Disassembly Note

CAUTION:

When pressing off components, hold the shaft so that it does not fall.

Fig 1: Measuring Output Shaft Clearances

Courtesy of MAZDA MOTORS CORP.

Measure the output shaft clearances.
1. Measure the clearance between first gear and the differential drive gear.
2. Measure the clearance between second gear and secondary third gear.
Fig 2: Pressing Off Bearing (Fourth Gear End)
Courtesy of MAZDA MOTORS CORP.
Using the special tools and press, press off the bearing (fourth gear end).

Fig 3: Pressing Off Fourth Speed Gear
Courtesy of MAZDA MOTORS CORP.
Using the special tools and a press, press off the fourth speed gear.

Fig 4: Removing Snap Ring
Courtesy of MAZDA MOTORS CORP.
Remove the snap ring.

Fig 5: Pressing Off Third Speed Gear & Second Gear
Courtesy of MAZDA MOTORS CORP.
Using the special tools and a press, press off the third speed gear and second gear.

Fig 6: Removing Synchronizer Blocking Ring
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
Remove the synchronizer blocking ring.

Fig 7: Removing Snap Ring
Courtesy of MAZDA MOTORS CORP.
Remove the snap ring.

Fig 8: Inspecting Synchronizer Components For Wear & Damage
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
NOTE:
- Inspect all the synchronizer components for wear and damage. Refer to SYNCHRONIZERS .
Using the special tools and a press, press off the synchronizer hub, synchronizer blocking ring, and first gear.

Fig 9: Pressing Off Bearing (First Gear End)
Courtesy of MAZDA MOTORS CORP.
Using the special tools and a press, press off the bearing (first gear end).

Fig 10: Measuring Output Shaft Gear Runout
Courtesy of MAZDA MOTORS CORP.
Measure output shaft gear runout.
1. Inspect the output shaft for worn or damaged gears.
2. Inspect the output shaft for clogged oil passage.
Fig 11: Inspecting Synchronizer Blocking Ring
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Set the synchronizer ring squarely in the gear, then measure around the circumference.
Inspect the synchronizer blocking ring.
1. Measure the clearance from the side of the gear.
2. Inspect for smooth engagement with the gear.
3. Inspect for worn or damaged teeth or tapered surface.
Inspect the synchronizer hub.
1. Inspect for worn or damaged splines, synchronizer insert groove or end surface.
2. Inspect for smooth hub sleeve movement when it is installed.
Fig 12: Measuring Clearance Between First/Second Synchronizer Hub & Shift Fork
Courtesy of MAZDA MOTORS CORP.
Measure the clearance between the first/second synchronizer hub and its shift fork.