clutch MAZDA PROTEGE 1992 Repair Manual

Jl TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem
Shift lever won’t shift
smoothly or is hard
to shift
Too much play in
shift lever
I------
Difficult to shift
Won’t stay in gear
Abnormal noise
I
Possible cause
Seized shift lever ball
Seized change control rod joint
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
Worn shift lever ball bushing
Bent change rod
No grease in transaxle control
Insufficient oil
Deterioration of oil quality
Wear or play of shift fork or shift rod
Worn synchronizer ring
Worn synchronizer cone of gear
Bad contact of synchronizer ring and cone of gear
Excessive longitudinal play of gears
Worn bearing
Worn synchronizer key spring
Excessive primary shaft gear bearing preload
improperly adjusted change guide plate
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
improperly installed extension bar
Worn shift fork
Worn clutch hub
Worn clutch hub sleeve
Worn gear sliding part of both shaft gears
Worn gear sliding part of each gear
Worn steel sliding groove of control end
Weak spring pressing against steel ball
Excessive thrust clearance
Worn bearing
Improperly installed engine mount
Insufficient oil
Deterioration of oil quality
Worn bearing
Worn sliding surfaces of gears or shafts
Excessive gear backlash
Damaged gear teeth
Foreign material in gears
Damaged differential gear or excessive backlash Remedy Replace
Replace
Replace
Replace
Replace
Replace
Replace
Lubricate with grease
Add oil
Replace with oil of
specified quality
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Replace
Replace
Replace
Tighten
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Tighten
Add oil
Replace
Adjust or replace
Replace
Replace
Replace with oil of
specified quality
Replace
Adjust or replace Page Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl- 7
Jl- 7
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-36
Jl-17
Jl-56
Jl-56
Jl-56
Jl-56
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-14
Jl-14
Jl-22, 24
Jl-22, 24
Jl-48
Jl- 7
Jl- 7
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-53
03UOJl-OC --
-../
51-6

TRANSAXLE Jl
1. Wheel and tire
2. Splash shield
3. Air hose and resonance chamber
4. Battery
5. Battery carrier
6. Speedometer cable
7. Back-up light switch connector
8. Neutral switch connector
9. Ground
10. Starter
11. Extension bar
12. Control rod
13. Engine mount member
Removal Note . . . . . . . . . . . . . . . . . . . . . . 14. Exhaust pipe
15. Engine mount No.2
16. Clutch release cvlinder
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-1 1
17. Tie-rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
18. Stabilizer (BP SOHC)
19. Driveshaft
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
20. Engine mount No.4
21. Transaxle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
page Jl-11
03UOJl-012
Removal Note
Engine mount member
1. Suspend the engine with the SST and remove the engine
mount member.
03UOJ2-015 Clutch release cylinder
Caution
l Do not damage the clutch pipe.
1. Remove the bolts shown.
2. Lay aside the clutch release cylinder and the clutch pipe
when removing the transaxle.
03UOJl-013
,Jl-11

TRANSAXLE Jl
1, Rear cover
2. Locknut (Primary shaft)
Disassembly Note .,......,,.,......... page Jl-15
3. Stop plate
4. Locknut (Secondary shaft)
Disassembly Note ,..,....,,.,......... page Jl-15
5. 5th shift fork
6. Clutch hub assembly (5th)
Inspection . . . . . . . . . . . . . . . . ..*............... page J l-29
7. Synchronizer ring (5th)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-27
8. 5th gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-28
9. Gear sleeve
Inspection . . . . . . . . . . . . . . . . ..*...*........... page Jl-28
10. Secondary 5th gear
11. Lock bolt and washer
12. Back-up light switch
13. Neutral switch
14. Transaxle case assembly
15. Magnet
16. Reverse idler shaft
17. Reverse idler gear
Inspection.. . . , . . . . . . . . . . . . . . . , , . , . . . . . . . . . . page J l-27
L ,
03UOJl-022
I
I I
03UOJl-023
18. 5th shift rod
19. 5th shift rod end
20. Pin
21. Crank lever shaft
22. Crank lever assembly
23. Shift fork and shift rod assembly
Disassembly Note ,.................... page Jl-16
24. Steel ball
25. Spring
26. Primary shaft gear assembly
27. Secondary shaft gear assembly
28. Differential assembly
29. Clutch housing
30. Synchronizer spring
31. Clutch hub sleeve
32. Synchronizer key
33. Clutch hub
34. 3rd/4th shift fork
35. Interlock sleeve
36. Control lever
37. lstl2nd shift fork
38. Control rod
39. Control end
03UOJl-021
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06-0.26mm (0.0024-0.0102 in)
Maximum : 0.31 mm (0.0122 in)
2. If the clearance exceeds the the maximum, check the con-
tact surfaces of 5th gear and the clutch hub. Replace worn
or damaged parts.
Disassembly note
Locknut
1, Mount the transaxle on the SST.
Jl-15

Jl TRANSAXLE
SHIFT ROD “I, -
CON-rPOL LEVE$:,
I I 03UOJ2.0
76U07A.22
2. Lock the primary shaft with the SST.
3. Shift to 1 st or 2nd gear to lock the rotation of the primary
shaft.
Caution
l Do not reuse the removed locknut.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary
shafts.
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control le-
ver (arrow). Turn the shift rod counterclockwise.
2. While holding the 1 st-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.
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.
51-16

TRANSAXLE Jl
Clutch Housing and Transaxle Case Components
Caution
l Do not remove oil seals unless necessary.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
-
.ACE
23UOJl-O(
1. Speedometer driven gear 17. Boot 28. Adjust shim
assembly 18. Oil seal (Change rod) 29. Adjust shim
2. Oil seal (Differential) Disassembly Note 30. Bearing outer race
Disassembly Note ,.,,,..,............. page Jl-18 (Differential)
..................... page Jl-19 19. Bushing Disassembly Note
Replacement (On-vehicle) 20. Oil seal (Primary shaft) ..................... page Jl-19
.....................
page Jl-20 Disassembly Note 31. Adjust shim (Differential)
3. Pivot ..................... page Jl-19 Disassembly Note
4. Bleeder 21. Bearing outer race ..................... page Jl-19
5. Bleeder cover Disassembly Note 32. Transaxle case
6. Gasket ..................... page Jl-18 33. Roll pin
7. Roll pin 22. Funnel 34. O-ring
8. Blind plug Disassembly Note 35. Driven gear
Disassembly Note ..................... page Jl-18 36. Packing
..................... page Jl-18 23. Bearing outer race 37. Oil seal
9. Reverse lever shaft (Differential) (Speedometer gear cace)
Disassembly Note Disassembly Note Disassembly Note
..................... page Jl-18 ..................... page Jl-19 ..................... page Jl-19
10. Lever set spring 24. Clutch housing 38. Gear case
11. Reverse lever 25. Oil passage 39. Joint
Inspection ....... page Jl-27 26. Oil seal (Differential) 40. Change rod
12. Guide plate assembly Disassembly Note
13. Roll pin ..................... page Jl-19
14. Selector Replacement (On-vehicle)
15. Change arm ..................... page Ji-20
16. Change rod assembly 27, Bearing outer race
Jl-17

Jl TRANSAXLE
03UOJl-025
Disassembly note
Blind plug
1. Remove the roll pin with pliers.
03UOJi-027
03UOJ 1.029
Jl-18
Reverse lever shaft
1. Protect the reverse lever shaft with a rag and remove the
shaft with pliers.
Oil seal (Change rod)
1 .Remove the oil seal with a screwdriver.
Funnel and bearing outer race (Secondary shaft)
Note
l Remove the bearing outer race with a screwdriver
if necessary.
1) Insert a screwdriver between the clutch housing
and bearing outer race.
2)Pt-y the bearing outer race free.
03UOJl-028
1. Remove the bearing outer race by lifting out the funnel and
race together.

TRANSAXLE
L I
03UOJl-030
03UOJl-03 81
-”
/
23UOJl-004
03UOJ l-03
03UOJl.0:
Oil seal (Primary shaft)
Caution
l Do not damage the clutch housing.
1. Remove the oil seal with a screwdriver.
Oil seal (Differential)
1. Remove the oil seal with a screwdriver.
Bearing outer race (Differential)
1. Remove the bearing outer race with the SST.
Bearing outer race and adjust shim (Differential)
1. Install the SST to the bearing outer race.
2. Remove the bearing outer race and adjust shim.
Oil seal (Speedometer gear case)
1. Remove the oil seal as shown in the figure.
Jl-19

Jl TRANSAXLE
Primary Shaft Assembly
1. Measure the thrust clearances of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
REPLACE
1. Bearing
Disassembly Note.. . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . .., . . . . . . . . . . . . . . . . . . . . . page J l-28
2.4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . . . . . . . . . . . . . . . . . . . . . page J l-28
3. Synchronizer ring (4th)
Inspection.. . . . . . . . . . . . . . . . . . . . . . page J l-27
4. Retaining ring
5. Clutch hub assembly (3rd/4th)
Disassembly Note . . . . . . . . . . . . . . . . page Jl-23
inspection.. . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (3rd)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . . .., . . . . . . ,.. . . . . . . . . page J l-27 7. 3rd gear
Disassembly Note.. . . . . . . . . . . . page J l-23
Inspection.. . . . . . . . . . . page J 1-28
8. Bearing
Disassembly Note.. . ., . . . page J l-23
9. Primary shaft
Inspection., . . . . . . . . . . . page J 1-27
10. Synchronizer spring
11. Clutch hub sleeve
12. Synchronizer key
13. Clutch hub
. . /’
Jl-22

.
TRANSAXLE Jl
03UOJl-03: 3
03UOJl-040
03UOJ l-04
I 03UOJl-04
2
03UOJl-043
Preinspection
3rd gear thrust clearance
1. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.06-0.21 mm (0.002-0.008 in)
Maximum : 0.26mm (0.010 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 3rd gear, 2nd gear and clutch hub (3rd/4th).
Replace worn or damaged parts.
4th gear thrust clearance
1. Measure the clearance between 4th gear and the ball
bearing.
Clearance: 0.21-0.61 mm (0.008-0.024 in)
Maximum: 0.66mm (0.026 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 4th gear, ball bearing, and clutch hub
(3rd/4th). Replace worn or damaged parts.
Disassembly note
Bearing and 4th gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the ball bearing and 4th gear with the SST.
Clutch hub assembly (3rd/4th), synchronizer ring (3rd)
and 3rd gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the clutch hub assembly (3rd/4th), synchronizer
ring (3rd) and 3rd gear with the
SST.
Bearing
1. Remove the bearing with the SST.
Jl-23

Jl TRANSAXLE
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
0 REPLACE-
/
1. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
2. Secondary 4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
3. Retaining ring
4. Secondary 3rd gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
5.2nd gear
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (2nd)
Inspection.. . . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . . page J l-27
7. Retaining ring
8. Clutch hub assembly (lst/2nd)
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-29 9. Synchronizer ring (1 st)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. ,,..... . . . . . . . . . . . . . . . . . . . . . . . . . page J l-27
10. 1st gear
Disassembly Note ..,..,,.,,,....,..,.. page Jl-25
Inspection ..,................,.............. page J l-29
11. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . , . . . . page Jl -26
12. Secondary shaft
Inspection., , , . , . , . . , , . . . . . . . . , . , . . . . . , . . . . . page J l-28
13. Synchronizer spring
14. Clutch hub sleeve
15. Synchronizer key
16. Clutch hub
Jl-24