need help replacing mazda clutch

BriceJohnson · **Joined:** Thu Apr 13, 2006 7:33 am **Posts:** 2230

FWIW, when I put mine back together, I was all worried, b/c I got that same resistance, and with the axles in the air, when I would put the clutch in, it wouldn't roll. First time I started it up thoguh, it popped into place and rolled fine. I wonder if the splines were just slightly misaligned between the clutch disc and the input shaft, causing a slight warp that just popped into place once it started up. At least thats my theory.

RodneyWright · **Posted:** Fri Sep 06, 2013 12:16 pm

OHHH, I am so freaking pissed right now. Started the car w/ out the drive axles in place. Shifted great and no issues. So what happened? The f'ing drive splines are now at the bottom of the transmission.. F me.... No clue how to put these back together.

Does anyone have a link to the tranny on these cars? I can really use some help here.... If can't get these back in place I guess the tranny comes back out. So much for saving money.

Scott Johnson · **Posted:** Fri Sep 06, 2013 12:40 pm

RodneyWright wrote:

Does anyone have a link to the tranny on these cars? I can really use some help here.... If can't get these back in place I guess the tranny comes back out. So much for saving money.

Pretty sure the first step will be transmission removal. Might as well do the clutch while the tranny is out.

Too early?

Sorry for the bad luck.

JamesShort · **Posted:** Fri Sep 06, 2013 1:10 pm

RodneyWright wrote:

The f'ing drive splines are now at the bottom of the transmission..

Please explain....are you saying that the side gears are no longer in place?!?

RodneyWright · **Posted:** Fri Sep 06, 2013 1:18 pm

JamesShort wrote:

RodneyWright wrote:

The f'ing drive splines are now at the bottom of the transmission..

Please explain....are you saying that the side gears are no longer in place?!?

Yup.... the splined or side gears that attach to the axles have slipped. I have one pseudo back in place, but I'm having a heck of a time getting to the other one. Fishing right now. It's caught under a "ledge" at the bottom of the tranny. I'm giving myself 1 hr to fish these back in place then I start taking the tranny out. This really sucks....

Vincent Keene · **Posted:** Fri Sep 06, 2013 1:22 pm

RodneyWright wrote:

OHHH, I am so freaking pissed right now. Started the car w/ out the drive axles in place.

Not trying to rub salt in the wound, but what why didn't you go ahead and put the axles in place?

Aaron Buckley · **Posted:** Fri Sep 06, 2013 1:26 pm

JamesShort wrote:

Please explain....are you saying that the side gears are no longer in place?!?

From the way it sounds, yes. They can fall out if they are really rocked around during installation (although very uncommon). I know people that use a coat hanger to wire them up just ensure this doesn't happen. I've never had this problem, but also never ran a car without axles.... which meant it either had tranny fluid pouring all over the floor during this time or had none in at all in there, which is really bad.

The first step is to remove the transmission, then open up the transmission case and fish the gears along with the shims that likely fell out too. Then put them back in place and button everything up. - AB

Vincent Keene · **Posted:** Fri Sep 06, 2013 1:37 pm

Aaron Buckley wrote:

...also never ran a car without axles.... which meant it either had tranny fluid pouring all over the floor during this time or had none in at all in there, which is really bad.

Those were my thoughts. I always snap the axle back in place and fill it with fluid before proceeding any further.

Brice's situation sounded unique because I've never been able to get the halves together unless the input shaft splines were aligned. If the case was close, and they aren't aligned, just slide one of the axles into place and use it to rotate the gears until it the input shaft splines line up.

FWIW, the transmission has been in/out of our Prelude at least 10 times. Stephen and I can almost do it blindfolded by now.

Jason Tower · **Joined:** Wed Jun 11, 2008 3:31 pm **Posts:** 1173

Vincent Keene wrote:

Aaron Buckley wrote:

...also never ran a car without axles.... which meant it either had tranny fluid pouring all over the floor during this time or had none in at all in there, which is really bad.

Those were my thoughts. I always snap the axle back in place and fill it with fluid before proceeding any further.

Brice's situation sounded unique because I've never been able to get the halves together unless the input shaft splines were aligned. If the case was close, and they aren't aligned, just slide one of the axles into place and use it to rotate the gears until it the input shaft splines line up.

FWIW, the transmission has been in/out of our Prelude at least 10 times. Stephen and I can almost do it blindfolded by now.

i think mike's record to replace a trans on the integra is 52 min

RodneyWright · **Posted:** Fri Sep 06, 2013 2:05 pm

Aaron Buckley wrote:

JamesShort wrote:

Please explain....are you saying that the side gears are no longer in place?!?

From the way it sounds, yes. They can fall out if they are really rocked around during installation (although very uncommon). I know people that use a coat hanger to wire them up just ensure this doesn't happen. I've never had this problem, but also never ran a car without axles.... which meant it either had tranny fluid pouring all over the floor during this time or had none in at all in there, which is really bad.

The first step is to remove the transmission, then open up the transmission case and fish the gears along with the shims that likely fell out too. Then put them back in place and button everything up. - AB

Shit.... I didn't even think of the shims. As for testing w/ out axles, I wanted to make sure it was all working ok before I started putting the axles and control arms back in place. My God, the extra work I've just created for myself....

I guess it's time to take it back out... :stick:

Vincent Keene · **Posted:** Fri Sep 06, 2013 2:25 pm

Be careful when you open the case. There can be detent balls, and snap rings that need to be placed back correctly.

Richard Casto · **Posted:** Fri Sep 06, 2013 2:43 pm

Rodney,

I feel your pain.

This reminds me of when I recently decided to rebuild the automatic transmission in my Honda Odyssey (I am willing to try most tasks myself at least just once).

After weeks of work I had the entire car together and while the main issue was fixed, it refused to shift into 1st gear reliably. I was so disgusted with the entire situation that it took me a good week to even consider diving back in to fix it. Ultimately I paid someone else to fix it (there was no smoking gun when they pulled it apart, it went back together and worked, they did replace a few solenoids that I didn't during my rebuild. It might have been a sticking valve.).

I would consider sleeping on it and seeing if there is any path to recovery vs. pulling it out right away. At least you don't have the suspension back on.

Good luck!

Richard

RodneyWright · **Posted:** Fri Sep 06, 2013 3:30 pm

Richard Casto wrote:

....

I would consider sleeping on it and seeing if there is any path to recovery vs. pulling it out right away. At least you don't have the suspension back on.

Good luck!

Richard

There's always a learning curve in life. I've at least stopped cussing after a beer and the trans is already out. I talked to Rex at Happy Japs and he doesn't think there's any shims. I don't think there are either. From what I can see there's a gear side and a beveled side to these drive gears. I don't see how you could have a beveled shim....

Anyway, tranny is on the bench, so now comes the task of lining these things up. I tried to work on it under the car and simply couldn't maneuver around or see if I had stuff lined up. Tranny came out some much easier the 2nd time....

RodneyWright · **Posted:** Fri Sep 06, 2013 4:07 pm

Well I found a shim :stick:

This is now beyond my ability and looks like I need professional help. This SO sucks.... Really hoping I'd been driving it by now. Yeehaw, let's spend more money cuz I'm stupid...

BriceJohnson · **Joined:** Thu Apr 13, 2006 7:33 am **Posts:** 2230

If it makes you feel better Rodney, I apparently missed a vacuum line when I put mine back together (from unneccesarily pulling the intake manifold). Car went back together, the clutch wouldn't disengage, and it wouldn't idle (b/c of a vacuum leak of course). I said SCREW IT I'M DONE!, had the car towed to Rex, he reconnected the vacuum line, the clutch popped into place and it worked from there. Thankfully Happy Japs is an honest garage and chose not to gouge me on it.

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