Removal and installation gearbox shafts (Mazda BT-50 (1))

Removal and installation of parts is carried out using the assembly drawing "Removal and installation of gearbox parts".

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. Front bearing housing.

Install suitable bolts into the holes in the front bearing housing and, tightening them one by one, remove the front bearing housing.



2. Outer bearing rings. Remove the outer bearing rings by moving the secondary and intermediate shafts back and forth.





3. Primary, secondary and intermediate shafts,

a) Tilt the primary and secondary shaft assemblies as shown in the figure and remove the secondary shaft.



b) Remove the input shaft.

c) Tilt the intermediate shaft as shown in the figure and remove it.

Installation Notes

1. Front oil seal.

a) Apply grease to the sealing lip of the oil seal.



b) Using a drift and hammer, install the seal into the front bearing housing.



2. Primary, secondary and intermediate shafts,

a) Install the intermediate shaft into the gearbox housing.



b) Install the primary shaft into the gearbox housing.

c) Install the secondary shaft into the gearbox housing.



d) Connect the primary and secondary shafts.





d) Install the intermediate shaft bearings.



e) Install the outer rings of the primary and secondary shaft bearings.



g) Install the rear bearing housing so that the arrow on the housing points upward.

• Tightening torque: 18-26 Nm

3. Bearing gaskets.



a) Install the clutch housing on top of the gearbox housing.

b) Using a depth gauge, measure the protrusion of the outer ring of the primary shaft bearing (dimension "A").



b) Using a depth gauge, measure the depth of the groove as shown in the figure (dimension "B").



c) Calculate the value "C" using the formula:

C = B - A

d) To ensure the specified clearance, select the gasket thickness according to the table below.

• Gap - 0.05 - 0.15 mm

d) Using a depth gauge, measure the distance to the outer ring of the intermediate shaft bearing (value "D").





e) Using a depth gauge, measure the groove depth as shown in the figure (value "E").



g) Calculate the value of "F" using the formula:

F = E + O

h) To ensure the specified clearance, select the gasket thickness according to the table below.

• Gap - 0.15 - 0.25 mm

i) Install the primary and intermediate shaft bearing gaskets and the oil deflector into the front bearing housing.



k) Apply sealant to the contact surface of the front bearing housing as shown in the figure.



l) Install the clutch fork pivot pin onto the front housing.

• Tightening torque - 31 - 46 Nm

m) Install the front bearing housing onto the gearbox.

• Tightening torque - 19 - 56 Nm

Caution: Be careful, the sharp shaft pins can damage the seals.