MAZDA 323 1989 Factory Repair Manual

DIFFERENTIAL J2
DIFFERENTIAL
PREPARATION
SST
49 GO17 1AO
Bearing remover
set
49 8092 375
Attachment J
(Part of
49
GO17 1AO)
49 GO30 338
Attachment E For
removal of
bearing
For
removal of side
bearing inner
race
For
installation of side
bearing inner
race 49 F401 366A
Plate
(Part of
49 GO17 1AO) For
removal of side
bearing inner
race
49 0839 425C
Puller set,
bearing For
removal of side
bearing inner
race I
23UOJ2-01
J2-43

J2 DIFFERENTIAL
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Pre-inspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
3. inspect all parts and repair or replace as necessary.
4. Assemble in the reverse order of disassembly, referring to
Assembly Note.
5 Mwn~lre the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin
2. Pinion shaft
3. Pinion gear
Inspection for wear and cracks
Pre-inspection .,...,........,............ page J2-44
Inspection of backlash. . . . ,.,.,..,,. page J2-45
4. Thrust washer
5. Side gear
Inspect for wear and cracks
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-44
Inspection of backlash . . . . . . . . . . . . . . page J2-45
6. Thrust washer
1
J ______ Ji
7. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-45
Assembly Note, .., ,.,..,,,,....,...,..,. page J2-45
8. Speedometer drive gear
9. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note .., ..,...., . ,. . . . . . . . page J2-45
Assembly
Note.. . . . . . . ,.. . . . ..,.. . . . . . . . page J2-45
10. Ring gear and gear case assembly
Inspect ring gear for wear or damage
Pre-inspection
Backlash of side gear and pinion gear
Measure the backlash by the following procedure.
1. Install the left and right driveshafts in the differential as-
sembly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O. 1 mm (O-0.004 in)
J2-44

DIFFERENTIAL
03UOJ2-10
03UOJ2-10
03UOJ2-10
03UOJ2-
03UOJ2-
Disassembly Note
Side bearing inner race (side opposite ring gear)
Caution
l Hold the gear case with one hand so that it does
not fall.
1. Remove the bearing inner race with the SST.
Side bearing inner race (ring gear side)
Caution
l Use pads in the vise to prevent damaging the
differential assembly.
1. Remove the bearing inner race with the SST.
Assembly Note
Side bearing inner race (Side opposite rlng gear)
1. install the speedometer drive gear.
2. Install the new side bearing inner race with the
SST.
Side bearing inner race (ring gear side)
1. Install the new bearing inner race with the SST.
Backlash of Side Gear and Pinion Gear
Measure the backlash by the following procedure.
1. Install the left and right driveshafts in the differential as-
sembly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O.1 mm (O-0.004 in)
4. If not as specified, replace the differential assembly.
--I
107
52-45

J2 SHIFT MECHANISM
SHIFT MECHANISM
OVERHAUL
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to
Assembly Note.
- --
(1.6-2.3, 12-17)
16-23 (1.8-2.3, 12-V)
N-m (m-kg, ft-lb)
03UOJ2-11
52-46

SHIFT MECHANISM
1. Change lever knob
2. Rear console
3. Front console
4. Boot
5. Nut
6. Washer
7. Bolt
8. Cover
9. Nut
10. Washer
11. Bushing
12. Spring
Inspect for damage and weaked
Assembly note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-47
13. Change lever
14. Ball seat (Upper)
15. Boot
Inspect for wear or damage 16. Holder
17. Ball seat (lower)
18. Nut
19. Washer
20. Pipe
21. Bushing
Inspect for wear or damage
22. Washer
23. Extension bar
Assembly note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-47
24. Insulator
Inspect for damage and cracks
25. Nut
26. Bolt
27. Bushing
Inspect for wear and damage
28. Change control rod
Inspect for bending
03UOJ2-109
CHAGE CONT
03UOJ2-111
Assembly Note
Extension bar
1. Connect the extension bar to the transaxle, and then mount
it to the floor.
Tightening torque:
16-23 N+m (1.6-2.3 m-kg, 12-17 ft-lb)
Spring
1. Verify that the hooked part of the spring is properly seated
in the bracket groove.
J2-47

M’
FRONT AND REAR AXLES
INDEX .....................................................
OUTLINE .................................................
SPECIFICATIONS ....................................
TROUBLESHOOTING GUIDE.. .................... ;I ;
FRONT AXLE ......................................... M- 3
REAR AXLE ........................................... M- 3
FRONT AXLE ........................................... M- 4
PREPARATION .......................................
WHEEL HUB, STEERING KNUCKLE.. ........ ii- d
-
REAR AXLE ............................................. M-10
PREPARATION ....................................... M-10
DRUM BRAKE TYPE ............................... M-l 1
DISC BRAKE TYPE ................................. M-14
DRIVE SHAFT .......................................... M-17
PREPARATION ....................................... M-17
JOINT SHAFT (BP DOHC). ....................... M-18
DRIVE SHAFT (TRIPOD JOINT). ................ M-21
23UOMX-001

INDEX
1. Front axle 3. Joint shaft (BP DOHC)
Preinspection ............................. M-l 8
............................. page M- 5 Preinspection page
Removal / Installation page M- 5 Removal / Installation
.................
................. page M-18
Disassembly / Inspection / Overhaul ....................................
page M-20
Assembly ................................. page M- 7 4. Drive shaft
2. Rear axle Removal / Installation
................. page M-22
[Drum brake type] Overhaul .................................... page M-25
Preinspection .............................
page M-l 1
Removal / Inspection /
Installation.. .............................. page
M-l 1
Disassembly I Assembly ............ page M-l 3
[Disc brake type]
Preinspection ............................. page M-14
Removal / Inspection /
Installation ................................ page
M-14
Disassembly / Assembly ............
page M-i 5
M-2

OUTLINE, TROUBLESHOOTING GUIDE M
OUTLINE
SPECIFICATIONS
Engine/Transaxle
86 SOHC
I BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX
Front axle
Bearing play axial direction Rear axle
Bearina olav axial direction I
mm (in) 0.05 (0.002)
mm (in) I 0.05 (0.002) Drive shaft
j Inside Tripod ioint
I Joint type I -
Outside I Ball ioint 1
Right side 919.3 (36.19)
918.7 (36.17) 630.7 (24.83)
Length of shaft
mm (in)
Left side 637.8 (25.11)
640.2 (25.20) 621.2 637.1
(24.46) (25.08)
Shaft diameter mm (in) Right side 21.5 (0.85) 23.0 (0.91)
Left side
21.5 (0.85)
23.0 (0.91)
23UOMX-003
TROUBLESHOOTING GUIDE
FRONT AXLE Problem
Steering wheel
vibration
Steering wheel pulls
or one-sided braking
Excessive steering
wheel play
Abnormal noise
Grease leakage from
boot Possible Cause Action
Worn or damaged wheel bearing
Excessive wheel bearing play
Worn or damaged wheel bearing
Excessive wheel bearing play
Excessive wheel bearing play Replace
Tighten or replace
Replace
Tighten or replace
Tighten or replace
Bent drive shaft or joint shaft
Worn or damaged wheel bearing
Worn drive shaft or joint shaft splines
Insufficient grease in joint or on splines of drive shaft
insufficient grease in joint or splines of joint shaft
Nom drive shaft tripod joint Replace
Replace
Replace
Replenish or replace
Add or replace
Replace
Damaged or broken boot
Faulty boot band
Excessive grease Replace
Replace
Reoair Page M- 7
M- 5,7
M- 7
M- 5,7
M- 57
M-18, 22
M- 7
M-18, 22
M-22, 25
M-18
M-25
M-25
M-25
M-25
23UOMX-004
REAR AXLE Problem Possible Cause Action Page
Steering wheel
Worn or damaged wheel bearing
Replace M-11, 14 vibration
Excessive wheel bearing play Tighten or replace M-11, 14 Steering wheel pulls
Worn or damaged wheel bearing Replace M-11, 14 or one-sided braking Excessive wheel bearing play Tighten or replace M-11, 14 Excessive steering
Excessive wheel bearing play Tighten or replace M-11, 14 wheel olav
Abnormal noise
Worn or damaged wheel bearing Replace M-11, 14
23UOMX-005
M-3

M FRONT AXLE
FRONT AXLE
PREPARATION
SST -’
.9 0118 850C
Uler, ball joint
19 8026 1AO
Uler, wheel hub
19 GO30 727
Attachment A
Part of
19 8026 1AO)
$9 F027 OAl
nstaller set,
oearing
49 F027 005
Attachment 62
(Part of
49 F027 OAl)
49 F027 009
Attachment
68 & 77
(Part of
49 F027 OAl) For
removal of tie rod
end
For
disassembly and
assembly of
wheel hub
For
removal of front
wheel hub
For
installation of
bearing
For
removal of wheel
bearing
For
installation of dust
cover 19 F026 103
qemoving plate !iiLzil
a-
l
49 GO33 102
Handle
(Part of
49 8026 IAO)
49 GO33 107
Installer, dust
cover
49 F027 003
Handle
(Part of
49 F027 OAl)
49 F027 007
Attachment 72
(Part of
49 F027 OAI)
49 VOOI 795
Installer, oil seal :or
disassembly of
vheel bearing
-01
,emoval of front
Nheel hub
-or
nstallation of dust
:over
For
removal and
installation of
wheel bearing
For
installation of
wheel bearing
For
installation of oil
seal
23UOMX-I
M-4