2000-05 MANUAL TRANSMISSIONS Mazda Y16M-D 6-Speed Overhaul (2024)

APPLICATION

MANUAL TRANSMISSION APPLICATIONS

IDENTIFICATION

LUBRICATION

RECOMMENDED FLUID

Use 75W/90 API GL-4 or GL-5 gear oil.

FLUID CAPACITIES

Fluid level should be level with bottom of filler plug opening. Add fluid as required. Capacity is 1.85 qts. (1.75L).

ON-VEHICLE SERVICE

ADJUSTMENTS

TROUBLE SHOOTING

REMOVAL & INSTALLATION

TRANSMISSION

TRANSMISSION DISASSEMBLY

EXTENSION HOUSING COMPONENTS

Disassemble parts in order of legend in illustration. See Fig.1. Note the following procedures during disassembly:

1. Use a rag to prevent damage to extension housing.
2. Use a suitable bar and hammer to remove plug and bushing.

Fig. 1: Exploded View Of Extension Housing
Courtesy of MAZDA MOTORS CORP.

TRANSMISSION CASE & 6TH GEAR

Disassemble parts in order of legend in illustration. See Fig.2. Note the following procedures during disassembly:

1. Remove snap ring using 2 screwdrivers and a hammer.
2. Remove inner shift lever by supporting shift rod with screwdriver and tapping shift rod with plastic hammer. See Fig.3.
3. Remove 6th gear clutch hub, and 6th gear shift fork together using puller.
4. Install service tool shaft in bearing retainer (bearing cover) and hold in vise. Use pin punch and hammer to remove spring pin.
5. Cover clutch hub component with rag to prevent steel ball and synchronizer key spring from popping out.

Fig. 2: Exploded View Of Transmission Case & 6th Gear
Courtesy of MAZDA MOTORS CORP.

Fig. 3: Removing Inner Shift Lever
Courtesy of MAZDA MOTORS CORP.

CLUTCH HOUSING COMPONENTS

Disassemble parts in order of legend in illustration. See Fig.4. Note the following procedure during disassembly:

Remove front cover by prying with screwdriver. See Fig.5.

Fig. 4: Exploded View Of Clutch Housing
Courtesy of MAZDA MOTORS CORP.

Fig. 5: Removing Front Cover
Courtesy of MAZDA MOTORS CORP.

SHIFT FORKS & SHIFT ROD

Disassemble parts in order of legend in illustration. See Fig.6.

Fig. 6: Disassembling Shift Fork & Shift Rod Components
Courtesy of MAZDA MOTORS CORP.

MAIN DRIVE GEAR & MAINSHAFT COMPONENTS

Disassemble parts in order of legend in illustration. See Fig.7. Note the following procedures during disassembly:

1. Remove bearing using bearing splitter and press.
2. Shift 1st-2nd clutch hub to 2nd gear. Remove 6th gear, bearing and 1st gear together using bearing splitter and press.
3. Remove 1st-2nd clutch hub assembly and 2nd gear together using bearing splitter and press.
4. Remove 5th-reverse clutch hub assembly and reverse gear together using bearing splitter and press.

Fig. 7: Disassembling Main Drive Gear & Mainshaft Component
Courtesy of MAZDA MOTORS CORP.

COUNTERSHAFT COMPONENTS

Disassemble parts in order of legend in illustration. See Fig.8. Note the following procedures during disassembly:

1. Remove roller bearing using bearing splitter and press.
2. Remove counter drive gear using bearing splitter and press.
3. Remove counter 3rd gear and 3rd-4th clutch hub assembly together using bearing splitter and press.

Fig. 8: Disassembling Countershaft Components
Courtesy of MAZDA MOTORS CORP.

TRANSMISSION INSPECTION

DRIVE GEAR INSPECTION

Thrust Clearance Inspection

Measure thrust clearance of each gear at indicated points using feeler gauge and dial gauge. See Fig.9. Clearances must be within specification. If clearances are not within specification, replace worn parts as necessary. See GEAR THRUST CLEARANCE SPECIFICATIONS table.

GEAR THRUST CLEARANCE SPECIFICATIONS

Fig. 9: Measuring Gear Thrust Clearance
Courtesy of MAZDA MOTORS CORP.

Radial Clearance Inspection

Measure radial clearance of each gear using dial gauge. See Fig.10. Clearances must be within specification. If clearances are not within specification, replace worn parts as necessary. See GEAR RADIAL CLEARANCE SPECIFICATIONS table.

GEAR RADIAL CLEARANCE SPECIFICATIONS

Fig. 10: Checking Gear Radial Clearance
Courtesy of MAZDA MOTORS CORP.

REVERSE IDLER GEAR & REVERSE IDLER SHAFT

Radial Clearance Inspection

Secure reverse idler gear and reverse idler shaft in vise. Measure radial clearance using dial gauge. Clearances must be within specification. If clearances are not .0016-.0032" (.040-.082 mm), replace reverse idler gear and reverse idler shaft.

Synchronizer Ring Inspection

Set synchronizer ring squarely onto gear. Measure clearance between synchronizer ring and flank surface of gear around circumference using feeler gauge. Clearances must be within specification. If clearances are not within specification, replace synchronizer ring. See SYNCHRONIZER RING CLEARANCES table.

SYNCHRONIZER RING CLEARANCES

Mainshaft Inspection

Place mainshaft into V-blocks and measure runout at points indicated. See Fig.11. Maximum allowable runout is .0012" (.030 mm). If run out exceeds specification, replace mainshaft.

Fig. 11: Identifying Mainshaft Inspection Points
Courtesy of MAZDA MOTORS CORP.

Countershaft Inspection

Place countershaft into V-blocks and measure runout at points indicated, using dial gauge. See Fig.12. Maximum allowable runout is .0012" (.030 mm). If run out exceeds specification, replace countershaft.

Fig. 12: Identifying Countershaft Inspection Points
Courtesy of MAZDA MOTORS CORP.

Clutch Hub Sleeve & Shift Fork Inspection

Measure shift fork thickness and groove width of clutch hub sleeve with vernier caliper. Calculate clearance of clutch hub sleeve. Clearance must be .006-.013" (.15-.35 mm). If clearance is not as specified, replace worn parts as necessary.

TRANSMISSION REASSEMBLY

COUNTERSHAFT COMPONENTS

Assemble parts in reverse order of disassembly. See Fig.1. After assembly, gear should rotate smoothly by hand. Synchronizer ring should not be in locked (engaged) position. Note the following procedures during reassembly:

CAUTION:

Do not damage synchronizer ring when installing clutch hub.

NOTE:

Do not reuse thrust washer.

1. Securely align tab on synchronizer ring with key groove of clutch hub. Carefully install 3rd-4th clutch hub assembly using press.
2. Install thrust washer removed during disassembly, and measure clearance between thrust washer and installation groove using feeler gauge. Select NEW thrust washer to allow clearance of 0-.0039" (0-.100 mm). See THRUST WASHER SPECIFICATIONS table. Install thrust washer on countershaft gear with identification mark facing up.

   THRUST WASHER SPECIFICATIONS
   

   ID Mark	Thickness - In. (mm)
   A	0.148 (3.75)
   B	0.150 (3.80)
   C	0.152 (3.85)
   D	0.154 (3.90)
   E	0.156 (3.95)
   F	0.157 (4.00)
   G	0.159 (4.05)
   H	0.161 (4.10)

3. Install counter drive gear using press.

   NOTE:

   Do not reuse snap ring.

4. Install snap ring removed during disassembly, and measure clearance between snap ring and groove using feeler gauge. Select NEW snap ring to allow clearance of 0-.0039" (0-.100 mm). See FRICTION GEAR SNAP RING SPECIFICATIONS table. Install snap ring onto countershaft.

   FRICTION GEAR SNAP RING SPECIFICATIONS
   

   ID Mark	Thickness - In. (mm)
   A	0.071 (1.80)
   B	0.073 (1.85)
   C	0.075 (1.90)
   D	0.077 (1.95)
   E	0.079 (2.00)
   F	0.081 (2.05)

5. Install roller bearing using press.

   NOTE:

   Do not reuse snap ring.

6. Install snap ring removed during disassembly, and measure clearance between snap ring and groove using feeler gauge. Select NEW snap ring to allow clearance of 0-.0039" (0-.100 mm). See ROLLER BEARING SNAP RING SPECIFICATIONS table. Install snap ring onto countershaft.

   ROLLER BEARING SNAP RING SPECIFICATIONS
   

   ID Mark	Thickness - In. (mm)
   A	0.148 (3.75)
   B	0.150 (3.80)
   C	0.152 (3.85)
   D	0.154 (3.90)
   E	0.156 (3.95)
   F	0.157 (4.00)
   G	0.159 (4.05)
   H	0.161 (4.10)

MAIN DRIVE GEAR & MAINSHAFT COMPONENTS

Assemble parts in reverse order of disassembly. See Fig.7. Note the following procedures during reassembly:

1. After assembly, gear should rotate smoothly by hand.
2. Synchronizer ring should not be in a locked (engaged) position.
3. Install bearing using press.

   NOTE:

   Do not reuse snap ring.

4. Install snap ring removed during disassembly, and measure clearance between snap ring and groove using feeler gauge. Select NEW snap ring so clearance measured is 0-.0039" (0-.100 mm). See BEARING SNAP RING SPECIFICATIONS table. Install snap ring onto countershaft.

   NOTE:

   Do not damage synchronizer ring when installing clutch hub. BEARING SNAP RING SPECIFICATIONS ID Mark Thickness - In. (mm) 0 0.077 (1.95) 1 0.079 (2.00) 2 0.081 (2.05) 3 0.083 (2.10) 4 0.085 (2.15) 5 0.087 (2.20)

5. Securely align tab on synchronizer ring with key groove of clutch hub. Carefully install 5th-reverse clutch hub components.

   NOTE:

   Do not reuse snap ring.

6. Install snap ring removed during disassembly, and measure clearance between snap ring and groove using feeler gauge. Select NEW snap ring to allow clearance of 0-.0039" (0-.100 mm). See REVERSE GEAR SNAP RING SPECIFICATIONS table. Install snap ring onto mainshaft.

   REVERSE GEAR SNAP RING SPECIFICATIONS
   

   ID Mark	Thickness - In. (mm)
   A	0.071 (1.80)
   B	0.073 (1.85)
   C	0.075 (1.90)
   D	0.077 (1.95)
   E	0.079 (2.00)
   F	0.081 (2.05)

   CAUTION:

   Do not damage synchronizer ring when installing clutch hub.

7. Secure alignment tab on each ring with installation hole of 2nd gear and key groove of clutch hub. See Fig.13. Carefully install 1st-2nd clutch hub assembly using press.
8. Install bearing and 6th gear using press.

   NOTE:

   Do not reuse snap ring.

9. Install snap ring removed during disassembly, and measure clearance between snap ring and groove using feeler gauge. Select NEW snap ring to allow clearance of 0-.0043" (0-.110 mm). See 6TH GEAR SNAP RING SPECIFICATIONS table. Install snap ring onto mainshaft.

   6TH GEAR SNAP RING SPECIFICATIONS
   

   ID Mark	Thickness - In. (mm)
   A	0.105 (2.67)
   B	0.107 (2.73)
   C	0.110 (2.79)
   D	0.112 (2.85)
   E	0.115 (2.91)
   F	0.117 (2.97)
   G	0.119 (3.03)
   H	0.122 (3.09)
   J	0.124 (3.15)
   K	0.126 (3.21)
   L	0.129 (3.27)

   Fig. 13: Assembling 1st-2nd Clutch Components
   Courtesy of MAZDA MOTORS CORP.

CLUTCH HOUSING, SHIFT FORKS & SHIFT ROD COMPONENTS

Assemble parts in reverse order of disassembly. See Fig.4. Note the following procedures during reassembly:

1. Turn friction gear clockwise. Insert setting plate through holes from counter drive gear side, and secure friction gear.
2. Turn friction gear counterclockwise by hand, and align reverse idler gear hole with friction gear hole. Insert setting plate through holes from reverse idler gear side, and secure friction gear.
3. Install countershaft and reverse idler gear with setting plates, main drive gear, mainshaft component, shift fork and shift rod component (mainshaft) onto clutch housing together. Remove setting plates installed to countershaft and reverse idler gear component after installing.
4. Install NEW gasket and bolts into clutch housing and tighten temporarily. Tighten to specification after installing transmission case.
5. Temporarily install 3rd-4th shift fork and reverse shift arm into clutch housing. Pass shift rod through 3rd-4th shift fork and reverse shift arm. Drive NEW spring pin into reverse shift arm head.
6. Install 5th-reverse counter lever, and secure counter lever with crank case lever shaft.

TRANSMISSION CASE & 6TH GEAR COMPONENTS

Assemble parts in reverse order of disassembly. See Fig.2. After assembly, gear should rotate smoothly by hand. Synchronizer ring should not be in a locked (engaged) position. Note the following procedures during reassembly:

1. Install shaft stopper into clutch housing. Install steel ball into 5th shift arm. Ensure steel ball does not drop out. Insert shift rod until it contacts shaft stopper installed onto clutch housing. Turn notch of shift rod toward shift rod "A". See Fig.14.

   NOTE:

   If countershaft center bearing interferes with transmission case when installing, pry roller of bearing aside slightly using screwdriver covered with a rag.

2. Set shift levers to Neutral position. Install pressure spring and steel ball into transmission. Install transmission case onto clutch housing pressing steel ball with pin punch so it does not pop out. See Fig.14.
3. Tighten transmission case mounting bolts to specification. Tighten bolt "A" (for reverse idle shaft). Temporarily tighten bolt "B" on clutch housing. See Fig.15. See TORQUE SPECIFICATIONS.
4. Install NEW oil seal into front cover.
5. Install push pin so notch faces in direction shown. See Fig.16.
6. Hold bearing cover, compress pressure spring using shaft. Drive in spring pin.
7. Install inner shift lever.

   CAUTION:

   Do not damage synchronizer ring when installing clutch hub assembly.

8. Securely align tab on synchronizer ring with key groove of clutch hub. Carefully install 6th clutch hub component using clutch hub installer.

   NOTE:

   Do not reuse snap ring.

9. Install snap ring removed during disassembly, and measure clearance between snap ring and groove using feeler gauge. Select NEW snap ring to allow a clearance of 0-.0039" (0-.100 mm). Install snap ring on countershaft gear. See COUNTERSHAFT GEAR SNAP RING SPECIFICATIONS.

   COUNTERSHAFT GEAR SNAP RING SPECIFICATIONS
   

   ID Mark	Thickness - In. (mm)
   A	0.110 (2.80)
   B	0.112 (2.85)
   C	0.114 (.290)
   D	0.116 (2.95)
   E	0.118 (3.00)
   F	0.120 (3.05)

10. Install 6th shift fork into clutch hub. Insert steel ball from transmission case. Pass guide pin through 6th shift fork and install into shift rod. Pull guide pin up. Install steel ball, pressure spring and plug from outside of transmission case, and secure shift rod.
11. Remove shaft stopper installed to clutch housing, and install plug.

Fig. 14: Identifying Shift Rod "A" & Components
Courtesy of MAZDA MOTORS CORP.

Fig. 15: Identifying Housing Bolts "A" & "B"
Courtesy of MAZDA MOTORS CORP.

Fig. 16: Identifying Push Pin Position
Courtesy of MAZDA MOTORS CORP.

EXTENSION HOUSING

Assemble parts in reverse order of disassembly. See Fig.1. Note the following procedures during reassembly:

1. Install NEW oil seal into extension housing.
2. Install NEW bushing into extension housing.
3. Install NEW plug into extension housing.
4. Grip pawl of baffle plate and compress outside diameter using pliers. Face baffle plate in direction shown in illustration. See Fig.17. Insert until baffle plate contacts depth of baffle plate installation hole.
5. Install torsion spring into control lever. See Fig.18.

   Fig. 17: Identifying Baffle Plate
   Courtesy of MAZDA MOTORS CORP.

   Fig. 18: Installing Torsion Spring
   Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS