Assembly Procedure

Install a new primary shaft oil seal in the clutch housing using the SST .

Fig 1: Installing Primary Shaft Oil Seal
Courtesy of MAZDA MOTORS CORP.
Install a new differential oil seal (clutch housing side) using the SSTs so that the seal is flush with the housing surface.

Fig 2: Installing Differential Oil Seal (Clutch Housing Side)
Courtesy of MAZDA MOTORS CORP.

NOTE:

When installing the oil channel, set the rib part of the oil channel to the hollow processing part of the clutch housing.

Fig 3: Installing Oil Channel

G01904335

Courtesy of MAZDA MOTORS CORP.

Install a new oil channel in the secondary shaft.
Install a new secondary shaft front bearing using the SSTs as shown in the figure.

Fig 4: Installing Secondary Shaft Front Bearing
Courtesy of MAZDA MOTORS CORP.
Install the bearing retainer with the stamp facing up.

Fig 5: Installing Bearing Retainer
Courtesy of MAZDA MOTORS CORP.

Tightening Torque
1. 6.27-8.33 N.m {64.0-84.9 kgf.cm, 55.5-73.7 in.lbf}
Measure the differential preload, and install the differential side bearing outer race using the SSTs . (See DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT .)

Fig 6: Installing Differential Side Bearing Outer Race
Courtesy of MAZDA MOTORS CORP.

Fig 7: Installing Differential Side Bearing Outer Race
Courtesy of MAZDA MOTORS CORP.
Install the differential to the clutch housing.
CAUTION:
- Installing the primary shaft can damage the oil seal, reducing the performance of the transaxle. When installing the primary shaft to the clutch housing, be careful not to damage it.
- The reverse idler gear will not function properly if the lip of the friction damper comes out of contact with the inner side of the gear. When moving the reverse idler gear component, do not handle the reverse idler gear. Move the component by grasping the ends of the reverse idler shaft.
Fig 8: Installing Differential
Courtesy of MAZDA MOTORS CORP.
Install the primary shaft component, secondary shaft component, and reverse idler component to the clutch housing at the same time.

Fig 9: Installing Primary Shaft Component, Secondary Shaft Component, & Reverse Idler Component
Courtesy of MAZDA MOTORS CORP.
Install the 1st/2nd bracket to the 1st/2nd fork rod, and install a new retaining pin.

Fig 10: Installing 1st/2nd Fork Rod Bracket Retaining Pin
Courtesy of MAZDA MOTORS CORP.
Install the 1st/2nd fork rod and 1st/2nd shift fork to the clutch housing, and install a new retaining pin.

Fig 11: Installing Retaining Pin
Courtesy of MAZDA MOTORS CORP.
Install the shift check sleeve.
Install the interlock pin to the 3rd/4th fork rod.
Install the 3rd/4th bracket, 3rd/4th shift fork, and 3rd/4th fork rod to the clutch housing.
Install a new C-ring to the 3rd/4th shift fork.

Fig 12: Installing C-ring To 3rd/4th Shift Fork
Courtesy of MAZDA MOTORS CORP.
Install a new retaining pin to the 3rd/4th bracket.
Install two check balls.
Install the 5th/reverse bracket, 5th shift fork, and 5th/reverse fork rod.
Install a new C-ring to the 5th/reverse fork rod.

Fig 13: Installing C-ring To 5th/Reverse Shift Fork
Courtesy of MAZDA MOTORS CORP.
Install a new retaining pin to the 5th shift fork.
Install the reverse shift fork and reverse fork rod.
Install the reverse lever component.
1. Install the cap to the cam part of the reverse lever component, and the reverse lever component to the reverse shift fork.
  
  Fig 14: Installing Cap To Cam Part Of Reverse Lever Component
  Courtesy of MAZDA MOTORS CORP.
2. Lift the reverse shift fork, and install the cam part of the reverse lever component to the 5th/reverse bracket.
  
  Fig 15: Installing Cam Part Of Reverse Lever Component To 5th/Reverse Bracket
  Courtesy of MAZDA MOTORS CORP.
3. Install a new reverse lever component installation bolt.
  
  Fig 16: Installing Reverse Lever Component Bolts
  Courtesy of MAZDA MOTORS CORP.
  
  Tightening Torque
  1. 11.8-15.6 N.m {1.2-1.5 kgf.m, 8.7-11.5 ft.lbf}

NOTE:

When installing the check ball, keep the check ball from dropping into the mold groove of the hole.

Install the check ball, the shift check sleeve (5th/reverse), the check spring (5th/reverse), and a new check plug (5th/reverse).
Install the magnet to the clutch housing.
Install a new differential oil seal to the transaxle case using the SSTs so that the seal is flush with the case surface.

Fig 17: Installing Differential Oil Seal
Courtesy of MAZDA MOTORS CORP.
Adjust the primary shaft end play. (See PRIMARY SHAFT END PLAY ADJUSTMENT .)
Install the primary shaft adjustment shim to the primary shaft.
Install the baffle plate and oil pass.
Install the transaxle case.
1. Adjust the secondary shaft end play. (See SECONDARY SHAFT END PLAY ADJUSTMENT .)
2. Install the secondary shaft rear bearing adjustment shim to the transaxle case.
3. Install a new snap ring of the secondary shaft rear bearing to the transaxle case.
4. Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the clutch housing.
  
  Fig 18: Applying Silicone Sealant To Transaxle Case And The Clutch Housing
  Courtesy of MAZDA MOTORS CORP.
  
  Sealant
  1. Three Bond product: TB1215
5. Place the transaxle case to the clutch housing.
  
  Fig 19: Installing Transaxle Case To Clutch Housing
  Courtesy of MAZDA MOTORS CORP.
6. Stretch the snap ring at the bore plug hole while lifting the secondary shaft at the control component installation hole.
7. Install the snap ring to the groove of the secondary shaft rear bearing.
  
  Fig 20: Installing Snap Ring To Groove Of Secondary Shaft Rear Bearing
  Courtesy of MAZDA MOTORS CORP.
8. Install the A bolt and a new B bolt to the transaxle case as shown in the figure.
  Tightening Torque
  1. A: 50.0-53.9 N.m {5.1-5.5 kgf.m, 36.9-39.8 ft.lbf}
  2. B: 63.0-66.9 N.m {6.4-6.8 kgf.m, 46.5-49.3 ft.lbf}
  Fig 21: Identifying Transaxle Case Bolts
  Courtesy of MAZDA MOTORS CORP.
Install a new bore plug using the SSTs .

Fig 22: Installing Bore Plug
Courtesy of MAZDA MOTORS CORP.
Install a new welt plug using the SSTs .

Fig 23: Installing Welt Plug
Courtesy of MAZDA MOTORS CORP.
Install the check balls, check springs, and a new check ball plugs as shown in the figure.

Fig 24: Installing Check Balls, Check Springs, & Check Ball Plugs
Courtesy of MAZDA MOTORS CORP.

Tightening Torque
1. 12.7-17.0 N.m {1.3-1.7 kgf.m, 9.4-12.5 ft.lbf}
Install a new O-ring to the control component.
Install the control component.
Tightening Torque
1. 6.30-8.30 N.m {64.3-84.6 kgf.cm, 55.8-73.4 in.lbf}
Fig 25: Installing Control Component
Courtesy of MAZDA MOTORS CORP.
Install a new shift check bolt.
Tightening Torque
1. 22.5-25.5 N.m {2.3-2.6 kgf.m, 16.6-18.8 ft.lbf}
Install a new stopper bolt.
Tightening Torque
1. 26.5-30.4 N.m {2.7-3.1 kgf.m, 19.5-22.4 ft.lbf}
Apply a light coat of silicone sealant to the screw of the neutral switch, and install it to the transaxle case.
Sealant
1. Three Bond product: TB1215
Tightening Torque
1. 22.5-33.3 N.m {2.3-3.4 kgf.m, 16.6-24.6 ft.lbf}
Apply a light coat of silicone sealant to the screw of the reverse switch, and install it to the transaxle case.
Sealant
1. Three Bond product: TB1215
Tightening Torque
1. 22.5-33.3 N.m {2.3-3.4 kgf.m, 16.6-24.6 ft.lbf}
Install a new drain plug.
Tightening Torque
1. 30.0-39.0 N.m {3.1-3.9 kgf.m, 22.1-28.8 ft.lbf}
Install a new gasket to the filler cap, and Install it to the transaxle case.
Tightening Torque
1. 30.0-39.0 N.m {3.1-3.9 kgf.m, 22.1-28.8 ft.lbf}