MAZDA 626 1987 Workshop Manual

INSPECTION AND REPAIR 7B
83U07B-326
83U07B-327
83U07B-328
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13. Install the front control body on the premain con-
trol body.
14. Loosely tighten the bolts and bracket.
Note
Match the bolt head letter as shown.
15. Install the control valve body mounting bolts as
shown for alignment.
16. Tighten the mounting bolts.
(1) Tighten the front control body.
Tightening torque:
6—8 N-m (66—80 cm-kg, 57—69 in-lb)
83U07B-329
7B—175

7B INSPECTION AND REPAIR
(2) Tighten the rear control body.
Tightening torque:
6—8 N-m (66—80 cm-kg, 57—69 in-lb)
17. Install the lock-up solenoid valve along with new
O-ring and oil strainer.
Tightening torque:
6—8 N-m (66—80 cm-kg, 57—69 in-lb)
7B—176
83U07B-330
83U07B-331

INSPECTION AND REPAIR 7B
DIFFERENTIAL
Disassembly
Disassemble in the sequence shown in the figure referring to the disassembly note for the specially
marked parts.
76G07B-221
1. Snap ring (G4A-HL)
2. Governor drive gear (G4A-HL)
3. Steel ball (G4A-HL)
4. Side gear
5. Side gear thrust washer
6. Roll pin
7. Pinion shaft
8. Pinion gear
9. Pinion gear thrust washer
10. Side bearing inner race
11. Speedometer drive gear
12. Ring gear and gear case assembly
Disassembly note
Checking backlash
Before disassembly, measure the backlash of the side
gears and pinion gears. If it is not within specifica-
tion, replace the differential assembly.
Backlash:
Standard 0.025—0.1 mm (0.001—0.004 in)
Maximum 0.5 mm (0.020 in)
83U07B-333
7B-177

7B INSPECTION AND REPAIR
76G07B-168
86U07B-324
86U07B-325
Governor drive gear (G4A-HL)
Remove the governor drive gear with the SST.
Note
Be careful not to lose the steel ball.
Roll pin
For removing the roll pin from the pinion shaft, place
the gear case on a vise and knock the pin out with
a suitable pin punch (02.0 mm (0.079 in) ) and
hammer.
Note
a) Use the protective plates to prevent dam-
age to the differential.
b) Insert the punch into the spring pin hole
from the ring gear side.
Side bearing inner race
1. Remove the side bearing inner race (side oppo-
site the ring gear) from the gear case with the SST.
2. Remove the side bearing inner race (ring gear side)
with a combination of parts from the SST.
86U07B-326
7B-178

INSPECTION AND REPAIR 7B
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn gears
2. Cracked or damaged gear case
3. Damaged bearings
86U07B-327
Assembly
1. Set the speedometer drive gear onto the ring gear
and case assembly.
86U07B-328
. Install the side bearing inner races.
(1) Press the side bearing inner race (side oppo-
site the ring gear) onto the ring gear and case
assembly with the SST.
(2) Press on the other side bearing inner race (ring
gear side) in the same manner.
Caution
Do not reuse the bearings if they were
removed.
86U07B-329
3. Install the pinion gears and thrust washers into the
case.
4. Install the pinion shaft.
B6U07B-330
7B—179

7B INSPECTION AND REPAIR
5. Install the roll pin.
76G07B-222
86U07B-332
76G07B-169
6. Install the thrust washers and side gears into the
gear case at the same time, then turn them back
on the pinion gear and align them with the pinion
shaft hole.
7. Set the steel ball in the hole in the gear case.
Note
Affix the ball with petroleum jelly.
8. Install the governor drive gear onto the gear case
with a plastic hammer.
9. Install the snap ring.
10. Check and adjust the backlash of the side gears
and pinion gears as follows:
(1) Install the left and right driveshafts in the
differential assembly.
(2) Support the driveshafts on V-blocks.
(3) Measure the backlash of both pinion gears.
Backlash:
Standard 0.025—0.1 mm (0.001—0.004 in)
Maximum 0.5 mm (0.020 in)
11. If the backlash is not within specification, replace
the differential assembly.
76G07B-170
7B—180

INSPECTION AND REPAIR 7B
OUTPUT GEAR
Disassembly
Disassemble in the sequence shown in the figure referring to the disassembly note for the specially
marked parts.
1. Seal ring
2. Output gear
3. Output gear
bearing
4. Output gear
bearing
86U07B-334
Disassembly note
Output gear bearings
Remove the output gear bearings from the output
gear with the SST.
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn output gear
2. Damaged bearing
86U07B-335
Assembly
1. Press the output gear bearings onto the output
gear with the SST.
86U07B-336
7B-181

7B INSPECTION AND REPAIR
IDLE GEAR
Disassembly
Disassemble in the sequence shown in the figure referring to the disassembly note for the specially
marked parts.
1. Locknut
2. Idle gear
bearing
3. Spacer
4. Idle gear
5. Adjust shim
6. Idle gear
bearing
7. Idle shaft
8. Bearing outer
race
9. Bearing outer
race
86U07B-337
Disassembly note
Locknut
Secure the idle shaft in a vise with the SST; then re-
move the locknut.
Note
Use the protective plates to prevent damage
to the SST.
86U07B-338
Bearing outer race
Remove the bearing outer race from the idle gear with
the SST.
86U07B-339
7B—182

INSPECTION AND REPAIR 7B
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn idle gear
2. Damaged or worn bearing
86U07B-340
Assembly
1. Press the bearing outer races in with the SST.
86U07B-341
86U07B-342
2. Install the idle gear bearing onto the idle shaft, then
install the idle gear, adjust shim, spacer, and
bearing.
3. Secure the idle shaft in a vise with the SST; then
tighten the locknut to the lower limit of the tighten-
ing torque.
Tightening torque:
128 N-m (13 m-kg, 94 ft-lb)
Note
Use the protective plates to prevent damage
to the SST.
86U07B-343
7B—183

7B INSPECTION AND REPAIR
4. Check and adjust the idle gear bearing preload.
(1) Turn the idle gear assembly and SST over, and
secure the gear in the vice.
Note
Use protective plates to prevent damage to
the idle gear.
(2) Attach the SST and spring scale or torque
wrench, and measure the preload while tight-
ening the locknut.
Tightening torque:
128—177
N m
(13—18 m-kg, 94—130 ft-lb)
49FT01 439
Preload:
0.03—0.9 N-m
(0.3—9.0 cm-kg, 0.26—7.8 in-lb)
Value indicated on pull scale:
0.3—9 N (0.03—0.9 kg, 0.066—1.98 lb)
Note
Read the preload when the idle shaft starts to
turn.
86U07B-345
86U07B-346
5. If the specified preload cannot be obtained within
the specified tightening torque, adjust by select-
ing the proper adjust shims.

Thickness
of
shim
0.10 mm (0.004
in)
0.12
mm
(0.005
in)
0.14
mm
(0.006
in)
0.16
mm
(0.0063
in)
0.18 mm (0.007
in)
0.20 mm (0.008
in)
Note
a) The maximum allowable number of shims
is 7.
b) Preload is reduced by increasing the thick-
ness of the shims, or increased by reduc-
ing the thickness of the shims.