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chewed up starter? Tranny filler bolt?

Posted: March 17th, 2007, 10:31 pm
by timexim
That's right, I pulled the starter as part of the process of pulling the tranny for my clutch and shift fork replacement and the starter was chewed up. Basically the metal that covers the section where the starter gear is when not engaged is chewed up. I looked in the whole for the starter and the edge of the clutch pressure plate appears to be what did it but I don't see how that is possible. I have a used starter to replace it but just dont understand how it happened. The starter was a used starter from a 2001 Millenia. The one I have to replace it is from a 96 MX6. I haven't gotten a full look at the pressure plate yet as we haven't gotten the tranny off. Ran into numerous stubborn bolts. For the axle nuts we needed a half inch breaker bar with a 5 foot long pipe on it to break them loose and that was after heating them up even. Another question while I'm at it, I've searched and found that the bolt for filling the tranny uses a ratchet without the socket only my 92 GS don't have one anywhere on the tranny. I see a few bolts that appear to be possibilities but wanted to ask first so I don't try something that isn't suppose to come out. Lastly, how exactly is the easiest way to get the passenger side axle out? On my sentra it's a merely a straight axle from the tranny to the hub so this is kinda new to me. Hopefully we are past the worst of it. We are planning to start early tommorow and hopefully get it done by the end of the night.

Posted: March 19th, 2007, 1:35 am
by PATDIESEL
Maybe a bit late, but better than never.
As for the fluwheel touching the starter, that should not happen of course. So you need to take a few measures to make sure it doesn't touch this time. First, when you get the flywheel off, have it resurfaced. Also, ask them to make sure it is balanced properly. Then upon reinstallation make sure to use the proper tightening order and torque spec. I also replace the flywheel bolts with new ones each time I take one out. Better safe than sorry for the few bucks the bolts cost. Most auto parts stores can sell you new ones with the lock-tight already on the threads if you bring in an old one.
As for the passanger axle. Mazda uses some great innovation that you might not see on most other cheap coupes. The passanger side axle uses a half shaft, some call it a jack shaft. This shaft bolted to the engine makes the axles about the same legnth and reduces the torque steer on front wheel drives dramatically. To take the passanger side axle off is just like the drivers except the axle's circlip snaps into the half shaft instead of the tranny. So take the axle out of the hub, then pry it loose from the half shaft and it should fall into your hands. Inspect the axles for smooth rotation of the CV joint, rips in the rubber boots and other general wear. If they have a fault, get new ones. AutoZone sells them with a lifetime warranty so the cost of replacing them this time will be free in the future. Also, if you replace an axle Always bring the old one with you when you pick up the new one. Stand both on the counter top and compress the axles so that the CV joints are as short as they go. Look to make sure the old and new axle are the same legnth. It is common for remanufacturers to mess up an axle legnth and it is a PITA to find the right size once if the new one is wrong once you've retuned the old one that is the right size.
As for filling the tranny. simple. To fill- remove the speedo gear from the top of the tranny (under the TB and back some, looks like a cylinder poking out of the tranny with a wire coming out the top of it) held in with one 10mm bolt. Then there is a large bolt on the front side of the tranny about half way up the side (it is a big bolt, something like 19mm or larger). Remove it. Now make sure the car is pretty close to level. Fill from the speedo hole until it pours out the front hole. When it pours out it is full. However, all this said, you need to drain it first. To do that there is a large bolt on the very bottom of the trans, again above a 19mm. Remove it and it drains out like the motor oil.
Axle bolts are always a pain. Without an air compressor I need heat and a lang breaker bar too. Make sure when you get the new ones on that you pinch them where you see the slit in the end of the axle that pokes out the hub. This keeps them from vibrating loose.
Good luck ;)