Mazda RX-7 Manual Transmission Removal and Installation: Miata, MX6, MX3 and more

Mazda RX7 1993-1995 FD3S

REMOVAL AND INSTALLATION

B2300, B3000 AND B4000

1. Disconnect negative battery cable. Shift transmission into Neutral. Remove shift lever. Raise and support vehicle. Drain fluid. Disconnect hydraulic line at transmission with Disconnect Tool (T88T-70522-A). Disconnect speedometer cable. Disconnect wiring at transmission. Mark front and rear drive shafts as necessary for installation reference.
2. Disconnect drive shaft(s). Remove starter. Remove exhaust components as necessary for clearance. Remove transfer case (if equipped). Secure transmission jack under transmission. Remove bellhousing bolts. Remove transmission. To install, reverse removal procedure. Tighten bolts to specification.

MIATA

Removal
1. Disconnect negative battery cable. Remove gearshift knob, console and shift lever. See Fig. 1 . Raise and support vehicle. Remove engine undercover. Disconnect exhaust pipe from manifold. Mark position of drive shaft flanges, and remove drive shaft.

Fig. 1: Exploded View Of Drive Line Components (Miata)

2. Remove clutch release cylinder. Remove starter. Disconnect speedometer cable from transmission. Note locations, and disconnect wiring harness from Power Plant Frame (PPF).
3. Remove PPF bracket from rear transmission extension housing. Remove PPF-to-differential side bolts, and pry out spacer. Remove PPF/differential mounting spacer. See Fig. 2 .
4. Install metric bolt (M14 X 1.5) into sleeve. See Fig. 3 . Twist bolt side-to-side while pulling it downward. Install a metric bolt (M6 X 1) into hole in housing block to hold sleeve, and remove long bolt (M14 X 1.5). Remove short bolt (M6 X 1).

DO NOT remove spacers attached to top of Power Plant Frame (PPF). If they are removed, replace PPF.

5. Remove PPF-to-transmission side bolts, and remove PPF. Remove clutch housing-to-engine bolts. Remove transmission from vehicle.

Fig. 2: Installing and Removing Power Plant Frame (Miata)



Fig. 3: Removing Reamer Bolt Sleeve (Miata)

Installation
1. Place jack (from front of engine) under transmission. Raise transmission until it is level with engine. Position Power Plant Frame (PPF) in place. Install PPF/differential mounting spacer, and tighten bolts to 27-38 ft. lbs. (37-52 N.m). Install and tighten PPF-to-transmission side mounting bolts.

Front PPF-to-differential side mounting bolt is considered reamer bolt and is used to align frame.

2. Ensure sleeve is installed into PPF housing block. Install spacer and bolts. Ensure reamer bolt is installed into front hole, and tighten bolt. See Fig. 2.
3. Install transmission-to-PPF bracket. Install remaining PPF bolts, and tighten to specification. To complete installation, reverse removal procedure.

MX-3, MX-6, PROTEGE, 626 REMOVAL AND INSTALLATION

1. Disconnect negative battery cable. Remove console, gear shift knob, and insulator. Remove gear shift lever. Remove transmission cover.
2. Raise and support vehicle. Remove right and left under covers. Leave fluid pipe connected to clutch release cylinder. Remove clutch release cylinder from bell housing and secure aside with wire. Remove starter and center tunnel reinforcement. Remove secondary air injection pipe and catalytic converter. Remove front and rear tunnel reinforcement.
3. Mark drive shaft flange for reassembly reference. Remove drive shaft. Insert Main Shaft Holder (49-S120-440) into extension housing. Support engine and differential. Remove Power Plant Frame (PPF) from transmission and differential. Remove back up light switch from transmission.
4. Remove service access covers "A" and "B". See Fig. 4 . Through service hole "A", swing clutch fork forward and hold release collar against pressure plate. Insert a screwdriver through service hole "B" into space between release collar and wedge collar. Pry and separate release from pressure plate.

Fig. 4: Identifying Clutch Housing Service Access Holes (RX7)

If release collar cannot be separated from clutch cover, remove cover-toflywheel bolts through service hole "B". Remove clutch cover and disc with transmission.

5. Secure transmission jack under transmission. Remove transmission bolts. Remove transmission. If clutch disc and clutch cover were removed with transmission, remove wire ring from release collar. Separate release collar from clutch cover. Remove clutch cover and disc.
6. To install, reverse removal procedure. Raise transmission into position. Install and tighten transmission bolts to specification.

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TORQUE SPECIFICATIONS

• B2300, B3000 & B4000: Tighten in sequence.
  • Clutch Housing-To-Engine Bolts: 28-38 (38-51) Ft. Lbs. (N.m)
  • Starter Bolts: 15-20 (21-27) Ft. Lbs. (N.m)
• Miata: Tighten in sequence.
  • Clutch Housing-To-Engine Block Bolts: 47-66 (64-90) Ft. Lbs. (N.m)
  • Drive Shaft Bolts: 20-22 (27-30) Ft. Lbs. (N.m)
  • PPF-To-Differential Mounting Spacer Bolt (Short): 27-38 (37-52) Ft. Lbs. (N.m)
  • PPF-To-Differential Side Mounting Bolts (Long): 77-91 (104-123) Ft. Lbs. (N.m)
  • PPF-To-PPF Bracket Bolt: 27-40 (37-54) Ft. Lbs. (N.m)
  • PPF-To-Transmission Side Mounting Bolts (Long): 77-91 (104-123) Ft. Lbs. (N.m)
  • Transmission-To-PPF Bracket Bolts: 27-40 (37-54) Ft. Lbs. (N.m)
  • Starter Bolts: 27-38 (37-52) Ft. Lbs. (N.m)
• MX-3, MX-6, Protege and 626: Tighten in sequence.
  • Axle Shaft Nut: 174-235 (235-319) Ft. Lbs. (N.m)
  • Control Rod-To-Transaxle Bolt: 12-17 (16-23) Ft. Lbs. (N.m)
  • Extension Bar-To-Bracket Bolt: 23-34 (31-46) Ft. Lbs. (N.m)
  • Lower Ball Joint Pinch Bolt: 32-43 (44-58) Ft. Lbs. (N.m)
  • Release Cylinder-To-Transaxle Bolt: 12-17 (16-23) Ft. Lbs. (N.m)
  • Stabilizer Bracket-To-Body Bolt: 23-33 (31-45) Ft. Lbs. (N.m)
  • Starter Mounting Bolt: 27-38 (37-52) Ft. Lbs. (N.m)
  • Stopper Bolt Lock Nut: 10-13 (14-18) Ft. Lbs. (N.m)
  • Transaxle-To-Engine Bolt
    • MX-6 AND 626: 66-86 (90-117) Ft. Lbs. (N.m)
    • Protege: 47-66 (64-90) Ft. Lbs. (N.m)
  • Wheel Lug Nuts: 65-87 (88-118) Ft. Lbs. (N.m)
• RX7: Tighten in sequence.
  • Clutch Housing-To-Engine Bolts: 28-38 (38-52) Ft. Lbs. (N.m)
  • Tunnel Reinforcement: 13-19 (18-26) Ft. Lbs. (N.m)

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Mazda RX-7 1993-1995 FD3S

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