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Home › Mazda › 1983 › B2000 Base › Repair and Diagnosis › Transmission › Manual Trans › M/T - Overhaul - RWD › Transaxle Reassembly

Transaxle Reassembly

  1. Install countershaft and mainshaft rear bearings into bearing plate and check clearance between bearing plate bore and bearing height. If clearance exceeds .004" (0.1 mm), replace adjusting shim. Using arbor press, install countershaft and mainshaft assembly into bearing plate.
  2. Install bearing cover and reverse idler gear shaft. On 4-speed models, install reverse gear with key onto mainshaft and chamfer on teeth of gear facing rearward. Secure mainshaft with holding tool and install and tighten lock nut using wrench.
  3. Bend over lock washer tab. Install countershaft reverse gear and snap ring. On 5-speed models, install thrust washer, reverse idler gear, thrust washer and snap ring on reverse idler shaft. Check clearance between thrust washer and snap ring using feeler gauge.
  4. If clearance exceeds .004-.012" (0.1-0.3 mm), replace thrust washer. Thrust washers are available in .106" (2.6 mm), .110" (2.8 mm) and .118" (3.0 mm) sizes. On all models, install counter reverse gear and spacer (5-speed only) on countershaft.
  5. On 5-speed models, install thrust washer, reverse gear, needle bearing and sleeve on rear end of mainshaft. Install 5th-Reverse clutch hub and sleeve and NEW lock nut on mainshaft. Engage clutch sleeves into 1st and reverse gear to lock mainshaft assembly. Tighten mainshaft lock nut using wrench and caulk lock nut.
  6. Install synchronizer ring, 5th gear, counter 5th gear, thrust washer, lock ball and snap ring to rear end of mainshaft.
  7. Check clearance between 5th gear thrust washer and snap ring using feeler gauge. If clearance exceeds .004-.012" (0.1-0.3 mm), replace thrust washer. Thrust washers are available in .252" (6.4 mm), .256" (6.5 mm), .260" (6.6 mm), and .264" (6.7 mm) sizes. Install mainshaft rear bearing using wrench tool.
  8. Install bearing, adjusting washer and snap ring. Check clearance between mainshaft adjusting washer and snap ring using feeler gauge. If clearance exceeds .004" (0.1 mm), replace adjusting washer. Adjusting washers are available in .075" (1.9 mm), .079" (2.0 mm), .083" (2.1 mm) and .087" (2.2 mm) sizes.
  9. Install countershaft rear bearing using bearing installer tool. Install countershaft thrust washer and snap ring. Check clearance between thrust washer and snap ring using feeler gauge. If clearance exceeds .004" (0.1 mm), replace thrust washer. Thrust washers are available in .079" (2.0), .083" (2.1 mm), .087" (2.2 mm), .091" (2.3 mm) and .094" (2.4 mm) sizes.
  10. On all models, install reverse shift spring and locking ball into bearing plate. Push ball down using screwdriver and install reverse shift rod, shift fork and reverse idler gear (4-speed only) at same time. Install washer and snap ring (5-speed only). See Fig 1 .
    Fig 1: Assembled View of Reverse Shift Fork and Shift Rod Assemblies
    G00309815Courtesy of MAZDA MOTORS CORP.
  11. Install 1st-2nd and 3rd-4th shift forks onto clutch sleeves. Using guide tools, install each shift fork rod and interlock pin. Align bolt holes in both shift forks and rods. Install and tighten lock bolts. Install snap rings onto shift rods (5-speed only).
    NOTE: On 4-speed, make sure that spacer is installed in position on reverse shift fork rod.
  12. Install shift locking balls and springs into respective bores in bearing plate. Install and tighten spring cap bolts. On 4-speed models, apply thin coat of sealer on contact surfaces of bearing plate and transmission case and assemble.
  13. On 5-speed models, apply thin coat of sealer on contact surfaces of bearing plate and intermediate housing and assemble. Install shift rod ends to shift rods and install and tighten bolts. On all models, install speedometer drive gear, lock ball and snap ring on mainshaft.
  14. On 5-speed models, apply thin coat of sealer on contact surfaces of bearing plate and transmission case, and assemble. On all models, install input shaft bearing, using bearing installer tool, and install snap ring. Install countershaft front bearing, using bearing installer tool. See Fig 2 .
    Fig 2: Locating Front Bearing Shim
    G93H24429Courtesy of MAZDA MOTORS CORP.
  15. Install speedometer driven gear assembly, lock plate and bolt into extension housing and tighten bolt. Install control lever through holes from front side of extension housing. Install control lever end, control lever and tighten bolt. Install back-up light switch, top switch and overdrive switch. See Fig 3 .
    Fig 3: Exploded View of 4-Speed Transmission Shift Control Linkage
    G00309816Courtesy of MAZDA MOTORS CORP.
  16. Apply thin coat of sealer on contact surfaces of bearing plate/intermediate housing and extension housing and assemble with control lever positioned to the left as far as possible. Install and tighten bolts, making sure control rod operates properly. Install gearshift lever retainer and gasket to extension housing.
  17. Lubricate lip of oil seal inside front cover and install front cover to transmission case. Check clearance between bearing outer race and front cover using feeler gauge. If clearance exceeds .004" (0.1 mm), replace adjusting shim. Adjusting shims are available in .006" (1.5 mm) and .012" (.30 mm) sizes.
  18. On GLC models, install throw-out bearing, spring, release lever, cross-shaft and cross-shaft bolt and tighten bolt. On all other models, install throw-out bearing, clutch release fork and dust cover.
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