Mazda Transaxle G35M–R. Manual - part 10

MANUAL TRANSAXLE 

J–21

J

Bearing and Secondary 4th Gear Disassembly Note

1. Remove the bearing and secondary 4th gear 

using the SST.

Secondary 3rd Gear and 2nd Gear Disassembly Note

1. Remove the retaining ring.
2. Shift the gears to 1st gear.
3. Remove the secondary 3rd gear and 2nd gear 

using the SST.

1st/2nd Clutch Hub Component, 1st Synchronizer Ring, and 1st Gear Disassembly Note

1. Remove the retaining ring.
2. Remove the 1st/2nd clutch hub component, 1st 

synchronizer ring, and 1st gear using a press.

Bearing (Secondary Shaft End) Disassembly Note

1. Remove the bearing using the SST.

End Of Sie

Z4F5112M041

Z4F5112M042

A6E5112M043

Z4F5112M044

J–22

MANUAL TRANSAXLE 

SECONDARY SHAFT COMPONENTS INSPECTION

A6E511217301M03

Gears Inspection

1. Inspect the synchronizer cones for wear.

•

If there is malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

•

If there is malfunction, replace parts as necessary.

3. Inspect the synchronizer ring matching teeth for damage and wear.

•

If there is malfunction, replace the synchronizer ring.

Synchronizer Ring Inspection

1. Inspect the synchronizer ring teeth for damage, wear, and cracks.

•

If there is malfunction, replace parts as necessary.

2. Inspect the tapered surface for wear and cracks.

•

If there is malfunction, replace parts as necessary.

3. Measure the clearance between the synchronizer 

ring and the side of gear circumferentially using a 
feeler gauge.

•

If the clearance is exceed the minimum, 
replace the synchronizer ring.

Standard clearance

1.50 mm {0.059 in}

Minimum

0.80 mm {0.031 in}

Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.

•

If there is malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

•

If there is malfunction, replace parts as necessary.

3. Inspect the synchronizer keys for damage, wear, and cracks.

•

If there is malfunction, replace parts as necessary.

4. Measure the clearance between the hub sleeve 

and shift fork.

•

If the clearance exceeds the maximum, 
replace the hub sleeve and shift fork as a set.

Standard clearance

0.10—0.45 mm {0.004—0.017 in}

Maximum clearance

0.95 mm {0.037 in}

Secondary Shaft Gear Inspection

1. Inspect the gear contact surface for damage and wear.

•

If there is malfunction, replace the secondary shaft.

2. Inspect the splines for damage and wear.

•

If there is malfunction, replace the secondary shaft.

3. Inspect the gear teeth for damage, wear, and cracks.

•

If there is malfunction, replace the secondary shaft.

4. Inspect the oil passage for clogging.

•

If there is malfunction, replace the secondary shaft.

A6E5112M047

A6E5112M049

MANUAL TRANSAXLE 

J–23

J

5. Measure the shaft gear runout.

•

If not as specified, replace the secondary 
shaft.

Secondary shaft gear runout

0.015 mm {0.0006 in} max.

6. Measure the clearance between the shaft gears 

and the gears.

•

If not as specified, replace parts as 
necessary.

mm{in}

End Of Sie

Gear

Shaft

(outer dia.)

Gear

(inner dia.)

Clearance

1st

39.445—39.470 

{1.553—1.554}

39.500—39.525 

{1.555—1.556}

0.030—0.080 

{0.002—0.003}

2nd

34.945—34.905 

{1.376—1.374}

35.015—35.035 

{1.378—1.379}

0.05—0.09 

{0.002—0.003}

A6E5112M050

Z4F5112M102

J–24

MANUAL TRANSAXLE 

SECONDARY SHAFT COMPONENTS ASSEMBLY

A6E511217301M04

1. Assemble in the order shown in the figure.

.

A6E5112M110

1

1st/2nd clutch hub
(See 

J–25 1st/2nd Clutch Hub Assembly Note

)

2

Synchronizer keys

3

Clutch hub sleeve (reverse gear)

4

Synchronizer key spring

5

Secondary shaft gear

6

Bearing (secondary shaft end)
(See 

J–25 Bearing (Secondary Shaft End) 

Assembly Note

)

7

1st gear
(See 

J–25 1st Gear, 1st Synchronizer Ring, and 1st/

2nd Clutch Hub Component Assembly Note

)

8

Synchronizer ring

9

Inner cone

10

Double cone

11

1st/2nd clutch hub component

12

Retaining ring

13

Synchronizer ring

14

2nd gear

15

Double cone

16

Inner cone

17

Friction damper

18

Secondary 3rd gear

19

Retaining ring

20

Secondary 4th gear
(See 

J–26 Secondary 4th Gear and Bearing 

Assembly Note

)

21

Bearing