Disassembly Note

CAUTION:

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

Fig 1: Measuring Input Shaft Clearances

Courtesy of MAZDA MOTORS CORP.

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

Fig 3: Removing Fourth Gear & Synchronizer Blocking Ring
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.
Remove fourth gear and the synchronizer blocking ring.

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

Fig 5: Pressing Off Synchronizer Hub Assembly, Synchronizer Blocking Ring, & Third Gear
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 assembly, synchronizer blocking ring, and third gear.

Fig 6: Pressing Off Bearing (Third Gear End)
Courtesy of MAZDA MOTORS CORP.
Using the special tools and a press, press off the bearing (third gear end).

Fig 7: Measuring Input Shaft Gear Runout
Courtesy of MAZDA MOTORS CORP.
Measure input shaft gear runout.
1. Inspect the input shaft for worn or damaged gears.
Fig 8: Inspecting Synchronizer Blocking Rings
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Set the synchronizer ring squarely in the gear, then measure around the circumference.
Inspect the synchronizer blocking rings.
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 tapper 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 9: Measuring Clearance Between Third/Fourth Synchronizer Hub & Shift Fork
Courtesy of MAZDA MOTORS CORP.
Measure the clearance between the third/fourth synchronizer hub and its shift fork.