Mazda Transaxle A65M–R. Manual - part 9

MANUAL TRANSAXLE 

J–17

J

5th Clutch Hub Set Assembly Note

Note

•

Align the synchronizer ring grooves with the synchronizer key during assembly.

1. Install the 5th clutch hub set using the SSTs.

Primary Shaft Bearing Spacer Assembly Note

1. Install the primary shaft bearing spacer using the 

SSTs.

Snap Ring Assembly Note

1. Install a new snap ring to the primary shaft.
2. Measure the clearance between the snap ring 

and the primary shaft bearing spacer.

•

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

Clearance

0.0—0.1 mm {0.0000—0.0039 in}

Snap ring size

AME5112M117

AME5112M118

Thickness (mm {in})

1.71 {0.067}

2.01 {0.079}

1.76 {0.069}

2.06 {0.081}

1.81 {0.071}

2.11 {0.083}

1.86 {0.073}

2.16 {0.085}

1.91 {0.075}

2.21 {0.087}

1.96 {0.077}

2.26 {0.089}

AME5112M053

J–18

MANUAL TRANSAXLE 

Primary Shaft Rear Bearing Assembly Note

1. Place the primary shaft rear bearing with the brown side facing toward the 5th gear.
2. Install the primary shaft rear bearing using the 

SSTs.

Primary Shaft Front Bearing Assembly Note

1. Install the primary shaft front bearing using the 

SSTs.

2. Inspect the 3rd gear and 5th gear thrust 

clearance and 4th gear end play. (See 

J–8 

PRIMARY SHAFT COMPONENTS 
PREINSPECTION

.)

End Of Sie

SECONDARY SHAFT COMPONENTS PREINSPECTION

AME511217301M01

1st Gear End Play

1. Set up the secondary shaft component, and fix it.
2. Slide the 1st gear up and down, and measure the length of the movement.

•

If not as specified, assemble the secondary shaft component again.

Length of the movement

0.20—0.30 mm {0.0078—0.0118 in}

2nd Gear End Play

1. Set up the secondary shaft component, and fix it.
2. Slide the 2nd gear up and down, and measure the length of the movement.

•

If not as specified, assemble the secondary shaft component again.

Length of the movement

0.06—0.16 mm {0.0024—0.0063 in}

End Of Sie

AME5112M119

AME5112M120

AME5112M094

MANUAL TRANSAXLE 

J–19

J

SECONDARY SHAFT COMPONENTS DISASSEMBLY

AME511217301M02

1. Disassemble in the order shown in the figure.

.

AME5112M096

1

Secondary shaft rear bearing adjust shim

2

Snap ring

3

Snap ring

4

C ring holder

5

Secondary shaft C ring

6

Secondary shaft rear bearing
(See 

J–20 Secondary Shaft Rear Bearing 

Disassembly Note

)

7

Snap ring

8

5th gear
(See 

J–20 4th Gear and 5th Gear Disassembly 

Note

)

9

4th gear

10

4th gear adjustment shim

11

3rd/4th secondary shaft spacer

12

3rd gear
(See 

J–20 3rd Gear, 2nd Gear, 2nd Needle Bearing, 

2nd Bushing, 2nd Inner Synchronizer Component, 
1st/2nd Clutch Hub Set, 1st Inner Synchronizer 
Component, 1st Needle Bearing, 1st Bushing, 1st 
Gear and Reverse Main Gear Disassembly Note

)

13

2nd gear

14

2nd needle bearing

15

2nd bushing

16

2nd inner synchronizer component

17

1st/2nd clutch hub set

18

1st inner synchronizer component

19

1st needle bearing

20

1st bushing

21

1st gear

22

Reverse main gear

23

Secondary shaft

24

Synchronizer key spring

25

1st/2nd synchronizer key

26

1st/2nd clutch hub and sleeve

J–20

MANUAL TRANSAXLE 

Secondary Shaft Rear Bearing Disassembly Note

1. Remove the secondary shaft rear bearing using 

the SSTs.

4th Gear and 5th Gear Disassembly Note

1. Remove the 4th gear and 5th gear at the same 

time using the SSTs.

3rd Gear, 2nd Gear, 2nd Needle Bearing, 2nd Bushing, 2nd Inner Synchronizer Component, 1st/2nd Clutch 

Hub Set, 1st Inner Synchronizer Component, 1st Needle Bearing, 1st Bushing, 1st Gear and Reverse 
Main Gear Disassembly Note

1. Remove the 3rd gear, 2nd gear, 2nd needle 

bearing, 2nd bushing, 2nd inner synchronizer 
component, 1st/2nd clutch hub set, 1st inner 
synchronizer component, 1st needle bearing, 1st 
bushing, 1st gear and reverse main gear at the 
same time using the SST.

End Of Sie

SECONDARY SHAFT COMPONENTS INSPECTION

AME511217301M03

Secondary Shaft and Gear 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.

3. Inspect the oil passage for clogging.

•

If there is malfunction, replace the shaft.

AME5112M113

AME5112M111

AME5112M112

AME5112M058