Fifth gear and reverse gears (Mazda BT-50 (1))

Removal and installation of parts is carried out using the assembly drawing "Fifth gear and reverse gear".

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. Nuts of secondary and intermediate shafts.

a) Move the synchronizer clutches as shown in the figure to engage second and fourth gears simultaneously.



b) Loosen the intermediate shaft nut by turning it clockwise.



c) Using a special tool, unscrew the secondary shaft nut by turning it counterclockwise.



2. Secondary shaft rear bearing. Using a puller, remove the secondary shaft rear bearing.





3. Intermediate gear and reverse gear shaft.

Loosen the lock bolt and remove the intermediate gear and reverse gear shaft assembly.



4. Reverse intermediate gear friction damper. Use a slotted screwdriver to remove the reverse intermediate gear friction damper.



5. Intermediate lever.

To prevent the intermediate lever shaft from shifting, do not loosen the nut while removing the intermediate lever.





6. Fork for engaging fifth gear and reverse gear.

a) Loosen the locking bolt of the fifth gear and reverse gear engagement rod.



b) Remove the fork assembly with the rod and synchronizer.

Installation Notes

1. Inner ring of the bearing of the fifth gear pinion,

a) Install the steel ball on the intermediate shaft.





b) Align the groove on the inner bearing ring with the ball and install the inner bearing ring.

2. Fifth gear pinion, synchronizer and fork,

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



c) Install the synchronizer and the fifth gear and reverse gear engagement fork into the gearbox.





d) Tighten the locking bolt of the fifth gear and reverse gear engagement rod.

• Tightening torque - 22 - 30 Nm

d) Install the thrust washer.

e) Measure the clearance between the thrust washer and the intermediate shaft groove.

• Gap - 0 - 0.05 mm

If necessary, adjust the thrust washer thickness to ensure the specified clearance.

Note: Thrust washers are available in thicknesses from 3mm to 3.4mm in 3.30mm increments.

3. Reverse gear drive pinion.

a) Measure the distances "A" and "B" shown in the figure.



b) Calculate the value of "C" using the formula:

C = A - B, where

C - distance between the synchronizer hub and the reverse gear pinion,

B - height of the leading gear of the reverse gear,

A - distance between the synchronizer hub and the thrust washer.

a) Using the table, select the thickness of the thrust washer to ensure the specified clearance.

• Gap - 0.25 - 0.35 mm

d) Install the thrust washer.

d) Install the reverse gear pinion.

4. Intermediate lever shaft. Install the intermediate lever shaft.

• Tightening torque: 8-11 Nm

Note:

• If the intermediate lever shaft has been replaced or the shaft nut has been loosened, install the shaft so that the bevel on the shaft is facing upward.
• Apply sealant to the threads of the nut.
• If the third and fourth gear engagement strokes are not normal, loosen the nut and repeat the adjustment.

5. Intermediate gear and reverse gear shaft.



a) Using mandrels and a hammer, install the friction damper.



b) Make sure the damper is installed as shown in the figure. Adjust the installation depth if necessary.



c) Install the gear on the shaft.

d) Measure the gap between the retaining ring and the thrust washer.



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

• Gap - 0.1 - 0.2 mm

Note: Retaining rings are available in thicknesses from 1.5 mm to 1.9 mm in 0.1 mm increments.

d) Install the intermediate gear assembly with the shaft into the gearbox housing.

Original version of the article on the website: mazbook.ru



e) Tighten the reverse gear intermediate gear shaft lock bolt.

• Tightening torque - 79 - 117 Nm

6. Nuts and bearings of secondary and intermediate shafts.

o) Move the synchronizer clutches as shown in the figure to engage second and fourth gears simultaneously.



b) Install the secondary and intermediate shaft bearings and tighten the nuts.

c) Using a special tool, tighten the secondary shaft nut.

• Tightening torque - 211 - 269 Nm

d) Tighten the intermediate shaft nut by turning it counterclockwise.

• Tightening torque - 126 - 196 Nm

d) Using a punch, lock the nuts of the secondary and intermediate shafts.