MAZDA 323 1989 Factory Repair Manual

Jl
MANUAL TRANSAXLE
(F5M-R)
INDEX ..................................................... Jl- 2
OUTLINE ................................................ Jl- 3
SPECIFICATIONS ................................... Jl- 3
STRUCTURAL VIEW ............................... Jl- 4
POWER FLOW ...................................... Jl- 5
TROUBLESHOOTING GUIDE.. ................... Jl- 6
TRANSAXLE OIL ..................................... Jl- 7
INSPECTION ......................................... Jl- 7
REPLACEMENT ..................................... Jl- 7
TRANSAXLE ........................................... Jl- 6
PREPARATION ...................................... Jl- 6
REMOVAL ............................................ 51-10
DISASSEMBLY ...................................... Jl-14
INSPECTION ......................................... 51-27
ASSEMBLY ........................................... Jl-30
INSTALLATION ...................................... Jl-46
DIFFERENTIAL ........................................ Jl-52
PREPARATION ...................................... 51-52
DISASSEMBLY I INSPECTION / ASSEMBLY Jl-53
SHIFT MECHANISM ................................. Jl-56
OVERHAUL .......................................... Jl-56
OWOJl-001

Jl INDEX
INDEX
BACK-UP LdHT SWITCH
SERVICE, SECTION T VISCOSITY: SAE 75W-90
CAPACITY : 2.68 liters (2.83 US qt, 2.36 Imp qt)
03UOJl-00
1, Transaxle 2. Differential
Removal.. ..................................
page Jl-IO Disassembly I Inspection I
Disassembly ................................ .............................. page Jl-14 Assembly page Jl-53
Inspection ..................................
page J 1-27 3. Shift mechanism
Assembly .................................. page J l-30 Overhaul ...................................
page Jl-56
Installation ................................. page Jl -48 4. Transaxle oil
Inspection. .................................
page Jl- 7
Replacement ............................. page Jl- 7

OUTLINE Jl
OUTLINE
SPECIFICATIONS
c EnginelTransaxle
B6 SOHC BP SOHC
Item FSM-R
I
Transaxle control
I Floor shift
Synchromesh system Forward: Synchromesh
Reverse: Selective sliding
1 1st
I 3.416
2nd 1.842
I
Gear ratio
4th
Final aear ratio 5th
Reverse I
0.918
0.731
3.214
4.105 3.619
Grade
I API service GL-4
Oil Viscosity
I SAE 75W-90
Capacity liters (US qt, Imp qt) 2.68 (2.83, 2.36)
13UOJl-00
Jl-3

Jl OUTLINE
1. Primary 1 st gear 6. Primary reverse gear
2. Primary 2nd gear 7. Secondary 1st gear
3. Primary 3rd gear 8. Secondary 2nd gear
4. Primary 4th gear 9. Secondary 3rd gear
5. Primary 5th gear 10. Secondary 4th gear 11. Secondary 5th gear
12. Secondary reverse gear
13. Reverse idler gear
14. Differential
51-4

OUTLINE Jl
POWER FLOW
1ST
3RD
5TH
A
2ND
4TH
REVERSE
03lJOJl-00
Jl-!

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 OIL Jl
/
03UOJl-00
03UOJl-O(
TRANSAXLE OIL
INSPECTION
Note
l Park the vehicle on level ground.
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Verify that the oil level is between the F and L.
3. Install the speedometer driven gear.
Tightening torque:
7.8-12 N,m (80-120 cm-kg, 89-l 04 in-lb)
4. Connect the speedometer cable.
REPLACEMENT
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Remove the drain plug and washer. Drain the oil into a suita-
ble container.
3. Install a new washer and the drain plug.
Tightening torque:
39-54 N#rn (4.0-5.5 m-kg, 29-40 ft-lb)
4. Add the necessary amount of the specified oil through the
speedometer driven gear mounting.
Specified oil
Grade: API service GL-4
Viscosity: SAE 75W-90
Capacity: 2.88 liters (2.83 US qt, 2.38 Imp qt)
5. Verify the oil level.
6. Install the speedometer driven gear and connect the
speedometer cable.
Jl-7

Jl TRANSAXLE
TRANSAXLE
PREPARATION
SST
19 GO17 5A0
support of engine removal of tie-rod
19 0107 680A
Hanger, transaxle
49 F401 440
49 BOO1 795
49 0839 42%
removal of gears
49 GO30 370
49 F401 366A
49 F401 3308
49 F401 335A -.,
.J

TRANSAXLE
49 F401 331
Body
(Part of
49 F401 3308)
49 F401 3368
Attachment B
(Part of
49 F401 3308)
49 F401 3818
Selector
(Part of
49 DO17 2A2A)
49 F401 385
Bar
(Part of
49 DO17 2A2A)
49 FTOI 515A
Adapter, preload For
installation of
gear and bearing
inner race
For
installation of
bearing
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
bearing preload 49 F401 337A
Attachment C
(Part of
49 F401 330B)
49 DO17 2A2A
Shim selector set
49 F401 384
Collar
(Part of
49 DO17 2A2A)
49 GO19 019
Bolt set
(Part of
49 DO17 2A2A) For
installation of
gear
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
bearing preload
23UOJl-00
Jl-9

Jl TRANSAXLE
REMOVAL
1. Disconnect the negative battery cable.
2. Raise the vehicle and support it with safety stands.
3. Drain the transaxle oil into a suitable container.
A D~.MP,~,~ in +hn nr,-4ar chnln,n in the finlIre re!fe,rrino to Removal Note,
4.
51-10