Primary Shaft: Reassembly
- To reassemble, reverse disassembly procedure. Measure clearance after each component is installed. See TRANSAXLE COMPONENT CLEARANCE SPECIFICATIONS
table. See Figure
.
- Select correct synchronizer keys. See SYNCHRONIZER KEY DIMENSIONS
table. See Fig 1
. Install keys and spring in synchronizer hub. Install synchronizer assembly with bevel facing away from input end of primary shaft. Locate synchronizer rings on correct clutch assembly.
Courtesy of MAZDA MOTORS CORP. SYNCHRONIZER KEY DIMENSIONS
| Synchro |
Dimension No. 1 In. (mm) |
Dimension No. 2 In. (mm) |
Dimension No. 3 In. (mm) |
| 1st/2nd |
0.748 (19.00) |
0.167 (4.25) |
0.197 (5.00) |
| 3rd/4th |
0.669 (17.00) |
0.167 (4.25) |
0.197 (5.00) |
| 5th/Rev. |
0.669 (17.00) |
0.167 (4.25) |
0.197 (5.00) |
TRANSAXLE COMPONENT CLEARANCE SPECIFICATIONS
| Application |
Standard In. (mm) |
Maximum In. (mm) |
| Primary Shaft |
| 3rd-To-2nd Gear |
| F25M-R & G25M-R |
.002-.008 (.05-.20) |
.010 (.25) |
| 4th Gear-To-Bearing |
| F25M-R |
.008-.024 (.21-.61) |
.026 (.66) |
| G25M-R |
.006-.015 (.17-.37) |
.017 (.42) |
| Secondary Shaft |
| 1st Gear Thrust |
| F25M-R & G25M-R |
.002-.011 (.05-.28) |
.013 (.33) |
| 2nd-To-3rd Gear |
| F25M-R |
.007-.020 (.18-.51) |
.22 (.56) |
| G25M-R |
.007-.018 (.18-.46) |
.020 (.50) |
| 1st/2nd Hub-To-Shift Fork |
| F25M-R |
.004-.014 (.10-.36) |
.034 (.86) |
| G25M-R |
.004-.018 (.10-.45) |
.037 (.95) |
| 3rd/4th Hub-To-Shift Fork |
| F25M-R |
.008-.020 (.20-.50) |
.039 (1.0) |
| G25M-R |
.004-.016 (.10-.40) |
.035 (.90) |
| 5th/Reverse |
| Hub-To-Shift Fork |
| F25M-R |
.016-.030 (.40-.75) |
.049 (1.24) |
| G25M-R |
.004-.014 (.10-.36) |
.034 (.86) |
| Synchronizer-To-Gear |
.059 (1.50) |
.031 (.80) |
| Reverse Idler |
| Gear-To-Shift Lever |
.004-.013 (.10-.32) |
.015 (.37) |
| Primary Shaft Run Out |
N/A |
.002 (.05) |
| Secondary Shaft Run Out |
N/A |
.0006 (.015) |
| Oil Clearance Between Shafts & Gears |
.001-.003 (.03-.08) |
.003 (.08) |