Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Transmission

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REMOVAL & INSTALLATION



GLC and GLC Wagon
  1. Disconnect the negative battery cable.
  2.  
  3. Put the transmission in Neutral, then remove the console and shift lever.
  4.  
  5. Remove the two upper bolts from the clutch housing.
  6.  
  7. Raise the vehicle and support it securely on axle stands or a lift.
  8.  
  9. Drain the transmission oil and replace the plug.
  10.  
  11. Remove the driveshaft, and plug or cover the hole in the extension housing.
  12.  
  13. Disconnect the speedometer cable and back-up light switch wires.
  14.  
  15. Disconnect the exhaust pipe hanger from the bracket on the clutch housing.
  16.  
  17. Remove the exhaust pipe support bracket from the clutch housing. Disconnect the clutch cable at the release lever.
  18.  
  19. Remove the lower clutch housing cover.
  20.  
  21. Remove the starter electrical connections, then remove the bolts and starter from the engine.
  22.  
  23. Disconnect the exhaust pipe hanger at the extension housing.
  24.  
  25. Place a jack under the engine, using a block of wood to protect the oil pan. Make sure the jack can securely support the weight of the engine.
  26.  
  27. Disconnect the transmission support member at the transmission.
  28.  
  29. Remove clutch housing-to-engine attaching bolts.
  30.  
  31. Carefully slide the transmission rearward until the input shaft has cleared the clutch disc, and lower it out of the car.
  32.  

To install:
  1. Carefully raise the transmission into position and slide the unit forward to engage the input shaft and the clutch disc. Align the clutch plate with an arbor or an old input shaft.
  2.  
  3. Install the clutch housing-to-engine bolts, then snug them evenly and alternately to hold the transmission in place. Install the frame member-to-transmission support attaching nuts. Tighten all the nuts and bolts properly at this time.
  4.  
  5. Remove the transmission jack.
  6.  
  7. Connect the exhaust pipe hanger to the extension housing.
  8.  
  9. Engage the starter motor with the flywheel ring gear, then install the mounting bolts and nuts. Connect the starter wiring.
  10.  
  11. Install the lower clutch housing cover plate.
  12.  
  13. Connect the clutch cable to the release lever, then connect the exhaust pipe support bracket to the clutch housing.
  14.  
  15. Connect the back-up switch wires and the speedometer cable.
  16.  
  17. Make sure that the transmission drain plug is installed and tightened properly.
  18.  
  19. Connect the driveshaft and lower the vehicle.
  20.  
  21. Install and tighten the remaining two clutch housing bolts.
  22.  
  23. Install the console shift lever and connect the negative battery cable.
  24.  
  25. Adjust clutch and shift linkage. Refill the transmission with the proper grade of gear oil.
  26.  

626
  1. Remove the gearshift lever knob.
  2.  
  3. Remove the console box.
  4.  
  5. Remove the gearshift lever boot and the gearshift lever.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Raise the vehicle and safely support it with jackstands.
  10.  
  11. Drain the transmission lubricant.
  12.  
  13. Disconnect the driveshaft.
  14.  
  15. Disconnect the exhaust pipe hanger.
  16.  
  17. Remove the starter motor.
  18.  
  19. Disconnect the back-up switch wire.
  20.  
  21. Disconnect the speedometer cable.
  22.  
  23. Place a jack under the engine, protecting the oil pan with a block of wood.
  24.  
  25. Remove the transmission attaching bolts and remove the transmission.
  26.  

To install:
  1. Carefully raise the transmission into position and slide the unit forward to engage the input shaft and the clutch disc. Align the clutch plate with an arbor or an old input shaft.
  2.  
  3. Install the bell housing-to-engine bolts, then snug them evenly and alternately to hold the transmission in place. Install the frame member-to-transmission support attaching nuts. Tighten all the nuts and bolts properly at this time.
  4.  
  5. Remove the transmission jack.
  6.  
  7. Connect the speedometer cable. Connect the back-up light switch wiring. Engage the starter motor with the flywheel ring gear, then install the mounting bolts and nuts. Connect the starter wiring.
  8.  
  9. Connect the exhaust pipe hanger.
  10.  
  11. Connect the driveshaft and lower the vehicle.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Install the gearshift lever and boot.
  16.  
  17. Install the console box and screw the knob onto the gearshift lever.
  18.  
  19. Add lubricant until the level reaches the bottom of the filler plug hole. Adjust the clutch linkage.
  20.  

929
  1. Remove the gearshift lever knob.
  2.  
  3. Remove the console box.
  4.  
  5. Remove the gearshift lever boot and the gearshift lever.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Raise the vehicle and safely support it with jackstands.
  10.  
  11. Drain the transmission lubricant. Wipe off the plug threads and replace it.
  12.  
  13. Disconnect the driveshaft.
  14.  
  15. Disconnect the speedometer cable from the rear of the extension housing. Disengage the multi-connectors from the transmission labelling or noting their connections to assure proper installation.
  16.  
  17. Disconnect the exhaust pipe hanger bracket by removing the through-bolt and spacer.
  18.  
  19. Disconnect the exhaust pipe from the exhaust manifold.
  20.  
  21. Remove the heat insulator from the bottom of the vehicle.
  22.  
  23. Unscrew and remove the protector from the clutch release cylinder. Unbolt the clutch release cylinder from the transmission housing, but leave the hydraulic line connected. Tie the release cylinder and line off to the side and out of the way.
  24.  
  25. Disconnect the wiring and remove the starter.
  26.  
  27. Place a jack under the engine, using a block of wood to protect the oil pan. Make sure the jack can securely support the weight of the engine.
  28.  
  29. Disconnect the transmission support mounts at the frame.
  30.  
  31. Remove transmission-to-engine attaching bolts.
  32.  
  33. Carefully slide the transmission rearward until the input shaft has cleared the clutch disc, and lower it out of the car.
  34.  

To install:
  1. Carefully raise the transmission into position and slide the unit forward to engage the input shaft and the clutch disc. Align the clutch plate with an arbor or an old input shaft.
  2.  
  3. Install the bell housing-to-engine bolts, then snug them evenly and alternately to hold the transmission in place. Install the frame member-to-transmission support attaching bolts. Torque the frame member and engine-to-transmission bolts to 27-38 ft. lbs. (37-51 Nm).
  4.  
  5. Remove the transmission jack.
  6.  
  7. Engage the starter motor with the flywheel ring gear, then install the mounting bolts and nuts. Connect the starter wiring. The starter bolts are torqued to 23-34 ft. lbs. (31-46 Nm).
  8.  
  9. Attach the clutch release cylinder to the transmission housing and install the protector.
  10.  
  11. Install the heat insulator. Connect the exhaust pipe using a new gasket. Torque the exhaust pipe nuts to 23-34 ft. lbs. (31-46 Nm).
  12.  
  13. Connect the exhaust pipe hanger to the extension housing. Torque the through-bolt to 12-17 ft. lbs. (16-23 Nm).
  14.  
  15. Connect the electrical wiring and speedometer cable.
  16.  
  17. Connect the driveshaft and lower the vehicle.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Insert the gear shift lever into the extension housing with the boot. The shift lever retaining screws are torqued to 67-95 inch lbs. (8-11 Nm). Install the console box and screw the knob onto the gearshift lever.
  22.  
  23. Add lubricant until the level reaches the bottom of the filler plug hole. Adjust the clutch linkage.
  24.  

RX-7
  1. Disconnect the negative battery cable. Remove the clutch release cylinder and tie the clutch release cylinder up out of the way. Do not disconnect the hydraulic line from the clutch release cylinder.
  2.  
  3. Remove the air cleaner assembly, from carbureted engines only.
  4.  
  5. Remove the bolts attaching the transmission to the rear end of the engine. Unscrew and remove the gear shift lever knob. Remove the console box, if so equipped.
  6.  
  7. Remove the gear shift lever boot and boot plate. Remove the gear shift lever and retainer assembly.
  8.  
  9. Raise the vehicle and support it safely. Remove the front and rear engine under covers. Remove the converter under cover and disconnect the air pipe.
  10.  
  11. Remove the converter brackets. Remove the rear exhaust pipe and converter assembly. Remove the front exhaust pipe and monolith converter assembly.
  12.  
  13. Remove the floor under covers. Drain the transmission oil into a suitable drain pan. Remove the driveshaft.
  14.  
  15. Disconnect the wiring and remove the starter motor. On 1986-89 RX-7s, unbolt and remove the crossmember from the frame. Remove the bolts attaching the transmission to the rear end of the engine. Disconnect the couplers from the back-up lamp switch.
  16.  
  17. Place a transmission jack under the transmission. Disconnect the speedometer cable. Remove the nuts attaching the transmission support to the vehicle. Place a piece of wood approximately 1 in. in height between the oil pan and the center link. This will prevent the engine from interfering with the dash panel.
  18.  
  19. Slide the transmission rearward until the main shaft clears the clutch disc, then carefully remove the transmission from under the vehicle.
  20.  

To install:
  1. Carefully raise the transmission into position, then slide the unit forward to engage the input shaft and the clutch disc. Align the clutch plate with an arbor or an old input shaft.
  2.  
  3. Install the bell housing-to-engine bolts, then snug them evenly and alternately to hold the transmission in place. Install the frame member-to-transmission support attaching bolts. Tighten all bolts at this time.
  4.  
  5. Connect the back-up switch wiring. Install the starter and connect the wiring. On 1986-89 models, bolt the crossmember to the frame.
  6.  
  7. Connect the driveshaft. Install the floor covers.
  8.  
  9. Install the front exhaust, monolith converter, converter and rear exhaust pipe using new gaskets as required.
  10.  
  11. Connect the air pipe and install the converter under cover. Install the front and rear engine under covers. Lower the vehicle.
  12.  
  13. Insert the gear shift lever and retainer assembly into the transmission opening. Install the boot plate and boot.
  14.  
  15. Install the console box and screw the knob onto the shift lever. Install the remaining rear engine-to-transmission bolts.
  16.  
  17. On carbureted engines, install the air cleaner.
  18.  
  19. Attach the clutch release cylinder and connect the negative battery cable.
  20.  
  21. Adjust the clutch and shift linkage. Refill the transmission and road test the vehicle.
  22.  

OVERHAUL



626 4 and 5-Speed Transmission

See Figures 1 and 2

The 4 and 5-speed transmission are basically the same, with an additional housing located between the adapter plate and the rear extension housing, to support the 5th/reverse gears. Additional roller bearings are used in the housing to prevent shaft misalignment.

DISASSEMBLY
  1. Remove the throw-out bearing return spring, throw-out bearing and the release fork.
  2.  
  3. Remove the bearing housing.
  4.  
  5. Remove the input shaft and countershaft snaprings.
  6.  
  7. Remove the floorshift lever retainer, complete with gasket.
  8.  
  9. Unfasten the cap bolt, then withdraw the spring, steel ball, select lock pin and spring from the retainer.
  10.  
  11. Remove the extension housing. Turn the control lever as far left as it will go and slide the extension housing off the output shaft.
  12.  
  13. Remove the spring seat and spring from the end of the shift control lever.
  14.  
  15. Loosen the spring cap, then withdraw the spring and plunger from their bores.
  16.  
  17. Remove the control rod and boss from the extension housing.
  18.  
  19. Remove the speedometer driven gear. Remove the back-up light switch.
  20.  
  21. Remove the speedometer drive gear.
  22.  
  23. Tap the front ends of the input shaft and countershaft with a plastic hammer, then remove the intermediate housing assembly from the transmission case.
  24.  
  25. Remove the three cap bolts; then withdraw the springs and lockballs.
  26.  
  27. Remove the reverse shift rod, reverse idler gear and shift lever.
  28.  
  29. Remove the setscrews from all the shift forks and push the shift rods rearward to remove them. Remove the shift forks.
  30.  
  31. Withdraw the reverse shift rod lockball, spring and interlock pins from the intermediate housing.
  32.  
  33. Remove reverse gear and key from the output shaft.
  34.  
  35. Remove the reverse countergear.
  36.  
  37. Remove the countershaft and output shaft from the intermediate housing.
  38.  
  39. Remove the bearings from the intermediate housing and transmission case.
  40.  
  41. Remove the snapring from the output shaft.
  42.  
  43. Slide the 3rd/4th clutch hub, sleeve, synchronizer ring and 3rd gear off the output shaft.
  44.  
  45. Remove the thrust washer, 1st gear, sleeve, synchronizer ring and 2nd gear from the rear of the output shaft.
  46.  



Click image to see an enlarged view

Fig. Fig. 1: Gear train position in 4-speed transmission with intermediate housing



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of shift selector rods and forks-4-speed transmission with intermediate housing

ASSEMBLY
  1. Install the 3rd/4th synchronizer clutch hub on the sleeve. Place the 3 synchronizer keys in the clutch hub key slots. Install the key springs with their open ends 120 degrees apart.
  2.  
  3. Install 3rd gear and the synchronizer ring on the front of the output shaft. Install the 3rd/4th clutch hub assembly on the output shaft. Be sure that the larger boss faces the front of the shaft.
  4.  
  5. Secure the gear and synchronizer with the snapring.
  6.  
  7. Repeat Step 1 for the 1st/2nd synchronizer assembly.
  8.  
  9. Position the synchronizer ring on 2nd gear. Slide 2nd gear on the output shaft so that the synchronizer ring faces the rear of the shaft.
  10.  
  11. Install the 1st/2nd clutch hub assembly on the output shaft so that its oil grooves face the front of the shaft. Engage the keys in the notches on the 2nd gear synchronizer ring.
  12.  
  13. Slide the 1st gear sleeve onto the output shaft. Position the synchronizer ring on 1st gear. Install the 1st gear on the output shaft so that the synchronizer ring faces forward. Rotate the 1st gear as required to engage the notches in the synchronizer ring with the keys in the clutch hub.
  14.  
  15. Slip the thrust washer on the rear of the output shaft. Install the needle bearing on the front of the output shaft.
  16.  
  17. Install the synchronizer ring on 4th gear and install the input shaft on the front of the output shaft.
  18.  
  19. Press the countershaft rear bearing and shim into the intermediate housing, then press the countershaft into the rear bearing.
  20.  
  21. Keep the thrust washer and 1st gear from falling off the output shaft by supporting the shaft. Install the output shaft on the intermediate housing. Be sure that each output shaft gear engages with its opposite on the countershaft.
  22.  
  23. Tap the output shaft bearing and shim into the intermediate housing with a plastic hammer. Install the cover.
  24.  
  25. Install reverse gear on the output shaft and secure it with its key.
  26.  

The chamfer on the teeth of both the reverse gear and the reverse countergear should face rearward.

  1. Install the reverse countergear.
  2.  
  3. Install the lockball and spring into the bore in the intermediate housing. Depress the ball with a screwdriver.
  4.  
  5. Install the reverse shift rod, lever and idler gear at the same time. Place the reverse shift rod in the Neutral position.
  6.  
  7. Align the boxes and insert the shift interlock pin.
  8.  
  9. Install the 3rd/4th shift rod into the intermediate housing and shift bores. Place the shift rod in Neutral.
  10.  
  11. Install the next interlock pin in the bore.
  12.  
  13. Install the 1st/2nd shift rod.
  14.  
  15. Install the lockballs and springs in their bores. Install the cap bolt.
  16.  
  17. Install the speedometer drive gear and lockball on the output shaft, then install its snapring.
  18.  
  19. Apply sealer to the mating surfaces of the intermediate housing. Install the intermediate housing in the transmission case.
  20.  
  21. Install the input shaft and countershaft front bearings in the transmission case.
  22.  
  23. Secure the speedometer driven gear.
  24.  
  25. Install the control rod through the holes in the front of the extension housing.
  26.  
  27. Align the key with the keyway and install the yoke on the end of the control rod. Install the yoke lockbolt.
  28.  
  29. Fit the plunger and spring into the extension housing bore, then secure with the spring cap.
  30.  
  31. Turn the control rod all the way to the left and install the extension housing on the intermediate housing.
  32.  
  33. Insert the sprig and select lockpin inside the gearshift retainer. Align the steel ball and spring with the lockpin slot, then secure it with the spring cap.
  34.  
  35. Install the spring and spring seat in the control rod yoke.
  36.  
  37. Install the gearshift lever retainer over its gasket on the extension housing.
  38.  
  39. Lubricate the lip of the front bearing cover oil seal and secure the cover on the transmission case.
  40.  
  41. Check the clearance between the front bearing cover and bearing. It should be less than 0.006 in. (0.15mm). If it is not within specifications, insert additional adjusting shims. The shims are available in 0.006 in. (0.15mm) or 0.012 in. (0.30mm) sizes.
  42.  
  43. Install the throwout bearing, return spring and release fork.
  44.  

The disassembly and assembly of the rear extension housing, selector levers and forks on the 5-speed transmission are completed in the same manner as the 4-speed transmission. After this has been done, the added housing can be removed by taking out the retaining bolts. The housing will have to be lightly tapped with a soft-faced hammer. The removal of the housing exposes the 5th/reverse synchronizer assembly, the reverse countergear, the countershaft and mainshaft bearings. The bearings are pulled from the shafts and the gears can then be removed. The transmission assembly is in the reverse of the disassembly procedure.

RX-7 (Non-Turbo) 5-Speed Transmission

See Figures 3 and 4

DISASSEMBLY
  1. Pull the release fork outward until the spring clip of the fork releases from the ballpivot.
  2.  
  3. Remove the fork and release bearing.
  4.  
  5. Remove the clutch busing shim and gasket.
  6.  
  7. Remove the gearshift lever retainer and gasket.
  8.  
  9. Remove the spring and steel ball, select lock spindle and spring from the gearshift lever retainer.
  10.  
  11. Remove the extension housing with the control lever end down to the left as far as it will go.
  12.  
  13. Remove the control lever end, key and control rod.
  14.  
  15. Remove the lock plate and speedometer gear.
  16.  
  17. Remove the back-up light switch and gasket.
  18.  
  19. Remove the snapring and slide the speedometer drive gear from the mainshaft.
  20.  
  21. Remove the bottom cover and gasket.
  22.  
  23. Remove the shift rod ends.
  24.  
  25. Remove the rear bearing housing.
  26.  
  27. Remove the snapring, then remove the mainshaft rear bearing, thrust washer and race, using Mazda puller No. 49 0839 425C or equivalent.
  28.  
  29. Remove the washer and countershaft rear bearing, using Mazda puller No. 49 0839 425C or equivalent.
  30.  
  31. Remove the counter 5th gear.
  32.  
  33. Remove the intermediate housing.
  34.  
  35. Remove the springs and shift locking balls.
  36.  
  37. Remove the two blind covers and gaskets from the case.
  38.  
  39. Remove the reverse/5th shift rod, fork and interlock pin.
  40.  
  41. Remove the 1st/2nd and 3rd/4th shift forks, rods and interlock pins.
  42.  
  43. Remove the snapring, then slide the washer, 5th gear and synchronizer ring from the mainshaft. Also, remove the steel ball and needle bearing.
  44.  
  45. Lock the rotation of the mainshaft with 2nd and reverse.
  46.  
  47. Remove the locknut and slide the reverse/5th clutch hub and sleeve assembly, synchronizer ring, reverse gear and needle bearing from the mainshaft.
  48.  
  49. Remove the spacer and counter reverse gear from the countershaft.
  50.  
  51. Remove the reverse idler gear, thrust washers and shaft from the transmission case.
  52.  
  53. Remove the bearing rear cover plate.
  54.  
  55. Remove the snapring from the front end of the countershaft and install Mazda tool No. 49 0839 445 synchronizer ring holder or its equivalent between the 4th synchronizer ring and the synchromesh gear on the main driveshaft.
  56.  
  57. Remove the countershaft front bearing.
  58.  
  59. Remove the adjusting shim from the countershaft front bearing bore.
  60.  
  61. Remove the countershaft center bearing outer race.
  62.  
  63. With a special puller and attachment, remove the mainshaft front bearing, thrust washer and inner race along with the adjusting shim from the mainshaft front bearing bore.
  64.  
  65. Remove the snapring and remove the main driveshaft bearing.
  66.  
  67. Remove the countershaft center bearing inner race with the puller.
  68.  
  69. Separate the input shaft from the mainshaft and remove the input shaft.
  70.  
  71. Remove the synchronizer ring and needle bearing from the input shaft.
  72.  
  73. Remove the mainshaft assembly.
  74.  
  75. Remove the 1st/2nd and 3rd/4th shift forks from the case.
  76.  
  77. Remove the snapring, then slide the 3rd/4th clutch hub and sleeve assembly, synchronizer ring and 3rd gear from the mainshaft.
  78.  
  79. Remove the thrust washer, 1st gear and needle bearing from the rear of the mainshaft.
  80.  
  81. Press out the needle bearing inner race, synchronizer ring, 1st and 2nd clutch hub, sleeve assembly, synchronizer ring and 2nd gear from the mainshaft.
  82.  



Click image to see an enlarged view

Fig. Fig. 3: Cross-section of the 5-speed transmission with added housing



Click image to see an enlarged view

Fig. Fig. 4: Shift rod and fork assemblies-RX-7 non-turbo

ASSEMBLY
  1. Install the 3rd/4th clutch hub into the sleeve, place the 3 keys into the clutch hub slots and install the springs onto the hub.
  2.  
  3. Assemble the 1st/2nd and reverse/5th clutch hub and sleeve as described in Step 1.
  4.  
  5. Install the needle bearing, 2nd gear, synchronizer ring and 1st/2nd clutch assembly on the rear section of the mainshaft.
  6.  
  7. Press on the 1st gear needle bearing inner race.
  8.  
  9. Install the 3rd gear and synchronizer ring onto the front section of the mainshaft.
  10.  
  11. Install the 3rd/4th clutch assembly onto the mainshaft.
  12.  
  13. Install the snapring on the mainshaft.
  14.  
  15. Install the needle bearing, synchronizer ring, 1st gear and thrust washer on the mainshaft.
  16.  
  17. Install the mainshaft assembly.
  18.  
  19. Install the needle bearing on the front end of the mainshaft.
  20.  
  21. Install the 1st/2nd and 3rd/4th shift forks in their respective clutch sleeves.
  22.  
  23. Check the mainshaft bearing end-play. Check the depth of the mainshaft bearing bore in the case. Measure the mainshaft bearing height. The difference indicates the required adjusting shim to give a total end-play of less than 0.004 in. (0.1mm).
  24.  
  25. Install the synchronizer ring holder tool between the 4th synchronizer ring and the synchromesh gear on the input shaft.
  26.  
  27. Position the shims and mainshaft bearing in the bore and install with a press.
  28.  
  29. Install the input shaft bearing in the same way.
  30.  
  31. Check the countershaft front bearing end-play in the same way as the mainshaft bearing end-play.
  32.  
  33. Install the front bearing snapring.
  34.  
  35. Press the countershaft center bearing into position.
  36.  
  37. Install the bearing cover plate.
  38.  
  39. Install the reverse idler gearshaft, thrust washers and reverse idler gear.
  40.  
  41. Install the counter reverse gear and spacer on the rear end on the countershaft.
  42.  
  43. Install the thrust washer and press the needle bearing inner race of the reverse gear on the mainshaft.
  44.  
  45. Install the needle bearing, reverse gear, synchronizer ring, reverse/5th clutch assembly and new mainshaft locknut on the mainshaft.
  46.  
  47. Lock the mainshaft with the 2nd and reverse gears. Tighten the locknut to 95-152 ft. lbs. (129-206 Nm).
  48.  
  49. Install the needle bearing, synchronizer ring and 5th gear on the mainshaft.
  50.  
  51. Install the thrust washer, steel ball and snapring on the mainshaft.
  52.  
  53. Check the thrust washer-to-snapring clearance. It should be 0.004-0.012 (0.10-0.30mm).
  54.  
  55. Install the 1st/2nd shift rod through the holes in the case and fork.
  56.  
  57. Install the interlock pin with a special installer and guide.
  58.  
  59. Install the 3rd/4th shift rod through the holes in the case and fork.
  60.  
  61. Align the holes and install the lockbolts of each shift fork and rod.
  62.  
  63. Install the interlock pin as above.
  64.  
  65. Position the reverse/5th shift fork on the clutch sleeve and install the shift rod.
  66.  
  67. Tighten the lockbolt.
  68.  
  69. Install the three shift locking balls, springs and cap bolts.
  70.  
  71. Place the 3rd/4th clutch sleeve in 3rd gear.
  72.  
  73. Check the clearance between the synchronizer key and the exposed edge of the synchronizer ring with a feeler gauge. The gap should be 0.026-0.079 in. (0.65-2.00mm). Adjust by varying thrust washers.
  74.  
  75. Install the two blind covers and gaskets.
  76.  
  77. Install the undercover and gasket.
  78.  
  79. Apply a thin coat of sealer to the mating edges and install the intermediate housing on the transmission case. Align the lockbolt holes of the housing and reverse idler gearshaft, install and tighten the lockbolt.
  80.  
  81. Position the counter 5th gear and bearing to the rear end of the countershaft, then install with a press.
  82.  
  83. Install the thrust washer and snapring.
  84.  
  85. Check the clearance between the washer and snapring. Clearance should be less than 0.004 in. (0.10mm).
  86.  
  87. Install the mainshaft rear bearing.
  88.  
  89. Install the thrust washer and snapring.
  90.  
  91. Check the thrust washer-to-snapring clearance. Clearance should be less than 0.006 in. (0.15mm).
  92.  
  93. Apply a thin coat of sealing agent to the mating surfaces and install the bearing housing on the intermediate housing.
  94.  
  95. Install the shift rod ends on their respective rods.
  96.  
  97. Install the speedometer drive gear and steel ball on the mainshaft. Secure it with a snapring.
  98.  
  99. Install a speedometer driven gear assembly on the extension housing, then secure it with the bolt and lock plate.
  100.  
  101. Insert the control rod through the holes from the front side of the extension housing.
  102.  
  103. Align the key and insert the control lever end in the control rod.
  104.  
  105. Install the bolt and tighten it to 20-30 ft. lbs. (27-41 Nm).
  106.  
  107. Install the back-up light switch.
  108.  
  109. Place the gasket on the case, then install the extension housing with the control lever end down and as far to the left as it will go.
  110.  
  111. Insert the select lock spindle and spring from the underside of the shift lever retainer.
  112.  
  113. Install the steel ball and spring in alignment with the spindle groove, then install the spring cap bolt.
  114.  
  115. Install the gearshift lever retainer and gasket on the extension housing.
  116.  
  117. Check the bearing end-play. Measure the depth of the bearing bore in the housing. Measure the height of the bearing protrusion. The difference indicates the thickness of the shim needed. The end-play should be less than 0.004 in. (0.10mm).
  118.  
  119. Place the gasket on the front side of the case. Apply lubricant to the lip of the oil seal and install the clutch housing on the case.
  120.  
  121. Install the release bearing and fork on the clutch housing.
  122.  

929 and RX-7 (Turbo) 5-Speed Transmission
DISASSEMBLY OF MAJOR COMPONENTS

See Figure 5

  1. Remove the throwout bearing and release fork.
  2.  
  3. Remove the input shaft front bearing cover.
  4.  
  5. Remove the speedometer gear from the right side of the extension housing.
  6.  
  7. Remove the back-up light switch from the left side of the extension housing.
  8.  
  9. Remove the control cover assembly.
  10.  
  11. Remove the shift gate assembly.
  12.  
  13. Unbolt the extension housing, rotate if clockwise and pull it from the case.
  14.  
  15. Remove the snapring from the output shaft, then the speedometer drive gear, snapring and key.
  16.  
  17. Unbolt and separate the bellhousing from the transmission case.
  18.  
  19. Drive the oil seal from the bellhousing.
  20.  
  21. Remove the transmission case lower cover and discard the gasket.
  22.  
  23. Remove the control rod from the extension housing.
  24.  
  25. Remove the control lever end and selector.
  26.  
  27. Remove the oil passage assembly.
  28.  
  29. Drive out the extension housing oil seal.
  30.  



Click image to see an enlarged view

Fig. Fig. 5: Clutch and extension housing components-929 and RX-7 turbo

DISASSEMBLY OF CENTER HOUSING AND RELATED PARTS

See Figure 6

  1. Remove the 5th/reverse shift rod end.
  2.  
  3. Remove the 3rd/4th shift rod end.
  4.  
  5. Remove the 1st/2nd shift rod end.
  6.  
  7. Remove the retaining ring, spring retainer, spring, pin and retaining ring from the 1st/2nd shift rod end.
  8.  
  9. Gently pry the bearing housing away from the transmission case. Be careful to avoid damage to the case. When the housing is loose, slide it off the shafts.
  10.  
  11. Remove the snapring, washer, retaining ring and C-washers then, using a puller, remove the mainshaft rear bearing.
  12.  

Tag the C-washers as to front and rear. They have different thicknesses.

  1. Uncrimp the tabs on the countershaft rear bearing locknut, shift the clutch hub sleeves to 1st and reverse engagement, and, using holding fixture 49 S120 440, or equivalent, remove the locknut. When reassembling, a new locknut must be used.
  2.  
  3. Using a puller, remove the countershaft bearing.
  4.  
  5. Remove the counter 5th gear and spacer from the rear of the countershaft.
  6.  
  7. Remove the idler gear shaft retaining bolt from the center housing.
  8.  
  9. Remove the oil guide.
  10.  
  11. Separate the center housing from the case by tapping it loose with a plastic mallet.
  12.  



Click image to see an enlarged view

Fig. Fig. 6: Main housing components-929 and RX-7 turbo

REMOVAL OF 5TH/REVERSE GEAR AND RELATED PARTS

See Figure 7

  1. Remove the 3 shift rod spring bolts, then remove the balls and springs.
  2.  
  3. Drive the spring pin from the 5th/reverse shift fork. Slide the 5th/reverse shift rod out of the case.
  4.  
  5. Remove the 2 access covers and gaskets.
  6.  
  7. Drive the spring pin from the 3rd/4th shift fork.
  8.  
  9. Slide the 3rd/4th shift rod out from the rear of the case.
  10.  
  11. Drive the spring pin from the 1st/2nd shift fork and slide the 1st/2nd shift rod out the rear of the case.
  12.  
  13. Remove both interlock pins.
  14.  
  15. Remove the thrust lockwasher, lock ball, needle bearings, 5th gear and synchronizer ring from the rear of the mainshaft.
  16.  
  17. Uncrimp the tabs on the 5th/reverse clutch hub locknut.
  18.  
  19. Lock the mainshaft by engaging 1st and reverse gears.
  20.  
  21. Remove the locknut by using tool 49 1243 465A, or equivalent. Discard the locknut. A new locknut must be used.
  22.  
  23. Remove the bearing cover bolts.
  24.  
  25. Remove the bearing cover assembly with a puller. From the cover disassemble the following parts:

    5th/reverse clutch hub
     
    Synchronizer ring
     
    Needle bearing
     
    Inner race
     
    Reverse gear
     
    Thrust washer
     

  26.  

  1. Remove the thrust washers, reverse idler gear shaft and reverse idler gear.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: 5th/reverse gear components-929 and RX-7 turbo

REMOVAL OF MAINSHAFT INPUT BEARING
  1. Remove the snapring from the main drive gear.
  2.  
  3. Install synchronizer ring holder 49 F017 101, or equivalent, between the 4th speed synchronizer ring and synchromesh gear on the main drive gear.
  4.  
  5. Turn the bearing snaprings so that the ring ends are at a 90 degree angle to the case grooves.
  6.  
  7. Remove the main drive gear bearing using a puller.
  8.  

REMOVAL OF COUNTERSHAFT FRONT BEARING
  1. Remove the snapring from the front of the countershaft.
  2.  
  3. Using a puller, remove the countershaft front bearing.
  4.  

DISASSEMBLY OF MAINSHAFT
  1. Using a puller, remove the mainshaft bearing.
  2.  
  3. Remove 1st gear.
  4.  
  5. Remove the countershaft center bearing with a puller.
  6.  
  7. Remove the countershaft.
  8.  
  9. Remove the main drive gear and needle bearing.
  10.  
  11. Remove the mainshaft and gear assembly.
  12.  
  13. Remove the snapring from the front of the mainshaft.
  14.  
  15. Position tool 49 0636 145, or equivalent, between 2nd and 3rd gears.
  16.  
  17. Using a press, drive the mainshaft out of 3rd gear and the 3rd/4th clutch hub assembly.
  18.  
  19. Press the 1st/2nd clutch hub assembly and 1st gear sleeve from the mainshaft.
  20.  
  21. Remove the countershaft center bearing inner race using a puller.
  22.  

COMPONENT INSPECTION
  1. Check all parts for signs of wear or damage. Replace any suspected part.
  2.  
  3. Using a dial indicator, check the mainshaft runout. Total runout must not exceed 0.0012 in. (0.03mm).
  4.  
  5. Check reverse idler gear-to-shaft clearance. Clearance must not exceed 0.006 in. (0.15mm).
  6.  
  7. Check the clearance between each synchronizer and its gear. Clearance should not exceed 0.031 in. (0.8mm).
  8.  
  9. Check clutch hub sleeve-to-shift fork clearance. Clearance must not exceed 0.02 in. (0.5mm).
  10.  
  11. Check control lever-to-shift rod gate clearance. Clearance must not exceed 0.031 in. (0.8mm).
  12.  
  13. Measure the free length of the springs.

    Detent ball spring: 0.89 in. (22.5mm)
     
    1st/2nd shift rod end spring: 1.26 in. (32mm)
     

  14.  

COMPONENT ASSEMBLY

All the synchronizers have the same basic shape. To differentiate:



5th and reverse are the smallest
 
5th has 2 notches in the teeth
 
4th and 3rd are the next size up and are identical
 
2nd and 1st are the largest and are identical
 

There are 2 types of synchronizer keys. They are differentiated by size.



1st and reverse are 0.71 in. x 0.21 in. x 0.24 in. (18mm x 5.45mm x 6mm)
 
3rd, 4th, 5th and reverse are 0.67 in. x 0.17 in. x 0.20 in. (17mm x 4.25mm x 5mm)
 

Check the illustrations before any assembly to make sure the parts are facing in the right direction

  1. Place the 2nd gear, with its needle bearing, and the 1st/2nd clutch hub assembly, on a press and press the mainshaft into them.
  2.  
  3. Place the 3rd gear, needle bearing and 3rd/4th clutch hub assembly into position and press the 3rd/4th clutch hub assembly onto the mainshaft.
  4.  
  5. Install the snapring on the front of the mainshaft.
  6.  
  7. Install the inner race, needle bearing, 1st gear and thrust washer.
  8.  
  9. Press the countershaft center bearing inner race onto the countershaft.
  10.  
  11. Measure the depth of the mainshaft bearing bore in the case.
  12.  
  13. Measure the mainshaft bearing snapring height. The difference between the two figures is the required thickness of the adjusting shim. Standard thrust play should be 0-0.004 in. (0-0.1mm). The adjusting shim thickness should be 0.004-0.012 in. (0.1-0.3mm).
  14.  
  15. Measure the depth of the countershaft front bearing bore in the case.
  16.  
  17. Measure the countershaft front bearing snapring height. Choose an adjusting shim that will allow the difference between the two figures to equal the standard bearing height. Standard bearing height should be 0.035-0.039 in. (0.9-1.0mm).
  18.  
  19. Position the 1st/2nd shift fork and 3rd/4th shift fork into the groove of the clutch hub and sleeve assembly.
  20.  
  21. Slide the needle bearing and main drive gear onto the front of the mainshaft.
  22.  
  23. Position the countershaft in the case, making sure that it engages each gear on the mainshaft.
  24.  
  25. Using a suitable length of pipe, drive on the countershaft center bearing.
  26.  
  27. Install the correctly predetermined shim on the mainshaft bearing.
  28.  
  29. Using a suitable length of pipe, drive on the mainshaft bearing.
  30.  
  31. Install the bearing cover and tighten the bolts to 20 ft. lbs. (27 Nm).
  32.  
  33. Install the synchronizer ring holder tool between the 4th synchronizer ring and the synchromesh gear on the main drive gear.
  34.  
  35. Using a driver, install in the main gear bearing.
  36.  
  37. Install the main gear bearing snapring.
  38.  
  39. Place the correctly predetermined shim in the countershaft front bearing.
  40.  
  41. Drive the countershaft front bearing on using a bearing driver.
  42.  
  43. Install the snapring.
  44.  

The countershaft bearing snapring is smaller than the mainshaft bearing snapring.

  1. Install the reverse idler gear and shaft with a spacer on each side of the gear.
  2.  
  3. Install the counter reverse gear and spacer, with the chamfer on the gear forward.
  4.  
  5. Install the thrust washer, reverse gear, inner race, needle bearing and clutch hub assembly.
  6.  
  7. Engage 1st and reverse gears to lock the mainshaft.
  8.  
  9. Install a new locknut on the mainshaft and torque it to 174 ft. lbs. (236 Nm) using tool 49 1243 465A, or equivalent.
  10.  
  11. Check the clearance between the synchronizer key and the exposed edge of the synchronizer ring. The clearance must not exceed 0.08 in. (2.0mm). If it does, adjust it by adding or deleting thrust washers at the mainshaft bearing front and rear.
  12.  

Total combined thickness of the front and rear thrust washers should not exceed 0.24 in. (6mm).

  1. Stake the locknut onto the shaft.
  2.  
  3. Install the synchronizer ring, 5th gear and needle bearing.
  4.  
  5. Install the 5th gear lock ball and thrust lockwasher.
  6.  
  7. Install the 5th gear 0.12 in. (3mm) thick C-washers and retaining ring.
  8.  
  9. Measure the clearance between the C-washers and the thrust lockwasher. Clearance should not exceed 0.008 in. (0.2mm). Adjust by installing thrust washers of differing thicknesses.
  10.  

When installing the shift rods, you can tell them apart by noting that the 3rd/4th rod is the longest; the 5th/reverse rod has a hole for the shift fork at the rear of the rod.

  1. Slide the 1st/2nd shift rod into the case.
  2.  
  3. Secure the 1st/2nd shift fork to the rod with the spring pin.
  4.  

The spring pin should be installed with the groove.

  1. Slide the 2 shift for assembly guides, 49 0862 350, into the case and install the first interlock pin.
  2.  
  3. Remove the 3rd/4th shift fork guide from the case.
  4.  
  5. Slide the 3rd/4th shift rod into the case.
  6.  
  7. Secure the 3rd/4th shift rod to the fork with the spring pin.
  8.  
  9. Insert the remaining interlock pin and remove the shift fork guide.
  10.  
  11. Install the 5th/reverse shift fork onto the clutch hub and slide the reverse/5th rod into the case.
  12.  
  13. Secure the 5th/reverse fork to the rod with the spring pin.
  14.  
  15. Install the 2 covers and gaskets.
  16.  
  17. Install the detent balls, springs and bolts. Torque the 2 upper bolts to 43 ft. lbs. (58 Nm) and the lower bolt to 19 ft. lbs. (26 Nm).
  18.  
  19. Coat the mating surface of the transmission case with RTV gasket material and install the center housing.
  20.  
  21. Install the oil guide. Torque it to 95 inch lbs. (11 Nm).
  22.  
  23. Install the spacer and counter 5th gear.
  24.  
  25. Align the reverse idler gear shaft boss with the holding bolt hole, then install the bolt and gasket. Torque the bolt to 122 inch lbs. (14 Nm).
  26.  
  27. Drive on the countershaft rear bearing using a bearing driver.
  28.  
  29. Install the mainshaft holder.
  30.  
  31. Engage 1st and reverse gears to lock the countershaft.
  32.  
  33. Install the countershaft locknut and torque the nut to 145 ft. lbs. (196 Nm). Stake the nut.
  34.  
  35. Drive on the mainshaft rear bearing.
  36.  
  37. Install the C-washers and hold them in place with the retaining ring.
  38.  
  39. Measure the clearance between the C-washers and the groove. Clearance should be 0-0.004 in. (0-0.1mm). If not, change the thickness of the C-washers.
  40.  
  41. Coat the contact surfaces of the center housing and bearing housing with RTV gasket material, then install the bearing housing on the center housing.
  42.  
  43. Engage the shift rod ends and shift rods, then install the spring pins.
  44.  
  45. Measure the depth of the main drive gear bearing bore in the clutch housing.
  46.  
  47. Measure the main drive gear bearing height. The difference between the two is the required thickness of the adjusting shim. The adjusting shim thickness should be 0-0.004 in. (0-0.1mm).
  48.  
  49. Apply oil to the seal lip and drive it into the bellhousing with a seal driver.
  50.  
  51. Coat the mating surfaces of the bellhousing and transmission case with RTV gasket material, then install the bellhousing. Torque the bolts to 34 ft. lbs. (46 Nm).
  52.  
  53. Install the input shaft bearing cover in the clutch housing. Torque the bolts to 19 ft. lbs. (26 Nm).
  54.  
  55. Install the bottom cover and gasket. Torque the bolts to 95 inch lbs. (11 Nm).
  56.  
  57. Apply a coat of molybdenum disulfide grease to the contact surfaces of the clutch release arm and install the throwout bearing and release arm.
  58.  
  59. Install the speedometer gear snapring and key.
  60.  
  61. Install the speedometer drive gear and snapring.
  62.  
  63. Install the oil passage in the extension housing. Torque it to 95 inch lbs. (11 Nm).
  64.  
  65. Install the control rod, control lever end and selector.
  66.  
  67. Install the roll pins.
  68.  

Make sure that the inner shift lever and shift rod end are aligned.

  1. Coat the contact surfaces of the extension housing and bearing housing with RTV gasket material.
  2.  
  3. Apply RTV sealant to the bolt threads and install the extension housing. Torque the bolts to 35 ft. lbs. (47 Nm).
  4.  
  5. Coat the mating surfaces of the shift control lever case and transfer case with RTV gasket material, then install the shift control case. Apply RTV to the bolts and tighten them to 22 ft. lbs. (30 Nm).
  6.  

 
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