The millenia s 5spd

[Mazdaguy84@yahoo.com]

Ok guys sorry it took so long but here is what i got,

http://s696.photobucket.com/albums/vv325/mazdaguys3/ pictures some of them


The miller 5sp project

Well where to begin, one day I was on a run to the junkyard for a few things and just to see what was new, when I came a crossed it. A nicely condition 96 Millenia S, no I thought to myself what’s wrong with it, I walk up to it and open the hood, the engine was not touch, so I said to my friend Ricky what you think, we both where like a kid in a candy store. I began to look for some reason that it possibly could be in there, and to my surprise, there wasn’t a reason that I saw. After looking around I found that key that would start my dreams, now the junkyard we’re in doesn’t take out anything just bring it in and that’s how it goes into the yard. So yes there was a bat. In it, I attempted to start it. Just turned over, and nothing. Good start for what it could of happen, I made up my mind it was coming home with me. Now since i was at the junkyard that was a well good friend of the family it wasn’t hard to get it out, five hundred dollars later and it was on its way to a new home. 
Well to make a long story short when I got it home I found that the timing belt was off, and thanks for a non-interference motor it was back and running again. A couple more miles on it and I was happy for a while…. Now I live in Maplewood Minnesota, and I was down visiting my dad who lives in Faribault Minnesota, (which is about 45 minute drive) and on my way home I notice something wasn’t right the car wouldn’t go into overdrive, when I got home the car only had first and third gears only. So I knew what had happen, same **** thing that happen in my 92 mx3 (v6 2.5) Mazda ATX trannys not so good… I knew right then and there that it was going to be a MTX like the mx3, a little research latter the plan was set in motion.
I found in the junkyard a KLO3 MTX and clutch kit out of a MX6, Clutch pedal assembly, and shift linkages and a jack shaft out of a 626. Now since I did the MTX swap in the Mx3 the first tranny I got was junk so I had a mock up tranny so I didn’t have to use the good one for it.
Here it goes I tore the old ATX out of the car (all 600 lbs.) I notice that I was able to use the motor mounts except for the top left side mount, so that was good, and as I was looking at it to the eye it looked like it would fit to the block… after getting the MTX up and facing the block I notice that it wasn’t going to be as easy as I thought, first of all the coolant pipes where going to hit the tranny, so something was going to have to be modified, I choose the mock tranny to get the cut up since I didn’t care what I did to that, I found that I had to cut the top part of the starter housing just for it to fit also I had to shave down the top of the tranny to fit under the coolant inlet to the block. After I figured and had done all that seen, it slid into place like it was meant to be.
Now for some fabricating, after doing some research I found that Europe as you all may know a 5spd on there 2.5s but that tranny is cable unlike the trannys we have here on our 2.5s so I had to figure out how to make the car shift, with the tranny in place I was looking how to run the shift linkage, problem power steering was in the way  so I had to costume make the shift linkage, but to start with I had to find out where the shifter bracket was going to be, I took out the ATX shifter out and looked where I could put the shifter bracket. I found out that I had to cut a hole in the floor boards, after that I was able to put the bracket in and measure the distance from the shifter and the tranny hook up for the shifter. I ended up getting a 15/16 rod to get through the power steering and the sub-frame, I welded that rod to a u shape plate that pinched that tranny shifting rod. Then I took the shift linkage from the 626 and cut the tranny side end off, then hooked that up to the shifter, so that I could find that right place to weld the rod to the shifter rod. After finding the right place, meaning shifter in the middle and the tranny in the neutral position, and then welding the rod into place. After that has done I tested it to see if it work and I found that I had to move the power steering lines out of the way of the shifter. Oh I forgot that you had to remove some of the sub-frame so that the shift linage was able to move more freely.
For the drive axle I used one from a 626 with abs so the sensors can read, as for the passenger side you would have to use the jackshaft from the 626 and you can use the original shaft that came with the Millennia s but you’re going to have to extends it one inch and half I did this by cutting it in half and wielding a inch and a half in between. Then put the axle in like you would.

Now for the left side mount I costume made mine but as I was doing this I figure you could use one out of a 626 but I'm not sure it look like it has the mounting holes for it,

Now for the clutch master I used one out of an mx3 cause it points down rather to the left like the 626 would, I use a brake line to form the line to the clutch slave, I also got a resovor from a Honda to supply the clutch master. Now begin taking out the cruise control to get to the point where the clutch master will be. There is a hole where a clutch master would fit.

on to the interior, I got the clutch pedal out of the 626 and I wish I got the brake pedal but maybe later I cut my old ATX pedal to fit the clutch in, you’re going to have to disconnect the ATX computer.

if you got question please feel free to ask...

[Mazdaguy84@yahoo.com]

That is how the 95-96 S had the intercoolers, bolt on for both ends. I noticed the exhaust was pretty loud too.[/b]

I didn't have the exhuast connected just headers on the video

[Matt64341]

Thanks for all the info, it sounds like there is a lot of stuff involved but shouldn't amount to too much money. I have a few questions
How much time did the project take you?
Did you use a lift for the project?
and did you pull the whole engine or just the transmission?
I am sure there will be more.

[Mazdaguy84@yahoo.com]

Thanks for all the info, it sounds like there is a lot of stuff involved but shouldn't amount to too much money. I have a few questions
How much time did the project take you?
Did you use a lift for the project?
and did you pull the whole engine or just the transmission?
I am sure there will be more.[/b]

i would say in all i put about a months worth doing it
i just jacked to up with a floor jack, and jack stands
i just pulled the tranny out

[Mazdaguy84@yahoo.com]

ok i fix the speed-o-meter i forgot to plug it in, so now it works also i'm putting a walk through of what i did to the car to show what i did and some explanation there is two videos, there under millenna 5spd walkthrough

[Matt64341]

Would it be possible for you to hook up a boost gauge temporarily to see what happens to boost? With the auto trans, the engine limits boost to 7 psi in first gear and 14 psi in all other gears. I am curious what way it would go with the TCM unplugged.

and what kind of welder did you use to do the welding work?

I would love to do this project in the future when I don't need the Millenia as my daily driver, or for a project car.

[Matt64341]

Also, here are the two walkthrough videos for anyone who didn't see them:

Walkthrough Part 1

Walkthrough Part 2