the crankshaft counter- clockwise. 2. Verify that the camshaft pulley marks are aligned with the seal plate marks. E for intake side and I for exhaust side. Do not turn the crankshaft counterclockwise. 3. lnstall the timing belt so that there is no looseness at the idler side or between the two camshaft pulleys. 4. lnstall the pulley boss and pulley lock bolt. 5. Turn the crankshaft two turns clockwise, and align the timing belt pulley mark with the timing mark. Do not turn the crankshaft counterclockwise. 6. Verify that the camshaft pulley marks are aligned with the seal plate marks. J If not aligned, remove the timing belt and repeat from tensioner installation. 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

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

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 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 Mainshaft Parts Assemble in the order shown in the figure, referring to Assembly Note. WPPLY SPEwim OIL To IwiviDwL PmTs 45UOJX-034 Clutch hub Synchronizer key Clutch hub sleeve Synchronizer key springs Mainshaft 2nd gear Assembly Note .............. page J-32 2nd synchronizer ring Double cone Inner cone Synchronizer assembly (2nd) Clutch hub assembly (Istf2nd) Assembly Note .............. page J-32 3rd gear Assembly Note .............. page J-32 3rd synchronizer ring Clutch hub assembly (3rdl4th) Assembly Note .............. page J-32 Snap ring Assembly Note .............. page J-32 1 st synchronizer ring Bearing race Assembly Note .............. page J-32 Bearing Assembly Note .............. page J-32 1 st gear Assembly Note .............. page J-32 5-31 Gartner Banana

TRANSMISSION 1. Clutch hub 2. Synchronizer key 3. Clutch hub sleeve b 4. Synchronizer key springs 5. 4th synchronizer ring 6. Bearing 7. Main drive gear 8. Bearing housing assembly 9. Washer 10. Mainshaft gear assembly Assembly Note .................. below 1 1 . Spacer 12. Countershaft .................. Assembly Note below 13. Counter reverse gear 14. Washer 15. Bearing race 16. Bearing 17. Reverse gear 18. Reverse synchronizer ring 19. Clutch hub assembly (5thlReverse) 20. Locknut (Mainshaft) .................. Assembly Note below 21. 5th synchro-niter ring 22. 5th gear 23. Steel ball 24. Thrust lock washer .............. Assembly Note page J-36 25. C-washer .............. Assembly Note page J-36 26. Retaining ring .............. Assembly Note page J-36 27. Spacer 28. Counter 5th gear 29. Mainshaft rear bearing .............. Assembly Note page J-36 30. C-washer .............. Assembly Note page J-36 31. Retaining ring .............. Assembly Note page J-36 32. Washer .............. Assembly Note page J-36 33. Snap ring 34. Countershaft rear bearing .............. Assembly Note page J-36 35. Locknut (Countershaft) .............. Assembly Note page J-37 45UOJX437 Assembly note Mainshaft and countershaft 1. Place the mainshaft gear assembly and the countershaft on the bearing housing. 2. Use a suitable bar to press in the countershaft. Locknut (Mainshaft) 1. Secure the bearing housing assembly in a vise. 2. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 3. Install a new locknut and tighten it by using the SST. Tightening torque: 128-235 N.m (13-24 kgf.m, 95-173 ftdbf) 4. Use a chisel to stake the locknut. Gartner Banana