This is a question that I think only someone that has rebuilt transmissions before can answer.
I've been rebuilding the tranny for my 1988 conv. Currently I'm reassembling the parts, and I'm stuck at the 5th gear/reverse clutch hub. I've noticed that the reverse side of the clutch hub has an additional larger key ring that sits in a groove on the inside of the hub. The problems are that when I fit the parts on the shaft, there is too much space between the synchro and the clutch hub sleeve. If I take it out, everything fits just fine.
This part also doesn't seem to show up in any parts diagrams or manuals for 86-88 or 89-91. I'll take a picture after i get my digital camera back from my brother.

What the hell is it???

Thanks,
Lars
PS This tranny shows evidence of a bad rebuild in the past.

 

bump

 

pics

 

Yah, Pics or sketch or something. I can't picture what you describing. Does sound like you got something mixed up but don't guess. You need it put together right for it to work.

 

I was just about to drive over to my brothers to get my camera back when it hit me... Does reverse have a synchro? I have a whole pile of extras and I might have tried to jam one in that doesn't belong.

Any thoughts?
Lars

 

Pic of the parts in question and the 5th /reverse hub.
You can see the channel where the ring lives.
After doing some searching, looks like I was trying to stick a synchro where there isn't one.
Thanks
[IMG]C:\My Documents\Mazda\Tranny rebuild\Image13.jpg[/IMG]

Ring installed.
[IMG]C:\My Documents\Mazda\Tranny rebuild\Image12.jpg[/IMG]
Lars

 

Here's a pic of what was left of my 1st / 2nd clutch hub.

[IMG]C:\My Documents\Mazda\Tranny rebuild\Image10.jpg[/IMG]
Lars

 

no synchro on reverse. was this your first tranny rebuild? how hard was it? what kind of pullers or other special tools did you need?

rebuilding a gearbox is the next thing i would like to try

 

It wasn't nearly as bad as I thought. I just laid all the parts out in an orderly fashion, took pictures, and took my time. Specialty tools include a standard gear puller metal straps from home depot to extend them (this was an idea I got from another thread), some big sockets, and a multi-directional impact generator (hammer). One of the sockets needs to be about a foot long, so I cut it in half and welded each end to a section of pipe.
I got my parts from www.drivetrain.com. They were polite, inexpensive and responsive. Pretty thorough website as well. They supplied me with Nachi bearings and Mazda OEM nuts. I didn't use the synchros since mine were in fine shape.

I looked over the turbo tranny section in the manual and it looks very different. It might need different tools.
89-91 trannys look almost identical except for some big harmonic damper at the end of the shaft.
Lars

 

pics don't work

 

lmao haha... I love those... they save me so much time on rusted *** cars...

 

pics

 

and one more

 

last one

 

Did you get it all figured out? Did you refit the syncro rings to the gear cones while you had them out. don't forget to check the endplay on the bearings as shown in the FSM. I had to add a little shim on mine.

Your 1ft long socket sounds interesting. Did you use that to remove the locknut off the main shaft? I used a 1 5/8 box end wrench from Napa.

Congrats for doing a rebuild. Wish more would do it.