Mazda Transaxle A65M–R. Manual — part 5
J–1
J
J
OVERHAUL
MANUAL TRANSAXLE. . . . . . . . . . .. J-2
PRECAUTION. . . . . . . . . . . . . .. J-2
CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS DISASSEMBLY . . . . . .. J-3
PREINSPECTION. . . . . . . . . . . . J-8
DISASSEMBLY. . . . . . . . . . . . . J-9
INSPECTION . . . . . . . . . . . . .. J-11
ASSEMBLY. . . . . . . . . . . . . . J-13
PREINSPECTION. . . . . . . . . . ... J-18
DISASSEMBLY. . . . . . . . . . . ... J-19
INSPECTION . . . . . . . . . . . . .. J-20
ASSEMBLY. . . . . . . . . . . . . . J-24
REVERSE IDLER SHAFT COMPONENTS
DISASSEMBLY/ASSEMBLY . . . . . . .. J-30
REVERSE IDLER SHAFT COMPONENTS
INSPECTION . . . . . . . . . . . . .. J-31
DIFFERENTIAL PREINSPECTION . . . . ... J-32
DIFFERENTIAL DISASSEMBLY . . . . . ... J-32
DIFFERENTIAL ASSEMBLY . . . . . . . . J-33
PRIMARY SHAFT END PLAY ADJUSTMENT .. J-35
SECONDARY SHAFT END PLAY
ADJUSTMENT . . . . . . . . . . . . J-36
ADJUSTMENT . . . . . . . . . . . . J-37
DIFFERENTIAL SIDE BEARING PRELOAD
ADJUSTMENT . . . . . . . . . . . . J-38
J–2
MANUAL TRANSAXLE
PRECAUTION
AME511201029M09
1. Clean the transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
Warning
••••
Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
Caution
••••
Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
bearing.
2. Clean the removed parts using cleaning solvent, and dry them using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
4. Use a plastic hammer when disassembling the transaxle case and other light alloy metal parts.
5. Make sure each part is cleaned before assembling.
6. Coat all movable parts with the specified oil.
7. Replace parts whenever required.
8. Remove old sealant from contact surfaces before applying new sealant.
9. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transaxle with transaxle oil.
Warning
••••
Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle
to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold
the rotating handle firmly when turning the transaxle.
End Of Sie
MANUAL TRANSAXLE
MANUAL TRANSAXLE
J–3
J
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY
AME511217010M01
Disassembly Components
.
AME5112M004
1
Drain plug
2
Filler cap
3
Neutral switch
4
Reverse switch
5
Air-bleed plug
6
Bore plug
7
Welt plug
8
Baffle plate
9
Oil pass
10
Transaxle case
11
Pivot pin
12
Magnet
13
Differential oil seal
14
Knock pin
15
Dowel pin
16
Secondary shaft bearing retainer
17
Secondary shaft front bearing
18
Oil channel
19
Primary shaft oil seal
20
Clutch housing
J–4
MANUAL TRANSAXLE
.
AME5112M097
1
Stopper bolt
2
Shift check bolt
3
Shift control component
4
O ring
5
Rod bushing
6
Reverse lever component
7
Reverse fork rod
8
Cap
9
Reverse shift fork
10
Retaining pin
11
C ring
12
5th/Reverse fork rod
13
5th shift fork
14
5th/reverse bracket
15
Check plug (5th/reverse)
16
Check spring (5th/reverse)
17
Shift check sleeve (5th/reverse)
18
Check ball
19
Inter lock pin
20
3rd/4th fork rod
21
3rd/4th shift fork
22
3rd/4th bracket
23
Shift check sleeve (1st/2nd)
24
1st/2nd fork rod
25
1st/2nd bracket
26
1st/2nd shift fork
27
Clutch housing
28
Transaxle case
29
Check plug (1st/2nd, 3rd/4th)
30
Check spring (1st/2nd)
31
Check spring (3rd/4th)
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