Mazda 3 manual transmission disassembly

Disassemble in the order shown in Figure 1.

Procedures for removing individual crankcase components are shown below

Fig.1. Dismantling components of the clutch housing: 1 - bearing cage (input shaft); 2 - stuffing box (primary shaft); 3 - bearing cage (secondary shaft); 4 - bell; 5 - element of the guide plate; 6 - lip seal; 7 - cylindrical pin; 8 - control rod; 9 - selector; 10 - change lever; 11 - breather cover element; 12 - breather; 13 - plug; 14 - gland (differential); 15 - bearing race (differential); 16 - reverse lever shaft; 17 - reverse lever; 18 - drain plug and washer; 19 - bearing cage (main gear housing); 20 - adjusting gasket; 21 - bearing race (differential); 22 - adjusting gasket; 23 - oil seal (differential); 24 - locating pin; 25 - sealing ring; 26 - crankshaft; 27 - an element of the cranked lever; 28 - cylindrical pin; 29 - element of the gear lever; 30 - key; 31 - end of control; 32 - spring and washer; 33 - gear lever shaft; 34 - covers; 35 - oil channel
Fig. 1 Removing the input shaft seal

Remove the input shaft seal using a screwdriver (fig. 1).

Fig. 2 Removing the output shaft bearing

Remove the mainshaft bearing race and bell together (fig. 2).

Fig. 3 Roll pin disassembly diagram

To disassemble the roll pin, align the clutch housing pin removal slot with the roll pin position.

Knock out the pin using a beard with a thin sting (fig. 3).

Fig. 4 Movement of the control rod before removal

To remove the control stem, move it in the direction of the arrow shown in Figure 4.

Fig. 5 Punching a hole in the crankcase cover

Using a flat-blade screwdriver and a hammer, make a hole in the cover (fig. 5).

Fig. 6 Removing the sealing cap

Remove the sealing cap by inserting a flathead screwdriver into the hole on the inside of the crankcase (fig. 6).

Fig. 7 Removing the control stem seal

Remove the control stem seal using a screwdriver (fig. 7).

Fig. 8 Removing the differential seal

Remove the differential seal using a screwdriver (fig. 8).

Fig. 9 Removing the outer ring of the differential bearing: 1 - bearing race

Before disassembling the differential bearing race, remove the outer race of the bearing using a special tool (fig. 9).

Fig. 10 Removing the roll pin

To remove the reverse lever shaft, first use pliers to remove the roll pin (fig. 10).

Fig. 11 Removing the reverse lever shaft

Protect the reverse lever shaft with a rag and use the same pliers to remove the shaft (fig. 11)

Fig. 12 Removing the main gear case bearing race: 1 – bearing race; 2 - Press

Using a special tool, remove the main gear housing bearing race (Fig. 12)

Checking input shaft elements

Fig. 13 Checking the clearance between the 3rd and 2nd gears

Measure the gap between the 3rd and 2nd gears (fig. 13).

If the gap exceeds the maximum, check the contact surfaces of the 2nd and 3rd gears, the 3rd/4th gear synchronizer clutch.

Replace worn or damaged parts. Gap: 0.05–0.20 mm. Maximum: 0.25 mm.

Fig. 14 Checking clearance between 4th gear and bearing

Measure the clearance between the 4th gear and the bearing (fig. 14).

If the clearance is greater than the maximum, check the contact surfaces of the 4th gear, bearing and 3/4th synchromesh clutch.

Replace worn or damaged parts. Gap: 0.17–0.37 mm. Maximum: 0.42 mm.