2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul APPLICATION MANUAL TRANSAXLE APPLICATIONS Application Transaxle Model Protege & Protege5 F25M-R/G15M-R 626 G25M-R LUBRICATION RECOMMENDED FLUID Use API SAE 75W/90 (all season) or SAE 80W/90 (above 10°C {50°F}) GL-4 or GL-5 oil. FLUID CAPACITIES Oil level should be level with bottom of fill plug opening. Add oil as needed to bring to correct level. For fluid capacity, see FLUID CAPACITIES table. FLUID CAPACITIES {1) Application Quantity - Qts. (Liters) F25M-R/G15M-R 2.83 (2.68) G25M-R 2.9 (2.7) (1) Approximate quantity. ON-VEHICLE SERVICE ADJUSTMENTS NOTE: No external adjustments are necessary. AXLE SHAFTS NOTE: See appropriate AXLE SHAFTS article in DRIVE AXLES. TROUBLE SHOOTING NOTE: See MANUAL TRANSMISSION in TROUBLE SHOOTING - BASIC PROCEDURES article. Thursday, April 26, 2007 7:00:26 AM Page 1 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul REMOVAL & INSTALLATION NOTE: For manual transmission removal procedure, see appropriate CLUTCHES article under TRANSAXLE/TRANSMISSION. TRANSAXLE DISASSEMBLY NOTE: Refer to appropriate exploded view for disassembly reference. See Fig. 1 and Fig. 2 . 1. Remove clutch release bearing and release fork. See Fig. 1 or Fig^ . Mount transaxle in holder. Remove rear cover. Secure primary shaft with Holder (49 F401 440). Shift to 1st or 2nd gear to lock rotation of primary shaft. Uncrimp the tabs of the locknuts. Remove and discard lock nuts from primary and secondary shafts. Align ends of interlock sleeve and control lever. Turn shift rod counterclockwise. Remove sleeve, primary reverse synchronizer cone assembly and synchronizer ring. 2. Remove 5th-reverse gear shift fork, 5th-reverse synchronizer hub assembly with synchronizer ring, 5th gear and gear sleeve from secondary shaft. 3. Remove secondary 5th gear. Remove guide bolt from outside of case. Remove back-up light switch, neutral switch and lock bolt. Remove bolts securing transaxle case to converter housing. Using soft-faced hammer, strike case to loosen and remove. 4. Remove reverse idler gear with shaft. Holding primary shaft assembly, secondary shaft assembly and shift forks as an assembly, lift and remove from clutch housing. Separate shift fork assemblies from shaft assemblies. Thursday, April 26, 2007 7:00:20 AM Page 2 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul 1. Rear Cover 2. Lock Nut (Primary Shaft) 3. Reverse Synchronizer Gear Sleeve 4. Reverse Synchronizer Cone Assembly 5. Reverse Synchronizer Ring 6. Lock Nut (Secondary Shaft) 7.5th/Reverse Shift Fork 8.5th/Reverse Clutch Hub Assembly 9.5th Gear Synchronizer Ring 10. 5th Gear 11. Gear Sleeve 12. Secondary 5th Gear 13. Guide Bolt & Washer 14. Back-Up Light Switch 15. Neutral Safety Switch 16. Lock Bolt 17. Case Assembly 18. Magnet 19. Reverse Idler Shaft 20. Reverse Idler Gear 21.5th/Reverse Shift Rod 22.5th/Reverse Shift Rod End 23. Pin 24. Crank Lever Shaft 25. Crank Lever Assembly 26. Shift Fork & Shift Rod Assembly 27. Steel Ball 28. Spring 29. Primary Shaft Gear Assembly 30. Secondary Shaft Gear Assembly 31. Differential Assembly 32. Clutch Housing 33. Synchronizer Key Springs 34. Clutch Hub 35. Synchronizer Keys 36. Clutch Hub Sleeve 37.3rd/4th Shift Fork 38. Interlock Sleeve 39. Control Lever 40.1 st/2nd Shift Fork 41. Control Rod 42. Control End Fig. 1: Exploded View Of Transaxle (F25M-R/G15M-R) Courtesy of MAZDA MOTORS CORP. Thursday, April 26, 2007 7:00:20 AM Page 3 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul 1. Rear Cover 2. Lock Nut (Primary Shaft) 3. Lock Nut (Secondary Shaft) 4. Spacer 5. Reverse Synchronizer Gear Sleeve 6. Reverse Synchronizer Cone Assembly 7. Reverse Synchronizer Ring 8. 5th/Reverse Shift Fork 9.5th/Reverse Clutch Hub Assembly 10.5th Gear Synchronizer Ring 11.5th Gear 12. Gear Sleeve 13. Secondary 5th Gear 14. Lock Bolt 15. Guide Bolt & Washer 16. Lock Bolt, Ball & Spring 17. Back-Up Light Switch 18. Neutral Safety Switch 19. Transaxle Case 20. Magnet 21. Reverse Idler Shaft 22. Reverse Idler Gear 23. 5th/Reverse Shift Rod 24.5th/Reverse Shift Rod End 25. Pin 26. Crank Lever Shaft 27. Crank Lever Assembly 28. Shift Fork & Shift Rod Assembly 29. Steel Ball 30. Spring 31. Primary Gear Shaft Assembly 32. Secondary Gear Shaft Assembly 33. Differential Assembly 34. Clutch Housing 35. Synchronizer Key Springs 36. Clutch Hub Sleeve 37. Synchronizer Keys 38. Clutch Hub 39.3rd/4th Shift Fork 40. Interlock Sleeve 41. Control Lever 42.1st/2nd Shift Fork 43. Control Rod 44. Control End Fig. 2: Exploded View Of Transaxle (G25M-R) Courtesy of MAZDA MOTORS CORP. Thursday, April 26, 2007 7:00:20 AM Page 4 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul GOO380237 Fig. 3: Exploded View Of Transaxle Case Components (F25M-R/G15M-R) Courtesy of MAZDA MOTORS CORP. Thursday, April 26, 2007 7:00:20 AM Page 5 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul 1. Primary Shaft Bearing Race 2. Primary Shaft Oil Seal 3. Secondary Shaft Bearing Race 4. Funnel 5. Guide Plate Assembly 6. Change Arm 7. Roll Pin 8. Change Rod G99C03759 9. Boot 10. Selector 11. Change Rod Oil Seal 12. Breather Cover 13. Breather 14. Speedometer Driven Gear 15. Differential Oil Seal 16. Reverse Lever Shaft 17. Reverse Lever 18 Drain Plug 19. Case Bearing Race 20. Case Adjustment Shim 21. Differential Bearing Race 22. Differential Adjusting Shim 23. Oil Passage Fig. 4: Exploded View Of Transaxle Case & Components (G25M-R) Courtesy of MAZDA MOTORS CORP. COMPONENT DISASSEMBLY & REASSEMBLY TRANSAXLE CASE Disassembly 1. Lift mainshaft oil funnel from clutch housing and remove funnel and outer race bearing as a unit. Remove 3 bolts retaining shifter guide plate. Remove shifter guide plate, reverse gate and spring. See Fig. 4 . 2. Drive out spring pin retaining selector arm to change rod and withdraw change rod from clutch housing. Remove boot from change rod and oil seal from rod bore. Remove vent cover and vent from top of clutch housing. Thursday, April 26, 2007 7:00:20 AM Page 6 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul reverse lever shaft roll pin. Remove spring and ball (if equipped). 4. Remove reverse lever set spring and reverse lever. Drive out differential bearing races. Remove 5th gear outer bearing races from transaxle. 5. Remove diaphragm spring and adjusting shims from transaxle case. Remove differential oil seal from transaxle case. NOTE: Check and adjust bearing preload before reassembling case. See BEARING PRELOAD under ADJUSTMENTS. Reassembly To reassemble, reverse disassembly procedure. Smaller diameter of diaphragm spring (located behind bearing race) should face toward inside of transaxle case. PRIMARY SHAFT NOTE: When disassembling synchronizer assemblies, note cut-outs in some blocking rings for reassembly reference. Cut-out rings must be installed in original position. Disassembly Remove snap rings as necessary. See Fig. 5 . On G25M-R, press off bearing next to 4th gear. On F25M-R, press off 4th gear and bearing together. Press off 4th gear. Press off 3rd gear with clutch hub assembly. Press off bearing on clutch end. Thursday, April 26, 2007 7:00:20 AM Page 7 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul 1. Taper Roller Bearing (Ball Bearing On F25M-R) 2. Primary Shaft 3. 3rd/4th Clutch Hub 4. Synchro Key Ring 5. Key G96A31617 6. Hub 7. Sleeve 8.3rd Gear 9. Synchronizer Ring 10. Retaining Ring 11.4th Gear 12. Secondary Shaft 13.1st Gear 14.1st/2nd Clutch Hub 15. Reverse Gear 16.3rd Gear 17. Retaining Ring 18. 4th Gear 19.2nd Gear Thursday, April 26, 2007 7:00:20 AM Page 8 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Fig. 5: Exploded View Of Primary & Secondary Shafts (G15M-R/G25M-R Shown; F25M-R Is Similar) Courtesy of MAZDA MOTORS CORP. Inspection 1. Using dial indicator, measure shaft gear runout. See Fig. 6 . See TRANSAXFE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT SPECIFICATIONS (G25M-R) table. 2. Inspect synchronizer cones for wear. Inspect gear teeth for damage, wear and cracks. Inspect synchronizer ring matching teeth for damage and wear. Inspect synchronizer ring teeth for damage, wear and cracks. Measure clearance between synchronizer ring and teeth on matching gear. See TRANSAXLE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT SPECIFICATIONS (G25M-R) table. Inspect clutch hub sleeve and hub operation. Inspect gear teeth for damage, wear and cracks. Inspect synchronizer keys for damage, wear and cracks. 3rd 4th G00031398 Thursday, April 26, 2007 7:00:20 AM Page 9 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Fig. 6: Measuring Primary Shaft Gear Runout At 3rd & 4th Gear Courtesy of MAZDA MOTORS CORP. Reassembly 1. To reassemble, reverse disassembly procedure. Measure clearance after each component is installed. See TRANSAXLE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT SPECIFICATIONS (G25M-R) table. See Fig. 5 . 2. Select correct synchronizer keys. See Fig. 7 . For F25M-R, see SYNCHRONIZER KEY DIMENSIONS table. For G25M-R, see TRANSAXLE COMPONENT SPECIFICATIONS (G25M- R) table. Install keys and spring in synchronizer hub. Install synchronizer assembly with bevel facing away from input end of primary shaft. Locate synchronizer rings on correct clutch assembly. TRANSAXLE COMPONENT SPECIFICATION S (F25M-R) Application Standard - In. (mm) Maximum - In. (mm) Primary Shaft 3rd Gear Thrust (3rd-To-2nd Gear) 0.002-0.008 (0.06-0.21) 0.010 (0.26) 4th Gear Thrust (4th Gear-To-Bearing) 0.002-0.008 (0.06-0.21) 0.066 (0.26) Shaft End Thrust Clearance 0.0002-0.0039 (0.005- 0.10) N/A Secondary Shaft 1st Gear Thrust (1st Gear-To-Differential Drive Gear) 0.002-0.011 (0.05-0.28) 0.013 (0.33) 2nd Gear Thrust (2nd-To-3rd Gear) 0.007-0.020 (0.18-0.51) 0.22 (0.56) lst-2nd Hub Sleeve-To-Shift Fork 0.004-0.014(0.10-0.36) 0.034 (0.86) 3rd-4th Hub Sleeve-To-Shift Fork 0.008-0.020 (0.20-0.50) .039(1.0) 5th-Reverse Hub Sleeve-To-Shift Fork 0.016-0.030 (0.40-0.75) 0.049(1.24) 5th Gear Thrust Clearance 0.0024-0.0102 (0.06- 0.26) 0.0122 (0.31) Synchronizer-To-Gear 0.044-0.074(1.12-1.88) 0.031 (0.80) Reverse Idler Gear-To-Shift Lever 0.004-0.013 (0.10-0.32) 0.015 (0.37) Primary Shaft Runout N/A 0.002 (0.05) Secondary Shaft Runout N/A 0.0006 (0.015) Oil Clearance (Gear Inner Diameter-To-Shaft Outer Diameter) All 0.001-0.003 (0.003-0.07) N/A Differential Backlash 0.0-0.004 (0.0-0.10) N/A TRANSAXLE COMPONENT SPECIFICATIONS (G15M-R/G25M-R) Application Standard - In. (mm) Limit - In. (mm) Gear 1 1 Thursday, April 26, 2007 7:00:20 AM Page 10 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul 1st Gear Thrust Clearance 0.002-0.011 (0.05-0.29) 0.013 (0.34) 2nd Gear Thrust Clearance 0.007-0.018(0.17-0.37) 0.018(0.46) 3rd Gear Thrust Clearance 0.002-0.011 (0.05-0.29) 0.013 (0.34) 4th Gear Thrust Clearance 0.007-0.015(0.17-0.37) 0.011 (0.27) 5th Gear Thrust Clearance 0.004-0.008 (0.10-0.22) 0.037 (0.95) 1st Gear Clearance (Gear Inner Diameter-To-Shaft Outer Diameter) 0.0012-0.0031 (0.030- 0.080) N/A 2nd Gear Clearance (Gear Inner Diameter-To-Shaft Outer Diameter) 0.0020-0.0035 (0.050- 0.090) N/A 3rd Gear Clearance (Gear Inner Diameter-To-Shaft Outer Diameter) 0.0012-0.0031 (0.030- 0.080) N/A 4th Gear Clearance (Gear Inner Diameter-To-Shaft Outer Diameter) 0.0012-0.0031 (0.030- 0.080) N/A 5th Gear Clearance (Gear Inner Diameter-To-Shaft Outer Diameter) 0.0012-0.0031 (0.030- 0.080) N/A Synchronizer Ring & Key Synchronizer Ring & Gear Clearance 0.059 (1.50) 0.031 (0.80) Synchronizer Key Dimension ^ Dimension No. 1 (1st & 2nd) 0.744-0.751 (18.9-19.1) N/A Dimension No. 2 (1st & 2nd) 0.188-0.194 (4.78-4.93) N/A Dimension No. 3 (1st & 2nd) 0.1670-0.1677 (4.24- 4.26) N/A Dimension No. 1 (3rd, 4th, 5th & Reverse) 0.666-0.673 (16.9-17.1) N/A Dimension No. 2 (3rd, 4th, 5th & Reverse) 0.188-0.194 (4.78-4.93) N/A Dimension No. 3 (3rd, 4th, 5th & Reverse) 0.1670-0.1677 (4.24- 4.26) N/A Clutch Hub & Shift Fork 1-2 Shift Fork & Reverse Gear Clearance 0.004-0.018(0.10-0.45) 0.037 (0.95) 3-4 Shift Fork & Clutch Hub Sleeve Clearance 0.004-0.016(0.10-0.40) 0.035 (0.90) 5-Rev. Shift Fork & Hub Sleeve Clearance 0.004-0.014(0.10-0.36) 0.033 (0.85) Reverse Idler Gear & Reverse Gear Clearance 0.004-0.014(0.10-0.35) 0.033 (0.84) Primary Shaft Runout N/A 0.002 (0.05) Bearing Preload (2) N/A Secondary Shaft Runout N/A 0.0006 (0.015) Bearing Preload (3) N/A Differential Bearing Preload (4) N/A Backlash 0.0020-0.0059 (0.05- N/A Thursday, April 26, 2007 7:00:21 AM Page 11 © 2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul J 0.15) (1) See Fig. 7 . (2) 0.9-2.1 INCH Lbs. (0.1-0.2 N.m) (3) 2.0-7.5 INCH Lbs. (0.2-0.7 N.m) (4) 13-17 INCH Lbs. (1.4-1.9 N.m) SYNCHRON IZER KEY DIMENSIONS (F25M-R) Synchro Dimension No. 1 - In. (mm) Dimension No. 2 - In. (mm) Dimension No. 3 - In. (mm) lst-2nd 0.748 (19.00) 0.167 (4.25) 0.197 (5.00) 3rd-4th 0.669 (17.00) 0.167 (4.25) 0.197 (5.00) 5th-Reverse 0.669 (17.00) 0.219(5.55) 0.197 (5.00) 2 -- i -H --3 y -^ G93H24809 Fig. 7: Measuring Synchronizer Key Courtesy of MAZDA MOTORS CORP. SECONDARY SHAFT Disassembly Press off 4th gear with bearing. Remove retaining ring. Shift clutch hub sleeve to 1st gear. Press off 3rd and 2nd gears. Remove retaining ring. Press off 1st gear with 1-2 clutch hub assembly. Press off bearing on differential drive gear end of shaft. See Fig. 10 or Fig. 11 . Inspection 1. Using dial indicator, measure shaft gear runout. See Fig. 8 . Maximum runout is .0006" (.015 mm). See TRANS AXLE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT Thursday, April 26, 2007 7:00:21 AM Page 12 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul SPECIFICATIONS (G15M-R/G25M-R) table. 2. Inspect synchronizer cones for wear. Inspect gear teeth for damage, wear and cracks. Inspect synchronizer ring matching teeth for damage and wear. Inspect synchronizer ring teeth for damage, wear and cracks. Measure clearance between synchronizer ring and teeth on matching gear. See TRANSAXLE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT SPECIFICATIONS (G15M-R/G25M-R) table. Inspect clutch hub sleeve and hub operation. Inspect gear teeth for damage, wear and cracks. Inspect synchronizer keys for damage, wear and cracks. G00031399 Fig. 8: Measuring Secondary Shaft Gear Runout At 1st & 2nd Gear Courtesy of MAZDA MOTORS CORP. Reassembly To reassemble, reverse disassembly procedure. Measure clearance after pressing on each component. See Thursday, April 26, 2007 7:00:21 AM Page 13 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul TRANSAXLE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT SPECIFICATIONS (G15M-R/G25M-R) table. See Fig. 5 . DIFFERENTIAL Pre-Disassembly Backlash Inspection Install left and right axle shafts into differential. Support axle shafts on V-blocks. See Fig. 9 . Measure backlash of both pinion gears. Backlash should be as specified. See TRANSAXLE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT SPECIFICATIONS (G15M-R/G25M-R) table. Rebuild or replace differential assembly if backlash is not as specified. G96F31620 Fig. 9; Checking Pinion Gear Backlash Courtesy of MAZDA MOTORS CORP. Disassembly 1. Remove roll pin and pinion shaft. See Fig. 10 . Remove pinion gears and rotate thrust washers out of differential housing. Thursday, April 26, 2007 7:00:21 AM Page 14 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul 2. Remove side gears and thrust washers. Using appropriate bearing puller, remove side bearings. DO NOT remove speedometer drive gear unless damaged. Reassembly Install speedometer drive gear (if removed) and bearings. Install thrust washers, pinion gears and side gears. Install pinion shaft. Install and crimp roll pin. 1. Roll Pin 2. Pinion Shaft 3. Thrust Washer 4. Pinion Gear 5. Side Gear 6. Thrust Washer 7. Side Bearing 8. Speedometer Gear 9. Side Bearing 10. Ring Gear G96C31619 Thursday, April 26, 2007 7:00:21 AM Page 15 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Fig. 10: Exploded View Of Differential Courtesy of MAZDA MOTORS CORP. ADJUSTMENTS BEARING PRELOAD (F25M-R) Primary Shaft 1. Install primary shaft assembly into clutch housing. Install transaxle case into clutch housing and tighten bolts to specification. See TORQUE SPECIFICATIONS . 2. Mount dial indicator to clutch housing and place plunger on end of primary shaft. See Fig. 11 . Zero dial indicator. Pull primary shaft upward and record measurement. 3. Ensure thrust clearance is within specification. See TRANSAXLE COMPONENT SPECIFICATIONS (F25M-R) or TRANSAXLE COMPONENT SPECIFICATIONS (G25M-R) table. Select appropriate shim to adjust clearance. Shims are available in the following thicknesses: 0.004-0.024" (0.10-0.60 mm) in 0.004" (0.10 mm) increments. Thursday, April 26, 2007 7:00:21 AM Page 16 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul G96I31623 Fig. 11: Measuring Primary Shaft Thrust Clearance (F25M-R) Courtesy of MAZDA MOTORS CORP. Secondary Shaft 1. Disassemble transmission case from clutch housing. Remove primary shaft. Install funnel and secondary bearing race in clutch housing. See Fig. 4 . Install secondary shaft into transaxle case. Install transaxle case to clutch housing and tighten bolts to specification. See TORQUE SPECIFICATIONS . 2. Mount dial indicator to clutch housing and place plunger on end of secondary shaft. See Fig. 12 . Zero dial indicator. Pull secondary shaft upward and record measurement. Add 0.0012" (0.03 mm) to measured thrust clearance and record. Add 0.0031" (0.08 mm) to thrust clearance and record. Select thickest adjustment shim in range determined by these two measurements. Shims are available in the following thicknesses: 0.006-0.020" (0.15-0.50 mm) in 0.002" (0.05 mm) increments. Thursday, April 26, 2007 7:00:21 AM Page 17 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul G96J31624 Fig. 12: Measuring Secondary Shaft Thrust Clearance (F25M-R) Courtesy of MAZDA MOTORS CORP. Differential Assembly 1. Remove bearing outer race and adjustment shims from transaxle case. Mount differential assembly in converter housing (with race installed). Install bearing outer race onto Selector Gauge (49 F401 381B- Shim Selector Tool Set). Set selector gauge on differential. Set transaxle case on selector gauge. 2. Eliminate gap on selector gauge by turning collars of selector gauge. Mount spacing collars between transaxle case and clutch housing. See Fig. 13 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . 3. Using rods on collars of selector, turn selector in a direction which widens gap between collars of selector. Turn selector (to widen gap) until it no longer turns. This will seat bearing race. 4. Turn selector collars in opposite direction until gap is closed. Mount preload adapter into differential until it contacts pinion shaft. Using INCH-lb. torque wrench, rotate differential. See Fig. 14 . Turn selector collars until turning torque is 0.26-6.59 INCH lbs. (0.03-0.74 N.m). Thursday, April 26, 2007 7:00:21 AM Page 18 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Using feeler gauge, measure gap between selector collars. See Fig. 13 . Take measurements around entire circumference of selector. Select shims equal to maximum clearance measured. Shims range in thickness from 0.008" (0.20 mm) to 0.022" (0.55 mm) in increments of 0.002" (0.5 mm). Unbolt converter housing from transaxle case. Remove selector gauge. Install selected shims in transaxle case. Install bearing race. Set differential in transaxle case. Install converter housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Position preload adapter into differential until in contacts pinion shaft. Measure bearing preload with INCH-lb. torque wrench. See Fig. 14 . Differential bearing preload should be 0.26-6.59 INCH lbs. (0.03- 0.74 N.m). If bearing preload is not within specification, repeat steps 1 -5 . Thursday, April 26, 2007 7:00:21 AM Page 19 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul /^Spacer Clearance 5= t Adjusting Rod Feeler Gauge Thursday, April 26, 2007 7:00:21 AM Page 20 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Fig. 13: Determining Differential Side Bearing Preload Shims Courtesy of MAZDA MOTORS CORP. G96H31622 Fig. 14: Measuring Differential Side Bearing Preload Courtesy of MAZDA MOTORS CORP. BEARING PRELOAD (G15M-R/G25M-R) 1. Install primary and secondary shaft bearing outer races (with shims removed) into transaxle case. Mount clutch housing onto transaxle hangar. Install differential bearing outer race into clutch housing, and tap into place. 2. Remove primary and secondary shaft outer race from clutch housing. Remove differential bearing outer race from transaxle case. Note selector arrangement. See Fig. 15 . 3. Install differential assembly into clutch housing. Install outer bearing race on differential bearing. Install appropriate selector from Shim Selector Tool Set (49 G030 380D) on outer bearing race. Install selector in primary and secondary outer bearing race bore. Place outer bearing races in selector and set shaft into appropriate selector. Install transaxle case, spacers and bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . 4. Seat bearings by turning selector to widen measuring gap. See Fig. 16 . Turn selector with adjuster bars until selector cannot be turned by hand. Reverse direction to eliminate measuring gap. Expand selector by Thursday, April 26, 2007 7:00:21 AM Page 21 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul hand until selector no longer turns. Ensure shafts turn smoothly. 5. Measure gap with feeler gauge. See Fig. 17 . Take measurements around entire circumference of selector. Select thinnest allowable shim to obtain standard clearance (primary shaft) or bearing preload (secondary shaft). 6. Primary shaft bearing clearance is 0.0-0.002" (0-0.05 mm). Shims range in thickness from 0.008" (0.20 mm) to 0.028" (0.70 mm) in increments of 0.002" (0.05 mm). 7. Secondary shaft bearing preload is selector clearance plus 0.001-0.003" (0.03-0.08 mm). Shims range in thickness from 0.008" (0.20 mm) to 0.028" (0.70 mm) in increments of 0.002" (0.5 mm). 8. Turn differential selector collars in opposite direction until gap is closed. Mount preload adapter into differential until in contacts pinion shaft. Using INCH-lb. torque wrench, rotate differential. See Fig. 14 . Turn selector collars until turning torque is 13-17 INCH lbs. (1.4-1.9 N.m). 9. Using feeler gauge, measure clearance of gap between selector collars. See Fig. 13 . Take measurements around entire circumference of selector. Select shims equal to maximum clearance measured plus 0.006" (0.15 mm). Shims range in thickness from 0.004" (0.10 mm) to 0.047" (1.20 mm) in increments of 0.002" (0.05 mm). 10. Disassemble transmission case. Remove selectors. Remove bearing races and install selected shims. See Fig^ . Install primary shaft and differential. Install transaxle case to clutch housing. Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS . 11. Using INCH-lb. torque wrench and appropriate adapter, measure turning torque (preload) of differential and primary shaft. See Fig. 14 and Fig. 18 . Differential preload should be 13-17 INCH lbs. (1.4-1.0 N.m). Primary shaft preload should be 0.9-2.1 INCH lbs. (0.1-0.2 N.m). If preload is not as specified, repeat adjustment procedure. 12. Disassemble transmission case. Remove primary shaft and differential. Install secondary shaft. Install transaxle case to clutch housing. Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS . 13. Using INCH-lb. torque wrench and appropriate adapter, measure turning torque (preload) of secondary shaft. See Fig. 18 . Secondary shaft preload should be 1.8-6.5 INCH lbs. (0.2-0.7 N.m). If preload is not as specified, repeat adjustment procedure. Thursday, April 26, 2007 7:00:21 AM Page 22 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Selector Bearing Race Differential Bearing Race- Selector- Transaxle Case Bearing Race Secondary Shaft Assembly Primary Shaft Assembly Bearing -Race Selector Clutch- Housing G96A31625 Fig. 15: Identifying Selector Location Courtesy of MAZDA MOTORS CORP. Thursday, April 26, 2007 7:00:21 AM Page 23 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Adjusting Rod Oi > G96B31626 Fig. 16: Expanding Selector Tool Courtesy of MAZDA MOTORS CORP. Thursday, April 26, 2007 7:00:21 AM Page 24 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Fig. 17: Measuring Selector Gap Courtesy of MAZDA MOTORS CORP. Thursday, April 26, 2007 7:00:21 AM Page 25 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul INCH/lb. Fig. 18: Measuring Primary & Secondary Turning Torque (G15M-R/G25M-R) Courtesy of MAZDA MOTORS CORP. TRANSAXLE REASSEMBLY 1. To reassemble, reverse disassembly procedure. Place primary and secondary shaft assemblies into clutch Thursday, April 26, 2007 7:00:21 AM Page 26 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul housing. Shift to 2nd gear and install shift fork and shift rod assembly. 2. Insert spring seat and spring into reverse lever shaft. Install steel ball and place scraper so that ball contacts steel ball. See Fig. 19 . With edge of control end against scraper, rod will line up with shift rod coupling hole in clutch housing. 3. Set each clutch hub sleeve to neutral position, and tap shift rod from above so steel ball goes into center groove. Pull steel ball section of control end forward so steel ball goes into detent in groove. 4. Fit crank lever between change arm and control end. Connect crank lever shaft and clutch housing. Align pin holes of crank lever shaft and clutch housing. Insert new retaining pin. See Fig. 20 . 5. Install 5th-reverse shift rod and rod end. Install reverse idler gear and idler shaft. Attach magnet to clutch housing. Align end of interlock sleeve with control lever and point reverse idler shaft screw hole toward outside of transaxle case. Apply sealant to case mating surfaces, and install clutch housing to transaxle case. Install 5th-reverse clutch hub assembly and shift fork. Shift transmission into 1st gear. Tighten lock nuts on primary and secondary shafts to specification and stake into place. See TORQUE SPECIFICATIONS . Feeler Gauge G96E31629 Fig. 19: Installing Shift Shaft Assembly Courtesy of MAZDA MOTORS CORP. Thursday, April 26, 2007 7:00:21 AM Page 27 ©2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul G96H31630 Fig. 20: Install Crank Lever Shaft Retaining Pin Courtesy of MAZDA MOTORS CORP. TORQUE SPECIFICATIONS F25M-R TORQUE SPECIFICATIONS (F25M-R) Application Ft. Lbs. (N.m) Back-Up Light Switch 15-18 (20-24) Drain Plug N/A Guide Plate Bolt (Long) 17-24 (23-32) Neutral Safety Switch 15-18 (20-24) Primary & Secondary Shaft Lock Nut 94-152(128-205) Transaxle Case-To-Clutch Housing Bolt 14-18(19-25) INCH Lbs. (N.m) Bleeder Cover Bolt 61-95 (6.9-10.7) Change Arm Joint Bolt 104-138 (11.8-15.6) Change Arm-To-Change Rod Bolt 105-121 (11.8-13.7) Guide Plate Bolt (Short) 70-99 (7.9-11.2) Lever Set Spring Bolt 106-124(12-14) Oil Guide Bolt 79-121 (8.9-13.7) Thursday, April 26, 2007 7:00:21 AM Page 28 © 2005 Mitchell Repair Information Company, LLC. 2003 Mazda Protege Mazdaspeed 2001-03 MANUAL TRANSMISSIONS Mazda F25M-R, G15M-R & G25M-R 5-Speed Overhaul Oil Passage Bolt 70-99 (7.9-11.2) Rear Cover Bolt N/A Speedometer Driven Gear N/A Top Cover-To-Clutch Housing Bolt 69-97 (7.8-11) 5th-Reverse Shift Rod Bolt 104-121 (11.8-13.7) G15M-R/G25M-R TORQUE SPECIFICATIONS (G15M-R/G25M-R) Application Ft. Lbs. (N.m) Back-Up Light Switch 15-21 (20-29) Drain Plug 30-43 (40-58) Guide Plate Bolt (Long) 17-24 (23-32) Neutral Safety Switch 15-21 (20-29) Primary & Secondary Shaft Lock Nut 95-140(130-190) Transaxle Case-To-Clutch Housing Bolt 28-38 (38-51) INCH Lbs. (N.m) Bleeder Cover Bolt (F25M-R) 61-95 (6.9-10.7) Change Arm-To-Change Rod Bolt 105-121 (11.8-13.7) Guide Plate Bolt (Short) 79-121 (8.9-13.7) Lever Set Spring Bolt 106-124(12-14) Oil Guide Bolt 79-121 (8.9-13.7) Oil Passage Bolt 70-99 (7.9-11.2) Rear Cover Bolt 69-97 (7.8-11) Speedometer Driven Gear 70-99 (7.9-11.2) Top Cover-To-Clutch Housing Bolt 69-97 (7.8-11) 5th-Reverse Shift Rod Bolt 104-121 (11.8-13.7) Thursday, April 26, 2007 7:00:21 AM Page 29 © 2005 Mitchell Repair Information Company, LLC.