Mazda Transaxle A65M–R. Manual - part 5

J–1

J

J

OVERHAUL

MANUAL TRANSAXLE.......................................... J-2

PRECAUTION...................................................... J-2
CLUTCH HOUSING AND TRANSAXLE CASE 

COMPONENTS DISASSEMBLY ...................... J-3

PRIMARY SHAFT COMPONENTS 

PREINSPECTION............................................. J-8

PRIMARY SHAFT COMPONENTS 

DISASSEMBLY................................................. J-9

PRIMARY SHAFT COMPONENTS 

INSPECTION .................................................. J-11

PRIMARY SHAFT COMPONENTS 

ASSEMBLY..................................................... J-13

SECONDARY SHAFT COMPONENTS 

PREINSPECTION........................................... J-18

SECONDARY SHAFT COMPONENTS 

DISASSEMBLY............................................... J-19

SECONDARY SHAFT COMPONENTS 

INSPECTION .................................................. J-20

SECONDARY SHAFT COMPONENTS 

ASSEMBLY..................................................... J-24

REVERSE IDLER SHAFT COMPONENTS 

DISASSEMBLY/ASSEMBLY .......................... J-30

REVERSE IDLER SHAFT COMPONENTS 

INSPECTION .................................................. J-31

DIFFERENTIAL PREINSPECTION ................... J-32
DIFFERENTIAL DISASSEMBLY ....................... J-32
DIFFERENTIAL ASSEMBLY ............................. J-33
PRIMARY SHAFT END PLAY ADJUSTMENT .. J-35
SECONDARY SHAFT END PLAY 

ADJUSTMENT ................................................ J-36

REVERSE IDLER GEAR END PLAY 

ADJUSTMENT ................................................ J-37

DIFFERENTIAL SIDE BEARING PRELOAD 

ADJUSTMENT ................................................ J-38

CLUTCH HOUSING AND TRANSAXLE CASE 

COMPONENTS ASSEMBLY .......................... J-40

J–2

MANUAL TRANSAXLE 

PRECAUTION

AME511201029M09

1. Clean the transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.

Warning

••••

Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. 
Wear protective eye wear whenever using compressed air.

Caution

••••

Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the 
bearing.

2. Clean the removed parts using cleaning solvent, and dry them using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
4. Use a plastic hammer when disassembling the transaxle case and other light alloy metal parts.
5. Make sure each part is cleaned before assembling.
6. Coat all movable parts with the specified oil.
7. Replace parts whenever required.
8. Remove old sealant from contact surfaces before applying new sealant.
9. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after 

assembly before filling the transaxle with transaxle oil.

Warning

••••

Although the stand has a self-locking brake system, there is a possibility that the brake may not 
hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle 
to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold 
the rotating handle firmly when turning the transaxle.

End Of Sie

MANUAL TRANSAXLE

MANUAL TRANSAXLE 

J–3

J

CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY

AME511217010M01

Disassembly Components

.

AME5112M004

1

Drain  plug

2

Filler cap

3

Neutral switch

4

Reverse switch

5

Air-bleed plug

6

Bore plug

7

Welt plug

8

Baffle plate

9

Oil pass

10

Transaxle case

11

Pivot pin

12

Magnet

13

Differential oil seal

14

Knock pin

15

Dowel pin

16

Secondary shaft bearing retainer

17

Secondary shaft front bearing

18

Oil channel

19

Primary shaft oil seal

20

Clutch housing

J–4

MANUAL TRANSAXLE 

.

AME5112M097

1

Stopper bolt

2

Shift check bolt

3

Shift control component

4

O  ring

5

Rod bushing

6

Reverse lever component

7

Reverse fork rod

8

Cap

9

Reverse shift fork

10

Retaining pin

11

C ring

12

5th/Reverse fork rod

13

5th shift fork

14

5th/reverse bracket

15

Check plug (5th/reverse)

16

Check spring (5th/reverse)

17

Shift check sleeve (5th/reverse)

18

Check ball

19

Inter lock pin

20

3rd/4th fork rod

21

3rd/4th shift fork

22

3rd/4th bracket

23

Shift check sleeve (1st/2nd)

24

1st/2nd fork rod

25

1st/2nd bracket

26

1st/2nd shift fork

27

Clutch housing

28

Transaxle case

29

Check plug (1st/2nd, 3rd/4th)

30

Check spring (1st/2nd)

31

Check spring (3rd/4th)