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ndh795

Ndh795's 2000 626 5 Speed Worklog (Tons Of Pictures!)

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Now to something that will hopefully wake you up after all that text!

 

Went up to a friend

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Now, back to the worklog!

 

We knew the car had some rust around the bottom of the boot area (trunk for you USA guys), but once we started looking at it we realised there was more than we thought. Luckily it wasn

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The next spot on the ownership timeline came about when we claybarred the whole car and gave it its first proper detail. The pictures were taken on my SLR (60d) with a pretty average Tamron lens (that is long gone now). I

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Not long after this both parkers and one low-beam bulb blew out, which was kinda dangerous to drive with and made it look like the car was not looked after at all. So we decided to go all out and replace all the globes!

 

Parkers, number-plate lights, interior map and main lights, and the boot light were replaced with eBay LED

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Not much really happened for a while other than the car hitting 230,000km

 

 

img-385096-1-15389116421_ff30b77c76_z.jp20131119_172821 by Nathan Haddad, on Flickr

 

img-385096-2-15392293495_e57e40207f_z.jp20131119_172950 by Nathan Haddad, on Flickr

 

And we also changed the crappy standard wiper blades to some sleeker ones that would actually clean the windscreen properly! The old ones were terrible.

 

Old:

 

img-385096-3-15205705228_5ab01d3869_z.jp20140102_125610 by Nathan Haddad, on Flickr

 

img-385096-4-15391965492_37ba67edde_z.jp20140102_125615 by Nathan Haddad, on Flickr

 

 

New:

 

img-385096-5-15392292395_60eb6eb0d0_z.jp20140102_130036 by Nathan Haddad, on Flickr

 

img-385096-6-15392292175_a159d42224_z.jp20140102_130051 by Nathan Haddad, on Flickr

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At this point in time we knew that the gearbox needed to have a rebuild. This thread on the forum that I created explained the problem we were having  (a whirring noise when the clutch was engaged) We later found out that even though I had asked the mechanic to check the oil level he never did, and the gearbox was running on 400mL of oil when it needs 2.7L (2700mL). This is the main reason why I will never be getting another car serviced there, and really made me distrust mechanics (already was sceptical of most of them!).

 

The total rebuild ended up including all bearings and seals on (and inside) the transaxle. The rebuilder found a few cracked bearings and many discoloured ones (due to heat from barely any oil).

 

We decided to pull the gearbox out ourselves to save some cash and have a learning experience, ended up taking about a month total. During this time we did lots of other stuff too, including;

 

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Also bought some trim removal tools which helped a lot. Also off to the side is a wire brush set we bought at the same time:

 

15369259126_f6e4485cbd_z.jpg20140114_160920 by Nathan Haddad, on Flickr

 

 

Mudflaps and bailey channels removed:

 

15391957822_dc6d4972b4_z.jpg20140114_164810 by Nathan Haddad, on Flickr

 

15392283955_c9738990b7_z.jpg20140114_164820 by Nathan Haddad, on Flickr

 

15205600470_db78f78dfb_z.jpg20140114_164834 by Nathan Haddad, on Flickr

 

15205531519_f660e81286_z.jpg20140114_164858 by Nathan Haddad, on Flickr

 

15205765367_bf045a1b8e_z.jpg20140114_164940 by Nathan Haddad, on Flickr

 

Went to a huge wrecking yard in Sydney

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A box arrived! From an awesome detailing company, Final Inspection. The main parts we were excited about were the big drying towel (so much better than a chamois, in effectiveness and wont hurt the paint), and the power wheel cleaner. This stuff is really good, we didn

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Condition of the old rotors:

 

15392271045_d6a0fe154e_z.jpg20140116_184202 by Nathan Haddad, on Flickr

 

15389092971_ea8f9e53fd_z.jpg20140116_214757 by Nathan Haddad, on Flickr

 

15392269145_ea055e0575_z.jpg20140116_214805 by Nathan Haddad, on Flickr

 

Jacked up and wheels off:

 

15205753457_22c91b3b48_z.jpg20140116_211436 by Nathan Haddad, on Flickr

 

15205517469_442ae0d750_z.jpg20140116_214902 by Nathan Haddad, on Flickr

 

Cowl and wipers off:

 

15389092021_618b023bce_z.jpg20140116_214846 by Nathan Haddad, on Flickr

 

15369242156_acafc4f8c5_z.jpg20140117_094526 by Nathan Haddad, on Flickr

 

15205744237_31f3075cd9_z.jpg20140117_143530 by Nathan Haddad, on Flickr

 

Inner tail lights, spoiler, and some other things off:

 

15392267855_ff5581d228_z.jpg20140116_214925 by Nathan Haddad, on Flickr

 

Airbox/intake and battery off:

 

15391938292_06f4dfcd62_z.jpg20140117_135423 by Nathan Haddad, on Flickr

 

15391937742_9f7fd91c1e_z.jpg20140117_135436 by Nathan Haddad, on Flickr

 

Cleaned the mudflap gunk off the paint, there was a lot back there!

 

15205675408_efd3f861b1_z.jpg20140117_143133 by Nathan Haddad, on Flickr

 

 

Floormats, old vs new:

 

15205509529_22aa89f050_z.jpg20140117_144215 by Nathan Haddad, on Flickr

 

New (to us) OEM is on the right:

 

15392259745_ef4899d4d7_z.jpg20140117_144810 by Nathan Haddad, on Flickr

 

Cracking the Axle nuts with a torch:

 

15205742647_a43216e886_z.jpg20140118_190325 by Nathan Haddad, on Flickr

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More disassembly pics:

 

15205508139_0fef45290b_z.jpg20140118_210037 by Nathan Haddad, on Flickr

 

15205507509_0db6b1b1b3_z.jpg20140118_210047 by Nathan Haddad, on Flickr

 

15389080751_0e37d046b3_z.jpg20140118_210128 by Nathan Haddad, on Flickr

 

15369232426_ab5ae0d9e8_z.jpg20140118_210218 by Nathan Haddad, on Flickr

 

15205740337_be7a16efab_z.jpg20140118_210250 by Nathan Haddad, on Flickr

 

15389078271_e28364641f_z.jpg20140119_115402 by Nathan Haddad, on Flickr

 

15205737707_3b65868c51_z.jpg20140119_115429 by Nathan Haddad, on Flickr

 

15205666458_79239189b9_z.jpg20140119_115444 by Nathan Haddad, on Flickr

 

15205665998_230f19f5d3_z.jpg20140119_115453 by Nathan Haddad, on Flickr

 

15205665668_c2c7450f55_z.jpg20140119_115552 by Nathan Haddad, on Flickr

 

15369227246_c8c180cc74_z.jpg20140119_115557 by Nathan Haddad, on Flickr

 

15392251725_77f8902cd5_z.jpg20140119_115634 by Nathan Haddad, on Flickr

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Chrome rear indicator bulbs, looks much tidier:

 

15205669178_dcbab9d3ae_z.jpg20140119_115318 by Nathan Haddad, on Flickr

 

15391924732_bfe34d18d1_z.jpg20140119_115825 by Nathan Haddad, on Flickr

 

15205499849_dc63d1e0c8_z.jpg20140119_115842(0) by Nathan Haddad, on Flickr

 

15392239305_367d85bdce_z.jpg20140125_161217 by Nathan Haddad, on Flickr

 

15205552530_ce598caccd_z.jpg20140125_165918 by Nathan Haddad, on Flickr

 

 

Had to buy a deep socket to get some of the transmission mount nuts:

 

15369225586_f6e33b8e38_z.jpg20140119_193809 by Nathan Haddad, on Flickr

 

15205662948_9cdb069b9d_z.jpg20140119_193820 by Nathan Haddad, on Flickr

 

 

Gearbox out, just removed crossmember, disconnect starter, etc. We actually had to hire an engine hoist/crane to tilt the motor down on the passenger side as the gearbox wouldn

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The old throwout/thrust/release bearing, looked horrible!

 

15205497119_6275c6ba6c_z.jpg20140124_114210 by Nathan Haddad, on Flickr

 

15205660108_dbe06b1acc_z.jpg20140124_114219 by Nathan Haddad, on Flickr

 

15391920602_49172cf5f4_z.jpg20140124_114225 by Nathan Haddad, on Flickr

 

Clutch and flywheel off, you can see the rear main seal:

 

15389070081_28ebd05082_z.jpg20140124_120449 by Nathan Haddad, on Flickr

 

15391919662_81b51894d6_z.jpg20140124_125401 by Nathan Haddad, on Flickr

 

15389068821_281ecff907_z.jpg20140124_125415 by Nathan Haddad, on Flickr

 

15389068051_dbaebfee89_z.jpg20140124_125428 by Nathan Haddad, on Flickr

 

The old clutch was an Exedy, the same as the new one we put in. It was actually in great condition but we had already bought a new clutch. So now we have a spare!

 

15205657608_f910bf4f68_z.jpg20140124_125504 by Nathan Haddad, on Flickr

 

15205656898_893fe82fcf_z.jpg20140124_125521 by Nathan Haddad, on Flickr

 

15205492299_d5a3debed4_z.jpg20140124_125553 by Nathan Haddad, on Flickr

 

15389065371_5903e9f336_z.jpg20140124_125601 by Nathan Haddad, on Flickr

 

15205558530_fc8ac6c2f9_z.jpg20140124_125623 by Nathan Haddad, on Flickr

 

15205725477_c71af07701_z.jpg20140124_125636 by Nathan Haddad, on Flickr

 

 

 

The amount of oil that came out of the gearbox its a 10L drain pan:

 

15392241235_d33c75df24_z.jpg20140124_130328 by Nathan Haddad, on Flickr

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New OEM Mazda Rear Main Seal

 

15205489529_b3510044bf_z.jpg20140124_130644 by Nathan Haddad, on Flickr

 

 

15205487629_88eed65c2d_z.jpg20140125_161441 by Nathan Haddad, on Flickr

 

Gearbox on its way to the shop:

 

15389062511_c6050b6d72_z.jpg20140124_133306 by Nathan Haddad, on Flickr

 

Gearbox completely gone:

 

15389060891_11c0b882bb_z.jpg20140125_161519 by Nathan Haddad, on Flickr

 

15391911202_d3c1aa4623_z.jpg20140125_161652 by Nathan Haddad, on Flickr

 

Non-cracked inner tail lights

 

Before:

 

15391951142_8451c1b922_z.jpg20140116_182535 by Nathan Haddad, on Flickr

 

15392277145_9aee799ee1_z.jpg20140116_182554 by Nathan Haddad, on Flickr

 

During:

 

15205720847_7921f36350_z.jpg20140125_161731 by Nathan Haddad, on Flickr

 

After:

 

15205485399_66c0c17860_z.jpg20140125_165911 by Nathan Haddad, on Flickr

 

15205552530_ce598caccd_z.jpg20140125_165918 by Nathan Haddad, on Flickr

 

Glove box LED, looks much better than the old yellow one, especially useful at night. The stock holder is very strange and the bulb is tiny!

 

15205484319_5f2fb7aefa_z.jpg20140125_170907 by Nathan Haddad, on Flickr

 

15205551200_b2f9daf11b_z.jpg20140125_171103 by Nathan Haddad, on Flickr

 

15392234755_ca7b6e46ed_z.jpg20140125_171137 by Nathan Haddad, on Flickr

 

15205717187_e33835a3fe_z.jpg20140125_171316 by Nathan Haddad, on Flickr

 

Terrible photo, but gives an idea of the colour:

 

15205508270_ab0cae19e2_z.jpg20140221_125003 by Nathan Haddad, on Flickr

 

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New to us used non-rusted tool kit:

 

Before:

 

15205645178_bc2402ec08_z.jpg20140125_172549 by Nathan Haddad, on Flickr

 

15389054701_2949bffce3_z.jpg20140125_172554 by Nathan Haddad, on Flickr

 

15205644008_d7076113b3_z.jpg20140125_172603 by Nathan Haddad, on Flickr

 

After:

 

15391906652_974a65f765_z.jpg20140125_172524 by Nathan Haddad, on Flickr

 

15205716437_52819714ee_z.jpg20140125_172536 by Nathan Haddad, on Flickr

 

Went past the house I grew up in and guess what was out front! I don

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Freshly-machined flywheel on! Borrowed a friends air compressor with an impact gun for most of this 1 month period, because flywheel bolts and other bolts are tough to crack with hand tools:

 

15205545330_b0bdb3afe7_z.jpg20140208_183351 by Nathan Haddad, on Flickr

 

15391902012_caf8a52a8c_z.jpg20140208_183413 by Nathan Haddad, on Flickr

 

New clutch pics and install, also munched a pressure plate bolt, used a die to re-thread it, went in all good. Borrowed an alignment tool from closest parts store (20 min away), they were completely trusting, champs!

 

15205477219_17a139175d_z.jpg20140208_183446 by Nathan Haddad, on Flickr

 

15205639978_a92cb6db80_z.jpg20140208_183546 by Nathan Haddad, on Flickr

 

15389049281_afb2e326df_z.jpg20140208_193151 by Nathan Haddad, on Flickr

 

15391899772_fd133c7059_z.jpg20140208_234456 by Nathan Haddad, on Flickr

 

15205474929_cae7d21c4a_z.jpg20140208_234522 by Nathan Haddad, on Flickr

 

Gearbox pics, the coat hanger through where the CV

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Gearbox install pics, note the old metal tray as a method of lifting it up into the car, how tilted the motor has to be in order to get it lined up properly, and the socket extensions and screw drivers as makeshift dowel pins!

 

15369198646_fb4367ceab_z.jpg20140210_202522 by Nathan Haddad, on Flickr

 

15392223165_9727a79b5a_z.jpg20140210_202546 by Nathan Haddad, on Flickr

 

15205471579_59276db7ac_z.jpg20140210_202604 by Nathan Haddad, on Flickr

 

15389044481_9eaf5e6c9b_z.jpg20140210_202608 by Nathan Haddad, on Flickr

 

15205390729_c115c24a7d_z.jpgSnapchat-20140212092816 by Nathan Haddad, on Flickr

 

To get the gearbox in properly required 3 people, thanks go to our friend Dan for the help! We had one person slowly rotating the crank pulley (to get splines lined up) while the other two were aligning/pushing the gearbox itself. A solid 15-20 mins of wrestling with it and it bolted up great :)

 

15205633688_35a1bbbbe4_z.jpg20140211_143022 by Nathan Haddad, on Flickr

 

Freshly painted mud flap, cowl, wipers, and mirror; Looks so much better! Spoiler not pictured but it looks amazing too:

 

15205632968_d7fc4b68e7_z.jpg20140211_154615 by Nathan Haddad, on Flickr

 

15205632738_168b0521d9_z.jpg20140211_160012 by Nathan Haddad, on Flickr

 

15205469079_fc7d2d8bcd_z.jpg20140211_160024 by Nathan Haddad, on Flickr

 

15205534640_cf109cfebb_z.jpg20140212_122629 by Nathan Haddad, on Flickr

 

New OEM driveshaft nuts, and old one:

 

15205535620_f051966a47_z.jpg20140212_122257 by Nathan Haddad, on Flickr

 

15392219295_9e3cf94011_z.jpg20140212_122331 by Nathan Haddad, on Flickr

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Old brake rotors vs new, and pads:

 

15205467259_b75d9f1961_z.jpg20140212_212743 by Nathan Haddad, on Flickr

 

15389040231_c7e0eec201_z.jpg20140212_213206 by Nathan Haddad, on Flickr

 

15392217425_a2b9eba042_z.jpg20140212_213211 by Nathan Haddad, on Flickr

 

15205465919_aff9060066_z.jpg20140212_213223 by Nathan Haddad, on Flickr

 

15205628318_93520b2b96_z.jpg20140212_213234 by Nathan Haddad, on Flickr

 

15205627618_9088be858b_z.jpg20140212_213310 by Nathan Haddad, on Flickr

 

Cool thing about these pads is you don't have to bed them in!:

 

15391889062_b24ec807ec_z.jpg20140213_134949 by Nathan Haddad, on Flickr

 

15392214785_7bae702c9b_z.jpg20140213_135105 by Nathan Haddad, on Flickr

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Various Assembly pics; gearbox fully bolted up but still a lot more to go, stripped the bottom bolt on the gearbox to engine, left it out because it wouldn

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New rotors and pads, calipers checked and slides greased:

 

15391882242_5023d28ef3_z.jpg20140217_164213 by Nathan Haddad, on Flickr

 

15392208755_0db9a9fc8e_z.jpg20140217_164242 by Nathan Haddad, on Flickr

 

15205524660_79ded10540_z.jpg20140220_190551 by Nathan Haddad, on Flickr

 

15389029591_e09e88c273_z.jpg20140220_190602 by Nathan Haddad, on Flickr

 

15205691077_35c2b7ee51_z.jpg20140220_190635 by Nathan Haddad, on Flickr

 

 

 

Shift rods, CV

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Crossmembers back in:

 

15205615238_4bbd0de8f7_z.jpg20140220_194027 by Nathan Haddad, on Flickr

 

15389024981_028cffbb42_z.jpg20140220_203342 by Nathan Haddad, on Flickr

 

15389024411_79d0fcf903_z.jpg20140220_203347 by Nathan Haddad, on Flickr

 

Brake fluid in and bled:

 

15389025781_be2e47a0f6_z.jpg20140220_193535 by Nathan Haddad, on Flickr

 

15205613758_69741350d3_z.jpg20140220_214324 by Nathan Haddad, on Flickr

 

15391874862_63a7590190_z.jpg20140220_214328 by Nathan Haddad, on Flickr

 

 

Bleeding the slave cylinder/clutch:

 

15205613098_645a5b4003_z.jpg20140220_221026 by Nathan Haddad, on Flickr

 

Hub/CV nuts tightened, yes we bent the pole! Those nuts are bloody tight. Also note the indent made with a screwdriver in the outside of the nut to lock it in, these are crucial:

 

15205517060_d5ea9d12dd_z.jpg20140220_223206 by Nathan Haddad, on Flickr

 

15392141195_be6380590e_z.jpgSnapchat-20140220103256 by Nathan Haddad, on Flickr

 

15205611368_9acbb2e67a_z.jpg20140220_224753 by Nathan Haddad, on Flickr

 

 

Nice clean wheels back on, also spash-guards fitted:

 

15205447819_6e32185c0a_z.jpg20140220_225233 by Nathan Haddad, on Flickr

 

15205447269_bd69d8e7a0_z.jpg20140220_225334 by Nathan Haddad, on Flickr

 

The wheels were guttered from the previous owner/s unfortunately. Hope to restore them someday:

 

15205446309_a367a8e907_z.jpg20140220_230930 by Nathan Haddad, on Flickr

 

15205513150_65e83d2913_z.jpg20140220_234000 by Nathan Haddad, on Flickr

 

15392195885_2277e9c979_z.jpg20140220_234036 by Nathan Haddad, on Flickr

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Tightened up the handbrake (looks very yucky in there!):

 

img-385113-1-15389011601_8a344a3ed3_z.jp20140221_140849 by Nathan Haddad, on Flickr

 

img-385113-2-15392188495_c6c761e975_z.jp20140221_140917 by Nathan Haddad, on Flickr

 

img-385113-3-15205437489_3862547394_z.jp20140221_140922 by Nathan Haddad, on Flickr

 

Back on the ground:

 

img-385113-4-15205436999_1b2a2bd1a8_z.jp20140221_150711 by Nathan Haddad, on Flickr

 

img-385113-5-15369163166_9cf841a561_z.jp20140221_150743 by Nathan Haddad, on Flickr

 

It moves!

 

img-385113-6-15205503560_0255aab046_z.jp20140221_152222 by Nathan Haddad, on Flickr

 

Video:

 

 

Finally out of the garage:

 

img-385113-7-15369162156_73396a5600_z.jp20140221_152243 by Nathan Haddad, on Flickr

 

img-385113-8-15205598068_566a565b0b_z.jp20140221_152252 by Nathan Haddad, on Flickr

 

img-385113-9-15369161216_87a8fb588b_z.jp20140221_152300 by Nathan Haddad, on Flickr

 

img-385113-10-15392185185_348c7915e0_z.j20140221_152309 by Nathan Haddad, on Flickr

 

img-385113-11-15388962301_fa9dc351f0_z.jSnapchat-20140221032445 by Nathan Haddad, on Flickr

 

img-385113-12-15205434399_200b79d4f0_z.j20140221_152313(0) by Nathan Haddad, on Flickr

 

img-385113-13-15205667137_e109195ef4_z.j20140221_152403 by Nathan Haddad, on Flickr

 

img-385113-14-15205666547_cbf95127d5_z.j20140221_152408 by Nathan Haddad, on Flickr

 

img-385113-15-15205431079_2f86d8f48c_z.j20140221_152413 by Nathan Haddad, on Flickr

 

 

 

Well that

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