Mazda Transaxle A65M–R. Manual - part 12

MANUAL TRANSAXLE 

J–29

J

Secondary Shaft C Ring Assembly Note

1. Install the secondary shaft C ring to the secondary shaft.
2. Measure the clearance between the secondary 

shaft C ring and the secondary shaft rear bearing.

•

If it is not within the specification, adjust it by 
selecting a proper C ring from below.

Clearance

0.00—0.06 mm {0.0000—0.0024 in}

Secondary shaft C ring size

3. Inspect the 1st gear and 2nd gear end play. (See 

J–18 SECONDARY SHAFT COMPONENTS 

PREINSPECTION

.)

End Of Sie

Thickness (mm {in})

2.535 {0.0998}

2.835 {0.1116}

2.565 {0.1010}

2.865 {0.1128}

2.595 {0.1022}

2.895 {0.1140}

2.625 {0.1033}

2.925 {0.1152}

2.655 {0.1045}

2.955 {0.1163}

2.685 {0.1057}

2.985 {0.1175}

2.715 {0.1069}

3.015 {0.1187}

2.745 {0.1081}

3.045 {0.1199}

2.775 {0.1093}

3.075 {0.1211}

2.805 {0.1104}

—

AME5112M066

J–30

MANUAL TRANSAXLE 

REVERSE IDLER SHAFT COMPONENTS DISASSEMBLY/ASSEMBLY

AME511217315M01

1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.

.

Insert Spring Assembly Note

1. Install the insert spring in the direction as shown 

in the figure.

End Of Sie

AME5112M005

1

Reverse idler adjust shim

2

Reverse idler rear gear and reverse coupling sleeve

3

Insert spring
(See 

J–30 Insert Spring Assembly Note

)

4

Reverse idler needle bearing

5

Thrust needle bearing

6

Reverse synchronizer ring

7

Reverse idler front gear

8

Reverse idler needle bearing

9

Thrust needle bearing

10

Reverse idler shaft

11

Spring pin

AME5112M071

MANUAL TRANSAXLE 

J–31

J

REVERSE IDLER SHAFT COMPONENTS INSPECTION

AME511217315M02

Reverse idler shaft and gears Inspection

1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.

•

If there is malfunction, replace the shaft.

2. Inspect the gears for damage, abnormal wear, 

dents, flaking, or bending.

•

If there is malfunction, replace the gear.

Synchronizer Ring and Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve, clutch hub, and 

insert spring contact surface for damage, 
abnormal wear, or bending.

•

If there is malfunction, replace the part where 
necessary.

2. Verify that the clutch hub sleeve and clutch hub 

move smoothly.

•

If there is malfunction, replace parts as 
necessary.

3. Inspect the synchronizer ring teeth and grooves 

for damage, abnormal wear, and cracks.

•

If there is malfunction, replace the 
synchronizer ring.

4. Inspect the tapered surface for abnormal wear 

and cracks.

•

If there is malfunction, replace parts as 
necessary.

5. Measure the clearance between the synchronizer 

ring and the flank surface of the gear.

•

If not as specified, replace the synchronizer 
ring.

Note

•

Set the synchronizer ring squarely in the 
gear; then measure around the 
circumference.

Standard clearance

0.95—1.40 mm {0.037—0.055 in}

Minimum clearance

0.70 mm {0.028 in}

AME5112M068

AME5112M139

AME5112M046

AME5112M070

J–32

MANUAL TRANSAXLE 

Bearing Inspection

1. Inspect the ball and the ball contact surface for damage and abnormal wear.

•

If there is malfunction, replace the bearing.

2. Verify that the bearing rotates smoothly.

•

If there is malfunction, replace the bearing.

End Of Sie

DIFFERENTIAL PREINSPECTION

AME511227100M01

Backlash Inspection

1. Measure the backlash of the side gear.

•

If not as specified, replace parts as 
necessary.

Standard

0.10—0.20 mm {0.0039—0.0079 in}

End Of Sie

DIFFERENTIAL DISASSEMBLY

AME511227100M02

1. Disassemble in the order shown in the figure.

.

AME5112M072

AME5112M140

AME5112M006

1

Ring gear

2

Bearing (ring gear-opposite side)
(See 

J–33 Bearing (Ring Gear-Opposite Side) 

Disassembly Note

)

3

Spacer

4

Bearing (ring gear side)
(See 

J–33 Bearing (Ring Gear Side) Disassembly 

Note

)

5

Gear case component