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Primary Shaft: Reassembly

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  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 Figure .
  2. Select correct synchronizer keys. See Fig 1 . 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 SPECIFICATIONS (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)
1st-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
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 (1)
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 (0.05-0.15) N/A
(1) See Fig 1 .
(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)
SYNCHRONIZER KEY DIMENSIONS (F25M-R)

Synchro Dimension No. 1 - In. (mm) Dimension No. 2 - In. (mm) Dimension No. 3 - In. (mm)
1st-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)
Fig 1: Measuring Synchronizer Key
G93H24809Courtesy of MAZDA MOTORS CORP.
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