lock MAZDA 626 1987 Workshop Manual

6 ON-VEHICLE MAINTENANCE
6-4
ON-VEHICLE MAINTENANCE
FLUID LEVEL
1. Clean the area around the reservoir and the reser-
voir cap.
2. Check the fluid level. If the level is near or below
the "MIN" mark, add clutch fluid to the "MAX"
mark.
Fluid specification:
DOT-3 or DOT-4
(FMVSS 116, or SAE J1703)
PEDAL HEIGHT
Inspection
Measure the distance from the upper center of the
pedal pad to the firewall and ensure that the distance
is within specification.
Pedal height A:
216.5—221.5 mm (8.524—8.720 in)
Adjustment
To adjust the pedal height, loosen locknut and turn
stopper bolt or clutch switch.
PEDAL FREEPLAY
Inspection
Depress the pedal lightly by hand and measure the
freeplay to ensure that it is within specification.
Pedal freeplay: 5—13 mm (0.20—0.51 in)
Adjustment
1. Adjust the free play by loosening locknut C and
turning push rod D.
2. Check that the distance from the floor to the cen-
ter of the upper surface of the pedal pad is as
specified or more when the clutch is fully dis-
engaged.
Disengagement height B:
LHD 68 mm (2.7 in)
RHD 85 mm (3.3 in)
3. Tighten locknut C after adjustment.

7A REMOVAL
REMOVAL
Fl except DOHC
76G07A-008
1. Battery
2. Main fuse block
3. Air cleaner assembly
4. Ventilation hose
5. Air hose
6. Ground(s)
7. Speedometer cable
8. Clutch release cylinder
9. Canister hose
10. Wheel
11. Splash sheild
12. Extension bar
13. Control rod
14. Stabilizer
15. Joint shaft
16. Gusset plate (rear)
17. Gusset plate (front)
18. Surge tank bracket
19. Starter
20. Under cover
21. Engine mount No.4
22. Engine mount No.2
23. Hunger rubber
24. Crossmember
7 A—10

REMOVAL 7A
DOHC
76G07A-009
1. Battery
2. Main fuse block
3. Air cleaner assembly
4. Ventilation hose
5. Air hose
6. Ground(s)
7. Speedometer cable
8. Clutch release cylinder
9. Canister hose
10. Wheel
11. Splash sheild
12. Extension bar
13. Control rod
14. Stabilizer
15. Joint shaft
16. Surge tank bracket
17. Starter
18. Engine mount No.4
19. Engine mount No.2
20. Rear member (4WS)
21. Hunger rubber
22. Crossmember
7A—11

7A REMOVAL
1. Remove the battery and battery carrier.
2. Disconnect the main fuse block. (Fl)
3. Disconnect the distributor lead.
4. Remove the air cleaner assembly.
76G07A-012
5. Remove the vacuum hose, the intercooler hose
(RF-CX) and the electric fan. (RF-N and RF-CX)
86U07A-021
8. Remove the front wheels.
9. Remove the splash shields.
10. Drain the transaxle oil.
86U07A-022
7A—14

7A DISASSEMBLY
DISASSEMBLY
STEP 1
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
76G07A-016
76G07A-017
24. Crank lever shaft
25. O-ring
26. Crank lever assembly
27. Shift fork and shift rod as-
sembly
28. Steel ball
29. Spring
30. Primary shaft gear as-
sembly
31. Secondary shaft gear as-
sembly
32. Differential assembly
33. Clutch housing
1. Rear cover
2. Lock nut
3. Lock nut
4. Primary reverse synchroniz-
er gear
5. Secondary reverse syn-
chronizer gear
6. Roll pin
7. Shift fork
8. Clutch hub assembly
9. Synchronizer ring
10. 5th gear
11. Gear sleeve
12. Secondary 5th gear
13. Lock bolt
14. Guide bolt
15. Lock bolt, ball and spring
16. Transaxle case
17. Magnet
18. Reverse idle shaft
19. Reverse idle gear
20. Lock bolt
21. Shift rod (5th and reverse)
and clip
22. Gate
23. Pin
7 A—18

DISASSEMBLY 7 A
Disassembly Note
Transaxle
Mount the transaxle on the SST.
86U07A-037
Lock nut
1. Lock the primary shaft with the SST.
2. Shift to 1st or 2nd gear.
3. Remove the lock nut.
86U07A-038
Shift rod
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Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the
control lever, then turn the shift rod counter-
clockwise.
2. While holding the 1st-2nd shift fork with one hand
and the 3rd-4th shift fork with the other, raise them
both at the same time and shift each of the clutch
hub sleeves.
86U07A-039
3. Lift the control end and remove the steel ball, and,
at the same time, remove the shift rod from the
clutch housing.
4. Separate the shift rod and shift fork assembly from
each of the clutch hub sleeves.
76U07A-227
7A-19

7 A DISASSEMBLY
STEP 3
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
Note
a) Replace the bearings with new ones whenever they are disassembled.
b) Before disassembly, check the thrust clearance of all gears. (Refer to page 7A—33, 35.)
76G07A-021
1. Shift fork (3rd and 4th 13. 2nd gear 26. 4th gear
gears) 14. Synchronizer ring 27. Synchronizer ring
2. Interlock sleeve 15. Retaining ring 28. Retaining ring
3. Roll pin 16. Clutch hub assembly 29. Clutch hub assembly (3rd
4. Control end 17. Synchronizer spring and 4th gears)
5. Shift fork (1st and 2nd 18. Synchronizer key 30. Synchronizer spring
gears) 19. Clutch hub 31. Synchronizer key
6. Roll pin 20. Clutch hub sleeve (reverse 32. Clutch hub
7. Control lever gear) 33. Clutch hub sleeve
8. Control rod 21. Synchronizer ring 34. Synchronizer ring
9. Bearing outer race 22.
1
st gear 35. 3rd gear
10. Secondary 4th gear 23. Bearing inner race 36. Bearing inner race
11. Retaining ring 24. Secondary shaft 37. Primary shaft
12. Secondary 3rd gear 25. Bearing inner race
IK—22

7A ASSEMBLY
86U07A-062
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86U07A-063
86U07A-064

Identification mark Thickness
0 2.0
mm
(0.079
in)

1 2.1
mm
(0.083
in)

2 2.2
mm
(0.087
in)
3. Install the thrust washers and pinion gears.
4. Install the pinion shaft.
5. Install the knock pin, then crimp it so that it cannot
come out of the gear case.
6. Install the thrust washers and the side gears.
Check and adjust using the following procedure.
7. Install the left and right driveshafts in the differen-
tial assembly.
8. Support the driveshafts on V-blocks as shown in
the figure.
9. Measure the backlash of both pinion gears.
Backlash: 0—0.1 mm (0—0.004 in)
86U07A-065
10. If the backlash is more than specified, adjust by
selecting thrust washers from the table and install
them between the case and side gears.
Note
Use the same thickness thrust washer on each
side.
7A-30

7A ASSEMBLY
49 F401 331
•
49 F401 331
•
86U07A-069
"Oil groove
(four places)
76G07A-030
ZJJ
49 F40I 336 B
49 0636 145
86U07A-071
Primary Shaft
1. Install the new bearing inner race with the SST.
Note Press to 19,620 N (2,000 kg, 4,400 lb).
2. Install the 3rd gear, synchronizer ring, and clutch
hub assembly with the SST. (Refer to page
7A—33)
Note
a) Press to 19,620 N (2,000 kg, 4,400 lb).
b) Align the synchronizer ring groove and
clutch housing hub key when installing.
3. Install the retaining ring.
4. Install the synchronizer ring, 4nd gear, and bear-
ing inner race with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
5. Install both shift forks and the interlock sleeve, as
in the figure.
86U07A-072
7A-32

7A ASSEMBLY
8. Fit the crank lever in between the change arm and
the control end, and connect the crank lever shaft
to the crank lever.
9. Align the pin holes of the crank lever shaft and the
clutch housing, and insert the pin.
Note
Use a new O-ring for the crank lever shaft.
86U07A-113
10. Install the gate © and the shift rod ©, and tight-
en the gate mounting bolt.
Note
The mark (indicated by the arrow in the fig-
ure) and the gate mounting bolt hole must be
in the same direction.
76U07A-121
11. Install the reverse idle gear and the reverse idle
shaft.
12. Connect the magnet to the clutch housing.
13. Align the end of the interlock sleeve with the con-
trol lever indicated by the arrow, and, at the same
time, face the reverse idle shaft screw hole in the
direction shown in the figure.
76U07A-122
14. Apply a thin coat of sealant to the contact surfaces
of the clutch housing and transmission case, tight-
en the transaxle case installation bolts to the speci-
fied torque.
Tightening torque:
18—26 N m (1.8—2.7 m-kg, 13—18.8 ft-lb)
15. Insert the SST to driveshaft coupling hole.
7A-46