Transmission Rebuild Thread

[j9fd3s]

the two trans tools mazda has are the giant long puller set and the giant socket. i think the socket is 36mm, but its a couple feet long so you can put it over the shaft and loosen the nut.

the socket also doubles as the bearing installer, although a few feet of 3" pipe and a couple old stationary gears work really well here too. the bearings are not a very tight press fit.

[FC Zach]

This thread was made just in time, since I damaged my 4th transmission. I have no more TII trannys left so a rebuild is in order. So far I have two of my old trannys apart. The S5 TII I just pulled from the car has a damaged 5th and reverse clutch, and the previous transmission I had in the car (S4 TII) has both synchros on the 5th and reverse clutch broke in half!

Originally Posted by j9fd3s

the two trans tools mazda has are the giant long puller set and the giant socket.

I just made my gear/bearing puller from some steel stock I purchased from Lowes, now I'm working on a way to remove the nut on the output shaft (rather than using a chisel like I did when I removed it).

Originally Posted by j9fd3s

i think the socket is 36mm, but its a couple feet long so you can put it over the shaft and loosen the nut.

That may be true but I swear I measured 40 or 41mm, I'll have to double check. I was thinking of using a crowfoot wrench and extension to remove this nut (if it'll fit in there, will check later). like this:
edit: Crowsfoot wont work on the 41mm nut, tried it the other day.

Originally Posted by j9fd3s

the socket also doubles as the bearing installer, although a few feet of 3" pipe and a couple old stationary gears work really well here too. the bearings are not a very tight press fit.

After reading this I'm thinking of ditching the crowfoot wrench idea and just buy a socket, chop it in half and weld it to a pipe. Better idea since it doubles as an installer as well.

I went to Mazda when I got off work yesterday morning and picked the guys brain on the parts I needed. Apparently all Mazda dealerships worldwide are liked together and when he looked up the 5th and reverse clutch, he said there were only 7 left! Hell, i need 2! so when they're out, they are out! There must be a cross somewhere to another manufacturer because if I need a pair for two different transmissions then its gotta be a common issue. He even said that it may not be available even though the system displayed 7 available, so I'm crossing my fingers

[FC Zach]

I'll take pics of the gear/bearing puller I made along with pictures of the nut socket/bearing press I'm about to make.

[FC Zach]

Here's the pics of the bearing/gear puller I made from steel stock I purchased from Lowes:



The 41mm socket in this pic was given to my neighbor, he works in a machine shop. When I get the socket back it'll be capable of removing the nut and reinstalling the bearing. I'll show a pic of it when I get it back, should be sometime this week.