Disassembly and assembly of gearbox shafts (Mazda BT-50 (1))

Removal and installation of parts should be carried out using the assembly drawing "Disassembly and assembly of gearbox shafts".

Note: when assembling, it is necessary to select the dimensions of the parts indicated on the assembly drawing by the inscription "Selection".

Notes on removal

1. Third and fourth gear synchronizer hub.

a) Using two slotted screwdrivers and a hammer, remove the retaining ring.

Note: Do not reuse the removed snap ring.

b) Hold the synchronizer hub with your hand and, using a plastic hammer to strike the secondary shaft, remove the hub.



2. Hub of synchronizer of first and second gears.

Using a press, remove the bearing, first gear driven gear, synchronizer assembly and second gear driven gear from the secondary shaft.

Caution: While performing the procedure, support the secondary shaft with your hand to prevent it from falling.

3. Primary shaft bearing.



Using a press, remove the bearing from the input shaft.



4. Outer ring of the rear bearing of the intermediate shaft.

Using a press, remove the outer race of the rear bearing from the intermediate shaft.

Caution: While performing this procedure, support the intermediate shaft with your hand to prevent it from falling.

5. Using a puller, remove the front intermediate shaft bearing.

Installation Notes

1. First and second gear synchronizer hub.

a) To assemble the synchronizer, align the grooves on the synchronizer rings with the crackers.

Note: Standard sizes of crackers are shown in the picture.

b) Align the projections on the synchronizer ring with the grooves of the inner conical ring.



c) Align the projections of the double cone ring with the holes in the gear.

d) Install the synchronizer hub of the first and second gears on the secondary shaft.

d) Align the mark on the synchronizer hub with the cracker as shown in the figure.



e) Using a press, install the bearing, first gear driven gear, synchronizer assembly and second gear driven gear onto the secondary shaft.

Caution: Be careful when using the press, do not damage the parts.

2. Third and fourth gear synchronizer hub.

a) To assemble the synchronizer, align the grooves on the synchronizer rings with the crackers.

Note: Standard sizes of crackers are shown in the picture.

b) Align the projections on the synchronizer ring with the grooves of the inner conical ring.



c) Align the projections of the double cone ring with the holes in the gear.

d) Install the third and fourth gear synchronizer hub onto the secondary shaft.

d) Align the mark on the synchronizer hub with the cracker as shown in the figure.



e) Install the spacer and snap ring.



g) Measure the gap between the retaining ring and the spacer.

• Gap - 0 - 0.05 mm

If necessary, adjust the thickness of the retaining ring to ensure the specified clearance.

Note: Thrust washers are available in thicknesses from 1.0 mm to 1.90 mm in 0.00 mm increments.

3. Primary shaft bearing.

Using mandrels and a press, install the bearing onto the gearbox input shaft.



4. Outer ring of the rear bearing of the intermediate shaft.

Using mandrels and a press, install the outer race of the rear bearing onto the intermediate shaft.



5. Outer ring of the front bearing of the intermediate shaft.



Using mandrels and a press, install the outer race of the front bearing onto the intermediate shaft.