Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Output Shaft: Disassembly
1984 Mazda GLC 2D HatchbackSECTION Disassembly
- Separate shift forks from output shaft. Remove shift control end piece, 1-2 shift fork, interlock sleeve, 3-4 shift fork roll pin and control lever from shift shaft.
- Measure end clearance between the following points: 4th gear and bearing inner race, 3rd gear and thrust washer, 2nd gear and thrust washer, as well as 1st gear and differential drive gear.
- Clearance should be .004-.020" (.095-.5 mm) on 4th and 3rd gears, .010-.020 (.245-.5 mm) on 2nd gear and .006-.020" (.14-.5 mm) on 1st gear.
- Press inner bearing race and 4th gear off rear of output shaft. Remove blocker ring and synchronizer retaining ring from shaft.
- Press 3-4 synchronizer assembly and 3rd gear off shaft with a bearing separator. Remove thrust ring, thrust washer, 2nd gear, blocker ring and synchronizer retaining ring from shaft.
- Press 1st gear and 1-2 synchronizer assembly off of shaft. Do not remove front bearing inner race unless replacement is necessary. To remove bearing, press off using bearing separator.
- Slide synchronizer sleeves off of their hubs and remove all keys and springs. Check end clearance between blocker ring matching teeth and gear matching teeth. Clearance should be .031-.059" (.79-1.5 mm). Check to make sure that blocker ring grips gear cone properly.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.