TRANSAXLE
The G5M-R manual transaxle is a fully synchronized five-speed transaxle. The forward gears are selected by a synchronizer mechanism. Third gear (3GR), fourth gear (4GR) and the fifth speed cluster gear are mounted on the input shaft. First gear (1GR), second gear (2GR) and the reverse output gear are mounted on the output shaft. The helical-cut forward gears are in constant mesh with the corresponding gears on the opposing shaft. The G5M-R features a synchronized reverse gear. The reverse gears have straight cut teeth and are engaged through the reverse idler gear and bushing.
TRANSFER CASE
Note. Transfer case is also rarefied to as Power Take Off (PTO) unit.
The Power Take Off (PTO) unit system consists of a power transfer unit, rear propeller shaft, coupling device and rear axle. The power transfer unit is a gearbox that attaches to a transaxle. The right hand halfshaft passes through the PTO unit and engages the differential side gear as in normal 2WD applications. The PTO unit provides power to the rear driveshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set. Repair of the PTO unit is limited to seals, gaskets and output flange on automatic transaxle vehicles only. In vehicles equipped with a manual transaxle, or if any of the geared components, tapered roller bearings, case cover or internal shafts fail, a new PTO unit must be installed.
Under normal driving conditions, replace transaxle fluid every 60,000 miles. Under severe driving conditions, replace transaxle fluid every 30,000 miles.
Check transfer case fluid level at least once a year. Change transfer case fluid at 150,000-mile intervals unless vehicle is driven in any of the following conditions
- Extended periods of idling or low speed operation.
- Off road operation.
Make sure the vehicle is on level ground and apply the parking brake. If necessary, disconnect the Vehicle Speed Sensor (VSS) harness connector. (Scheme 17) If necessary, remove the VSS bolt and the VSS. (Scheme 18) Check VSS for the full level as shown. (Scheme 19) Install the VSS and the bolt. Tighten VSS bolt to specification. See TORQUE SPECIFICATIONS. Connect the VSS electrical connector.
Scheme 17
Scheme 18
Scheme 19
Raise and support vehicle. Check fluid level at transfer case fill plug hole. (Scheme 20) Fluid should be level with bottom of fill plug hole. Add appropriate fluid as necessary. See RECOMMENDED FLUID.
Scheme 20
Manufacturer recommends MAZDA 115A SAE 75W-90 gear oil meeting API GL-4 specifications.
Note. Transfer case is also referred to as Power Take Off (PTO) unit.
Manufacturer recommends SAE 75W-140 synthetic gear lubricant.
Raise and support the vehicle. Remove the drain plug and drain the fluid. (Scheme 21) Install a new gasket on the drain plug. Install the drain plug and tighten to specification. See TORQUE SPECIFICATIONS. Lower the vehicle. Make sure the vehicle is on level ground and apply the parking brake. If necessary, disconnect the Vehicle Speed Sensor (VSS) harness connector. (Scheme 17) If necessary, remove the VSS bolt and the VSS. Place a funnel into the VSS hole. Fill the transaxle with appropriate fluid through the VSS opening until the full level on the VSS is reached as shown. (Scheme 19) See RECOMMENDED FLUID. Install the VSS and the bolt. Tighten VSS bolt to specification. See TORQUE SPECIFICATIONS. Connect the VSS electrical connector.
Scheme 21
- Raise and support vehicle. Remove the drain plug and drain the fluid. (Scheme 22) Clean the area around the fill plug. Clean and install the drain plug after fluid is drained and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-151563-S06461829652002123100000). Remove the fill plug and fill the transfer case to appropriate level with proper fluid. See «RECOMMENDED FLUID»(ref-151563-S33979410562002123100000).
- Make sure the fluid level is even with the filler opening. Add fluid as necessary. See «CHECKING FLUID LEVEL»(ref-151563-S26685110722002123100000). Install fill plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-151563-S06461829652002123100000).
Scheme 22
ON-VEHICLE REPAIRS
Various components may be serviced without transaxle removal, depending on application. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION .
GEARSHIFT CABLE
Note. Make sure that the gearshift lever is in neutral and the parking brake is set.
- If necessary, remove the center console trim and gearshift lever boot. Remove the gearshift lever knob. Remove the center console trim and gearshift lever boot. Release the gearshift cable adjuster lock. (Scheme 23)
- Release the gearshift cable adjuster. (Scheme 25) Set the transaxle in neutral. Push in the adjuster and secure the lock. If necessary, install the center console trim, the gearshift lever boot assembly and the gearshift lever knob.
