HOW-TO: MAZDASPEED3 REPLACE CLUTCH

[sdetweil]

thanks guys.. actually it turned out to be easier than that.. I had failed to disconnect the tierod.

once i did that I had enough movement, drivers side came out after three pulls.. then I used my air hammer to drive the splined end out of the hub.. axles out of the way,

engine + tranny out..

[AwAfrican]

Originally Posted by sdetweil thanks guys.. actually it turned out to be easier than that.. I had failed to disconnect the tierod. once i did that I had enough movement, drivers side came out after three pulls.. then I used my air hammer to drive the splined end out of the hub.. axles out of the way, engine + tranny out..

Derp...glad it worked out

[Fonsi]

@MATT DAMOND What a great write up!! Any chance to get the pictures back again? Photobucket seems to be down / not responding...

[shome1289]

hey there, brand spanking new member, but not a newb when it comes to Mazda. I am here on THIS forum, and on this particular post, to ask a rather simple question:

How different is this procedure on a 2012 Mazda3 2.5S 6 Speed sedan?

I am getting a noise that is getting louder and louder. It is speed dependent, so the noise graduates in pitch the faster you go, but not necessarily volume. It's a cyclical grinding/rubbing almost a rough bumping sound, du-du-du-du-du-du-du, gets faster with speed, in any gear. The car is driving absolutely FINE, able to bang gears all day, whatever this noise is, it is not affecting driveability whatsoever. The noise is relatively quiet, even now, that it is "getting louder". At first it was VERY quiet but now it's noticeable in the cockpit. I don't necessarily feel anything either. Clutch in or out, still hear it. In gear, definitely more noticeable, and with On load or Off load in any gear, it becomes more pronounced. Coming to a slow stop while in 6th, then going in to 1st, for example, the volume changes with the different loads. I am thinking it is a differential issue, since the trans feels fine and the noise is present (now) even in neutral when coasting.

About 2 weeks ago, I replaced the driver's side axle (WHAT A PAIN IN THE ASS, it's a 100k mile NY raised car ((TX now for the past 2 years)) and talk about seized EVERYTHING) because it was leaking and slinging quite a bit of grease for the past 3 years, so I attributed the noise to that. NOPE, of course not. The Dealership told me simply "You need a new tranny". Quoted me about 6500 for that and a main catalytic. blow me. That's with my Mercedes Benz wholesale discount (I work the parts counter at the local MB dealer).

After seeing this rather impressive write up, I can only HOPE AND PRAY that the procedure/parts are similar. The only frigging thing I have been able to find online about the particular transmission is the name of it, the G66M-R, and man, it took me probably a solid few days to just get that information. I seem to have an issue when googling any information about it. Just cant find any specs, part numbers, diagrams, etc etc etc.

I figured that I would drop the trans myself and then crack the bastard open and take a gander at what might be the issue. Seems like possibly a bearing or something in the diff, maybe an output or inpout shaft bearing? The Mazda tech noted some sort of metallic chunks, which he referred to as "maybe it's bearing material...?" so before I go and drop all this damn money on just buying a new car, id like to drop the thing myself and get my hands dirty.

Within the past week, I got my 2004 Mazdaspeed Miata (56k miles, 2nd owner) up and running again, after ALL maintenance was completed, as well as motor mounts, coilovers, brakes, tires, etc etc etc etc...so I am not afraid to tackle something like this. Any information regarding my initial question (the removal procedure) would be REALLY appreciated. And thanks for being here (the forum in general) I dont know what I would do without these things man!! Cheers!

[Lex2007]

Originally Posted by shome1289 hey there, brand spanking new member, but not a newb when it comes to Mazda. I am here on THIS forum, and on this particular post, to ask a rather simple question: How different is this procedure on a 2012 Mazda3 2.5S 6 Speed sedan? I am getting a noise that is getting louder and louder. It is speed dependent, so the noise graduates in pitch the faster you go, but not necessarily volume. It's a cyclical grinding/rubbing almost a rough bumping sound, du-du-du-du-du-du-du, gets faster with speed, in any gear. The car is driving absolutely FINE, able to bang gears all day, whatever this noise is, it is not affecting driveability whatsoever. The noise is relatively quiet, even now, that it is "getting louder". At first it was VERY quiet but now it's noticeable in the cockpit. I don't necessarily feel anything either. Clutch in or out, still hear it. In gear, definitely more noticeable, and with On load or Off load in any gear, it becomes more pronounced. Coming to a slow stop while in 6th, then going in to 1st, for example, the volume changes with the different loads. I am thinking it is a differential issue, since the trans feels fine and the noise is present (now) even in neutral when coasting. About 2 weeks ago, I replaced the driver's side axle (WHAT A PAIN IN THE ASS, it's a 100k mile NY raised car ((TX now for the past 2 years)) and talk about seized EVERYTHING) because it was leaking and slinging quite a bit of grease for the past 3 years, so I attributed the noise to that. NOPE, of course not. The Dealership told me simply "You need a new tranny". Quoted me about 6500 for that and a main catalytic. blow me. That's with my Mercedes Benz wholesale discount (I work the parts counter at the local MB dealer). After seeing this rather impressive write up, I can only HOPE AND PRAY that the procedure/parts are similar. The only frigging thing I have been able to find online about the particular transmission is the name of it, the G66M-R, and man, it took me probably a solid few days to just get that information. I seem to have an issue when googling any information about it. Just cant find any specs, part numbers, diagrams, etc etc etc. I figured that I would drop the trans myself and then crack the bastard open and take a gander at what might be the issue. Seems like possibly a bearing or something in the diff, maybe an output or inpout shaft bearing? The Mazda tech noted some sort of metallic chunks, which he referred to as "maybe it's bearing material...?" so before I go and drop all this damn money on just buying a new car, id like to drop the thing myself and get my hands dirty. Within the past week, I got my 2004 Mazdaspeed Miata (56k miles, 2nd owner) up and running again, after ALL maintenance was completed, as well as motor mounts, coilovers, brakes, tires, etc etc etc etc...so I am not afraid to tackle something like this. Any information regarding my initial question (the removal procedure) would be REALLY appreciated. And thanks for being here (the forum in general) I dont know what I would do without these things man!! Cheers!

Welcome to the forum. Before you drop the trans why dont you send an oil sample to Blackstone. That *might* give you a little extra info on what is going on. And check the drain plug for metal chunks.

Once you drop it, why not bring it to a trans shop and have them rebuild? Gotta be cheaper than buying new no?

Sorry I cannot help on the procedure question.

[Vansquish]

Are you sure it's not just a wheel bearing? You're describing a sound that could be as simple as that.

[Lex2007]

Originally Posted by Vansquish Are you sure it's not just a wheel bearing? You're describing a sound that could be as simple as that.

Good point. At 100k you could be due for a front wheel bearing. You should have changed those when you had the axles out.

[shome1289]

definitely not a wheel bearing...since the noise sounds like its coming from the left front/more central-left, is one reason...but the real proof is that I absolutely DEMOLISHED the bearing AND hub assembly with a 10 lb hammer trying to free the old axle from said assembly, so I went and bought a hydraulic floor shop press and all the right parts and basically rebuilt the entire left front area, including ball joint, tie rod, sway bar end link, hib, bearing, lugs and lugnuts. and brake caliper was cleaned and new seal in there too. The noise is still there, and its the same noise as before I did all that work. So I was hoping it WAS the axle or perhaps the bearing, but to my chagrin, shit was still the same, maybe even worse since I was really going at the axle shaft trying to free the unbelievably stuck splines. I dont want to talk about it...lmfao

[Lex2007]

Originally Posted by shome1289 definitely not a wheel bearing...since the noise sounds like its coming from the left front/more central-left, is one reason...but the real proof is that I absolutely DEMOLISHED the bearing AND hub assembly with a 10 lb hammer trying to free the old axle from said assembly, so I went and bought a hydraulic floor shop press and all the right parts and basically rebuilt the entire left front area, including ball joint, tie rod, sway bar end link, hib, bearing, lugs and lugnuts. and brake caliper was cleaned and new seal in there too. The noise is still there, and its the same noise as before I did all that work. So I was hoping it WAS the axle or perhaps the bearing, but to my chagrin, shit was still the same, maybe even worse since I was really going at the axle shaft trying to free the unbelievably stuck splines. I dont want to talk about it...lmfao

Been there bro. Ive had to use some crazy strong hydraulic axle pullers myself to get those badboys free.

Can I suggest you change the other wheel bearing JUST IN CASE?...and before you drop the transaxle? Noises can travel....

[shome1289]

well, I believe the dealer when they at least tell me theres an internal problem with the trans, and after messing about with that drivers side axle and bearing and all that banging and whacking and prying that axle out of the trans, the noise definitely was affected by it, I double checked the right side bearing using all the usual techinques and, nah, definitely internal. Luckily, here in Austin TX, we have a pretty great "wrench a part" place about 20 min from my house (pretty close to circuit of the americas, actually lol about 5-10 min away) and TODAY AND TOMORROW they are selling ANY trans for 79 bucks...good, bad, new, old...engines are 89. I got the frigging text this morning, how crazy is that? Whats crazier, they have a 2011 teal blue hatch 2.5S 6 speed there right now. I have a guy, willy, who literally just pulls parts and hovers around the parking lot there, going inside to check the car physically if the engine/trans are still in tact/present. Cross your fingers!! Ill buy the whole drivetrain at that price lol I have finally found, at the same time no less, all the mazda3tech .com manuals and FINALLY i am seeing specific diagrams and procedures for the G66M-R which is a huge find, for me at least, because for some strange reason my search results would never give me ANYTHING of use, no matter how complicated or simple my googling was. Let us pray that darn trans is there. Car looks OK, slight front end damage, and it has i believe under 60k on it...texas native car it's whol....-----------

update as I type this, the trans is MINE!! Oh my god so relieved, I was stressing waiting for the guy to get back to me...was unsure if the trans was in the car, but I called the local dude to go check it out and he said it was in the car and it is indeed a 2.5 with the g66m-r...79 bucks for the unit, 50 dollar core charge, and 100 bucks to have him pull it. WOWWW. Im gonna be a busy bee this weekend lol (besides tomorrow, im going on a long ass cruise with some miata guys for a few hundred miles. should be fun!!!)

[Lex2007]

Originally Posted by shome1289 update as I type this, the trans is MINE!! Oh my god so relieved, I was stressing waiting for the guy to get back to me...was unsure if the trans was in the car, but I called the local dude to go check it out and he said it was in the car and it is indeed a 2.5 with the g66m-r...79 bucks for the unit, 50 dollar core charge, and 100 bucks to have him pull it. WOWWW. Im gonna be a busy bee this weekend lol (besides tomorrow, im going on a long ass cruise with some miata guys for a few hundred miles. should be fun!!!)

Whats the normal price for that used gearbox?

[shome1289]

Originally Posted by Lex2007 Whats the normal price for that used gearbox?

For the past 3 weeks I've been stalking the lots and LKQ and other sources available to me via wholesale parts channels and the lowest price one I have found, and was THIIIS close to buying last week, was 800 and it had over 100k on the clock. They seem to range anywhere from 800 to 1300.

Stayed up all night, its 5am right now, got my miata sorted and wetsand and polished and got about halfway through the 3 disassembly. Just gotta take the axles out next, mock up some sort of rig to hang the motor, and then start cracking bolts to get it out. So easy it's not even funny, and to think I've been stressing lol thankfully thendrivers side stiff was all just changed and greased so getting that out is easy, the pass. Side is gonna be a bitch I already know it.

[shome1289]

Just replying here, so sorry for hinacking/bumping but figured it was better than creating a new thread....for now...will create a detailed thread once I get everything going/finished.

The G66M-R is quite the unicorn when it comes to information available for it. Does anyone know of any factory service manual, specs, part numbers, etc, available for it? Or for the speed3's transmission? I've got both transmissions on my workbench and my idea is to essentially take 2 semi-good transmissions and make 1 good one out of both. I'd like to know if theres any torque specs, factory procedures or SOMETHING that I can refer to during reassembly?