MAZDA 232 1990 Workshop Manual Suplement

H CLUTCH UNIT
PREPARATION
SST
49 E301 060
Brake, ring gear
For removal and
i nstaI\abon of
c!utch cover and
flywl-leel
49 E301 062
Collar
(Part
of 49 E301 060) For
removal and
installation of
cIutch cover and
flywheel
49 1285 071 For
I removal of blot
Puller, bearing
Lj , - e bearing
49 0823 U72A 1 For
I installation of pilot 49 E3OI 061
Body
(Part
of 49 E301 060)
49 SE01 310
Centering tool,
clutch disc
49 1285 073
Chuck
(Part of
49 1285 071)
Installer 1 eccentric
shaft bearing @@D bearing -
For
removal and
installation of
dutch cover and
flywheel
For
support and
alrgnment of
clutch disc 7
For
removal of pilot
bearing
93GOHX-726
H-18

t .-
1
CLUTCH UNIT H
REMOVAL I fNSTALLATION
l Remove the clutch release cylinder with the clutch pipe connected.
- Do not remove the pilot bearing if not necessary.
f . Remove in the order shown in the figure, referring to Removal Note.
2. Instal! in the reverse order of removal, referring to Installation Note.
-761 BP SOHC
,E+--l BP DOHC TURBO
-; (MORI Wl-llTE TA No.2 OR
B EQUIVALENT ORGANIC
MOLYBDENUM GREASE)
1. Clutch release cylinder
2. Transaxle
Service ~......-...tl.*I.*-......*,,.**..l....... Section J3
3. Bout
4. Release bearing
5. Clutch release fork
6. Clutch cover
Removal Note _....._._._.-..._....___.._. page H-20
lnstaflation Note .._.......-..._.. . .._..._. page H-21 7. Clutch disc
Removal Note . . . . . . . .._...
Installation Note.. . . . . . . . . .
8. Pilot bearing
Removal Note . . . . . . . . . .._.
1 nstatlation Note.. . . . . __ . _.
9. Flywheel
Removal Note . . . . . . . . . . . . .
Installation Note . . . . . . . . . . . *..*.
w....
*.*..
-....
. . . . .
. . . . ..*.a.*.
page H-20
.,..I.._ page H-21
.**-. ..- page H-20
.,..... -
page H-21
. ..*.-.- page H-20
_...a-.. page H-20
H-19

C1UTCf-f UNtT
9MUOHX-032
I
03UOf-lX-028
I
93GOHX-729
I
i
Removal Note
Clutch cover and disc
1. Install the SST.
2. Loosen each bolt one turn at a time in a crisscross pattern
until spring tension is released. Then remove the ciutch cov-
er and disc.
Pilot bearing
1. Remove the pilot bearing with the
SST if necessary.
Flywheel
Note
l After removing the flywheel, inspect for oil leakage
past the crankshaft rear oil seal.
If necessary, replace the oil seal.
1. Hold the flywheel with the SST.
2. Remove the flywheel.
Instalfation Note
Flywheel
1 -Wipe the bolts clean and apply sealant to the bolt threads.
2. Install the flywheel and SST.
3. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque:
96403 Nmm (9.8-10.5 m-kg, 71-76 ft.lb)
PiIot bearing
Note
l Install the pilot bearing ftush with the flywheeL
I_ Install the new bearing with the SST.
03UOHX-030
H-20

CLUTCW UNIT
Clutch disc
1. Clean the clutch disc splines and main drive gear spIines;
then apply organic molybdenum grease.
2. Hold
the clutch disc in position with the SST.
Clutch cover
1. Install the SST.
2. Align the
dowel holes with the flywheel dowels.
3. Tighten the
botts evenly and gradually in the pattern shown.
Tightening torque:
18-26 N-m (1.8-2.7 m-kg, 13-20 ft-lb)
EWOHX-040
Ii-21

I

J3
MANUAL TRANSAXLE AND
TRANSFER UNIT (GSMX-R)
INDEX .........................................
J3- 2
/FEATURES] I
OUTLINE .....................................
J3- 4
OUTLINE OF CONSTRUCTION ..... J3- 4
SPECIFlCATtUNS ....................... J3- 5
TRANSAXLE AND TRANSFER UNIT J3- 5
STRUCTURAL VIEW.. ................. J3- 6
TRANSAXLE ................................ J3- 8
DOUBLE CONE SYNCHRU
MECHANlSM ........................... J3- 8
SHIFT FORKS AND SHIFT RODS . . J3- 10
iNTERLUCK MECHANISM ......... ., J3- 11
TRANSFER UNtT
.......................... J3- 12
CENTER DIFFERENTIAL ............. J3- 14
VISCOUS COUPLING
(BP DOHC TURBO). .................. J3- 20
CENTER DlFFERENTIAL LUCK
SYSTEM (MANUAL) .................. J3- 23
CENTER DIFFERENTIAL LOCK
SYSTEM (ELECTRICAL) ............. J3- 24
CENTER DIFFERENTIAL LOCK
CONTROL SWITCH ................... J3- 28
CENTER DIFFERENTIAL LUCK
ASSEMBLY
.............................. J3- 29
CENTER DIFFERENTIAL LOCK
SENSOR SWlTCH.. ................... J3- 31
IDLER GEAR SHAFI- ................... J3- 33
POWERFLOW .............................. J3- 34
TROUBLESHOOTING GUIDE ......... J3- 35 TRANSAXLE OIL .......................... J3- 36
INSPECTlON ............................. 33- 36
REPLACEMENT.. ....................... J3- 36
TRANSFER CARRIER CM .............
339 36
INSPECTION ............................. J3- 36
REPLACEMENT. ........................ J3- 36
TRANSAXLE AND
TRANSFER UNIT ........................ J3- 38
PREPARATION .......................... J3- 38
REMOVAL ................................. J3- 42
DISASSEMBLY
........................... J3- 48
INSPECTION ............................. J3- 72
ASSEMBLY ............................... J3- 75
INSTALLATION
.......................... J3-I I2
SHIFT MECHANISM.. .................... J3-119
OVERHAUL ............................... J3-119
CENTER DIFFERENTIAL
LOCK SYSTEM ........................... J3-121
SYSTEM DIAGRAM ..................... J3-121
INSPECTION ............................. J3-122
CENTER DIFFERENTIAL
LOCK MOTOR ............................ J3-123
INSPECTDN ............................. J3-123
REPLACEMENT ......................... J3-123
4x4 CONTROL UNIT.. ................... J3-126
INSPECTION ............................. 53-l 26
REPLACEMENT.. ....................... 53-l 26
CENTER DIFFERENTIAL
LOCK SWITCH ........................... J3-126
INSPECTION ............................. J3-126
REPLACEMENT ......................... J3-127
CENTER DIFFERENTIAL
LUCK SENSOR SWITCH ............. J3-127
INSPECTION ............................. J3-127
REPLACEMENT ......................... J3-127
93GOJ3-701

J3 INDEX
JNDEX
LHD
// /
vIscOsIn:
ALL SEASON DEXRON-II, \_\;/ M-III
ABOVE -18OC @OF): ?5W-90
CAPACITY: 2.6 liters
(2.7 us qt, 2.2 Imp qt) ABOVE -18OC (UOF): 90
BELOW --t8OC (UOF): 8UW
CAPACITY: 0.5 liter
IO.53 US qt, 0.44 Imp qt 1. Transaxle oil
Inspection.. ._._.. . . . . . . . . . . . . . . . . . . . . . . . . page J3- 36
Replacement -.._.......-............... page J3- 36
2. Transfer carrier oi!
Inspection
. . . ..-*..-.*a. . . . . * . . . . . . . . . . . . . page J3- 36
Replacement . . ..-...Ir.....*....~......
page J3- 36 3. Transaxle and transfer unit
Removal . . . . . . . ..-.-........-._._._....... page J3- 42
Disassembly, .._. . . .-. ._. .-. . . . . . . . . . . . . page J3- 48
Inspection.. . . . . . . ._. .-. .-. .-. . ._. . . . ._. . . page J3- 72
Assembly _.._..._.__._......._._..._...._ page J3- 75
Installation _.._.._.._._..._. . . . . . . . . .._.._ page J3-1 I 2
4. Shift mechanism
Overhaul ,._.._... . . . . . . . . . . . ._..._......_ page
J3-1 19 J3-2 Inspection . . . . . . . . . . . . . .._......._._...... 5. Center differential lock motor
page J3-I 23 Replacement .,-.....,..._..............
page J3-123 6.4x4 Control unit
Inspection ,.......... ~ ....._._._........I- page J3-I 26
Replacement ..*...** . . . . *.*...- . . . . . . . - page J3-126 7. Center differential lock switch
1 nspection ..,....*.....*.. *.*.* . . . . -.- . . . . page J3-126
Replacement ..~ ..,....._.........._,... page 33-l 26
8.
Center differential lock sensor switch
Inspection.. . . . . . . _ _ _ . . . _. . . _. _ _ _. __. . . . _ _ page J 3- 128
Replacement ..,.. . . . . . . . . . . . . . .._...... page J3-128

t
1
lNDEX J3
GRADE: API SERVICE GL-5
ABOVE -18OC (OOF): 90
BELOW -18°C (OOf): 80W
CAPACITY: 0.5 liter
(0.53 us qt, 0.44 Imp qt)
SERVICE, SECTiON T
GRADE: API SERVICE Gt4
ALL SEASON DEXRON-II, M-D
ABOVE -18OC (OOF): 75W-90
CAPACITY: 2.6 liters
(2.7 US qt, 2.2 Imp qt)
I. Transaxle oil
Inspection . . . . .._........_................ page J3-
36
Reptacement . . . . . . . . . _,. . . . ._. . . . . . . . . .
page J3-
36
2. Transfer carrier oil
Inspection.. . .._. . . .._ ._. ._.. . . . . . . . . . . . . .
page
J3- 36
Replacement . . . . . . . . . . ..l._............ page J3-
36
3. TransaxIe and transfer unit
Removal .I...............~.......~......__
page J3- 42
Disassembly .**.,.--......-.**.....,.._.
page J3- 48
t nspection . . .._........*...*I.-..-........
page J3- 72
Assembly . .._....._.....--......-........ page J3- 75
lnstaliation . . . . ._. . . _ .-. . . . . . ..-. . . .._., . _ page J3-I 12
4. Shift mechanism
Overhaul . . . ..*..-.*._.........-..........
pageJ3-119 5. Center differential lock motor
Inspection . . . . . . . . . . . . . . . . . . .._..._....... page J3-123
Replacement . . . _ , . . . . . . *. . . . . _ . _. . . . _ . .
page J3- 123
6. 4x4 Control unit
Inspection . . . . . . . . . . . . .._...._......._....
page J3-126
Replacement . . . .._......_........ . . . . . .
page J3-126
7. Center differential lock switch
Inspection.. . _ . _ . _. _. . _. . . . . _ . . . _ . . . . . . . . .
page J3-f 27
Replacement . . . . . .._...._........_..... page 33-l 27
8. Center differential lock sensor switch
Inspection . . . . . . . . . . . . . . ** .-... 1*..**-.I..
pageJ3-128
Replacement
. . ..=......-.... -* . . . . -..-. page J3-I 28
J3-3

J3 OUTLtNE
OUTLINE OF CONSTRUCTION
l Full-time 4-wheel drive, incorporating a viscous coupling is used on the BP DUHC Turbo model. BP SUHC
engine equipped models are fitted with an electronically controlled, lockable center differential.
With this system all driving conditions are easily contended with; from good roads to bad roads and
ad-
verse weather conditions.
l The transaxle and transfer unit were developed based on the GSM-R type transaxle.
The transaxle, center differential, viscous coupling, and front differentia! are a single, compact unit.
l The center differential employs a planetary carrier. system and a viscous coupling, and functions to distrib-
ute the driving force to the front and rear differentials as needed.
Through the use of this center differential, tire scuffing common to 4-wheel drive vehicles during tight cor-
nering, is eliminated.
l The speedometer driven gear (for detection of vehicle speed) is installed in the transfer carrier and detects
the speed of the rear wheels.
l Lubrication oil of the transaxle and transfer unit and of the carrier is contained separately.
93GOJ3-704
J3-4

OUTLINE 33
SPECIFICATIONS
TRANSAXLE AND TRANSFER UNIT
Item Engine model
Transaxle control
Forward
Synchromtsh system
Reverse
I St
2nd
3rd
Gear ratlo 4th
5th
Reverse
Final gear ratio
Speedometer gear ratlo
Type
Number of ring Outer
gear teeth
Inner
Center differential
gear teeth
Inner
Number of sun Pinion gear side
gear teeth
Idler gear side
Number of idler gear teeth
Type
011
Capacity BP DOHC turbo BP SOHC
Floor shift
Synchromesh
Selectrve sfiding and synchromesh
3.454 3.307
1.833
I.310 1.233
0.970 Cl.91 4
0.717
3.166 L
4.214 4.388
1 .oo
Planetary carrier
59 79
75 66
14
14
43 33
43
37
ATF: DEXRON-II, M-III Above -18OC (O°F)
API servie GL-4 SAE 75W-90
2.6 liters (2.7 US qt, 2.2 Imp qt)
93GOJ3-305
Transfer Carrier
Number of teeth Ring gear
Pinion gear 37
11
API service GL-5
Oil Type
Capacity Above -18OC tOoF) SAE 90
Below -18OC tOoF) SAE 8OW
0.5 liter (0.53 US qt,
0.44 Imp qt)
93GOLl3-776 -
J3-5