popping out of gear

[thisfords4u]

I have an opportunity to buy a 91 Ranger xcab 4x4, 4.0 manual from a friend for 1000.00. the catch 22 on it is it pops out of first gear, and all other gears are making a lot of noise. So: how hard is it to rebuild, how hard is it to get bearing/gear kits, and any tell tale signs to look for like case damage areas???

Thanks, Rob

 

[adsm08]

I've said it before and I'm sure I'll say it again.

A transmission build is one of those things, if you have to ask how hard it is, it's above your skill level. Better and easier to just find another one and sell that trans off as a core.

 

[thisfords4u]

I was more interested in pointers than anything else. Ive done several trans rebuilds in my 30 years of wrenching, I am looking for answers from those that have dealt with particular trans. Thanx

 

[adsm08]

Ok, THAT is an altogether different matter. I've just gotten used to new guys coming in here and asking about rebuilding transmissions when the most complex thing they'd done before that is a rad swap.

The M5OD isn't hard to go through. The worst parts of it are the front main bearings are hard to get out, mostly because the bell can't be removed, and the gears are pressed on to the shafts, so you need a press if you want to take them off.

I can probably come up with a rebuild manual for you if you like.

 

[thisfords4u]

now we're talkin. thats exactly what Im talking about. If you could that would be great. Ive already looked through my manuals and they dont cover it. I do have a press, and pullers. Thanx, Rob

 

[AllanD]

Actually not much "pressing" is involved at all.

And the bellhousing not being removeable isn't really a factor.

It takes less time to completely disassemble a Mazda trans that it takes to simply replace the bearing in an earlier trans, and frankly the mazda input bearing is effectively indestructable, If I had $5 for each dead input bearin I've seen in the last 15 years I still wouldn't have enough money to buy a meal at my favorite chinese buffet

Other than the puller to get the rear most bearing off the mainshaft.... there are few special tools needed.

THE issue is people taking apart things they don't need to that are essentially impossible to reassemble the way they take them apart....

there are two "NEVERS" to mazda trans disassembly:
1)NEVER remove the 5/Rev shift fork from it's shaft, remove it as an assembly by removing th eshaft retaining bolt from the case.
2)NEVER Remove the reverse idler from the reverse idler shaft (the idler shaft must come out of the case ANYWAY) EXCEPT to inspect the ID of the gear and the rollers (I have seen pitted rollers and a pitted ID on a reverse idler gear.... exactly ONCE)

If you first remove the 3/4 synchro assembly and 3rd gear from the FRONT of the mainshaft

You can then stand the bare (empty) transmission case on it's bellhousing place the mainshaft in the rear mainshaft bearing bore and several taps with a 3lb hammer will drife the shaft out of the rear tapered bearing and leave you with a bare shaft insied the trans case and a stack of gears resting on the bearing bulkhead
(This takes me less time to do than it took to type the paragraph above... Yes, really!)


IF there was ever a perfect transmission for a beginner to rebuilt the Mazda M5OD-R1 would get my vote.

That all being said THE thing about rebuilding a manual transmission is knowing what you are looking at when you've got it apart.

I'm not talking about identifying the bad parts, that can be done by almost any idiot, with as much difficulty as picking the zebra out of a herd of horses...what I'm talking about is identifying the ALMOST bad part...

Some stuff if obviously bad, what I'm talking about is stuff that isn't "obviously" bad but is still bad...

spotting cavitation pitting at the tooth roots on 5th gear....

Or knowing how much play there should be between a synchro collar and the shift fork...



And it really can't be explained in a few short posts here on the forum

And please don't PM me with general questions requesting more in-depth answers....
I dislike typing tech information that only one person can benefit from....

So keep it in the public forums.

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[goodie85]

I've said it before and I'm sure I'll say it again.

A transmission build is one of those things, if you have to ask how hard it is, it's above your skill level. Better and easier to just find another one and sell that trans off as a core.

ahhhh i subject to object i asked my uncle the same question and he owns a tranny shop and one day i stopped in and he said take a turbo 350 apart and put it back together and i was able to do it with few questions