service MAZDA 232 1990 Suplement Owner's Guide

H
CLUTCH
iNDEX ..*..*.............*..*..............................* l-l- 2
OUTLINE .................................................. l-b- 4
OUTLtNE OF CONSTRUCTION
................. H- 4
SPECtFlCATtUNS ....................................
H- 4
CLUTCH CONTROL
.................................... t-i- 5
CLUTCH PEDAL ..................................... H- 5
CLUTCH MASTER CYLINDER ................... H-
7
RELEASE 5EARlNG ................................ H- 8
1 SERVICE /
SUPPLEMENTAL SERVICE INFORMATION.. H- 9
TROUBLESHOOTlNG
GUIDE.. .................... Ii- 9
CLUTCH FLUID (WITH ABS) ......................
H-l 0
PREPARATION ....................................... u-IO
REPLACEMENT ......................................
H-10
CLUTCH PEDAL (BP DOHC TURBO) ........... H-1 1
REMOVAL I INSPECTION / INSTALLATtON . . H-11
CLUTCH MASTER CYLINDER
(BP DOHC TURBO OR WITH ABS)
............ H-f 3
PREPARATION .......................................
u-1 3
REMOVAL I INSPECTION I INSTALLATION
(BP DOHC TURBO) ............................... H-13
AIR BLEEDlNG (-WtTH ABS) ...................... ti-14
OVERHAUL
(BP DOHC TURBO). ............... H-15
CLUTCH RELEASE CYLINDER (WITH ABS). H-l 7
PREPARATION .......................................
H-l 7
AtR
BLEEDING (WITH ABS). ..................... H-17
CLUTCH UNIT
.......................................... u-1 8
PREPARATION
....................................... H-f 8
REMOVAL I INSTALLATION ...................... H-19
93GOHX-701

SUPPLEMENTAL SERVICE INFORMATION, TROU8LESHOOTlNG GUIDE H
SUPPLEMENTALSERVICE INFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual (1206IO-89F).
Troubleshooting guide
Clutch fluid (with ABS)
l Replacement
Clutch pedal (BP DOHC Turbo) Clutch release cylinder (with ABS) l Air bleeding
Clutch unit
l Removal I Inspection I installation
Clutch master cylinder
(BP DOW Turbo or with ABS) l Removal I Inspection I installation
93GOHX-710
l Removal I Inspection I Installation (BP DUHC Turbo)
l Air bleeding (with ABS)
l Overhaul (BP DUHC Turbo)
TROUBLESHOOTING GUlDE
Problem
Possibte Cause Remedy Page
Slipping
Clutch disc facing worn excessively
Replace U-l 9
Clutch disc facing surface hardened or oifed
Repair or replace H-l 9
Pressure plate damaged Replace H-19
Diaphragm spring damaged or weakened
Replace H-l 9
Insufficient clutch pedal piay
Adjust H-12
Clutch pedal sticking
Repair or replace U-11
Flywheel damaged
Repair or replace H-19
Faulty
Excessive runout or damaged clutch disc
Replace H-19
disengagement
Clutch disc spiines rusted or worn ’
Remove rust or replace H-l 9
Clutch disc facing oiled
Repair or replace H-19
Diaphragm spring weakened
Reptace H-19
Excessive clutch pedal ptay
Adjust -
Insufficient clutch fluid
Add fluid H-10
Leakage of clutch fluid
Locate and repair or -
replace
Clutch vibrates
Clutch disc facing oiled
Repair or replace H-l 9
when accelerating
Torsion rubbers weakened
u-19 Clutch disc facing hardened or damaged Replace
Repair or replace H-19
Clutch disc facing rivets loose
Replace H-l 9
Pressure plate damaged or excessive runout
Replace H-l 9
Flywheel surface hardened or damaged
Repair or replace H-19
Loose or worn engine mount
Tighten or replace -
Clutch pedal
sticking Pedal shaft not properly lubricated
Lubricate or replace H-l 1
Asistireturn spring damaged or poor adjust
Replace or adjust H-11, 12
Abnormal noise
Clutch release bearing damaged
Replace N-1 9
Poor iubrication of release bearing sleeve
Torsion rubbers weakened Lubricate or replace H-19
Replace u-t9 Excessive crankshaft
end play
Repalr -
Pilot bearing worn or damaged
Replace H-79
Worn pivot points of reiease fork
Repair or replace H-19

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

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

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