clutch MAZDA 626 1987 Workshop Manual

REMOVAL 7A
RF-N and RF-CX
1. Battery
2. Air cleaner assembly
3. Vacuum hose
4. Intercooler pipe and hose
(RF-CX)
5. Electric fan
6. Speedometer cable
7. Ground(s)
8. Clutch release cylinder
9. Pressure and return hoses
(power steering)
10. Starter
11. Wheel
12. Splash shield
13. Stabilizer
14. Joint shaft
15. Extension bar
16. Control rod
76G07A-011
17. Exhaust pipe bracket
18. Water pipe
19. Gusset plate (rear)
20. Gusset plate (front)
21. Under cover
22. Engine mount No.4
23. Engine mount No.2
24. Crossmember
7 A—13

REMOVAL 7A
86U07A-023
86U07A-024
86U07A-025
11. Disconnect the clutch release cylinder.
12. Disconnect the tie-rod ends using SST.
13. Remove the stabilizer bar control links.
14. Remove the bolts and nuts at the left and right low-
er arm bolt joints.
15. Pull the lower arms downward to separate them
from the knuckles.
Note
Do not damage the ball-joint dust boots.
16. Separate the left driveshaft from the transaxle by
prying with a bar inserted between the shaft and
the case.
Note
Do not damage the oil seal.
17. Remove the joint shaft bracket.
18. Separate the right driveshaft together with the joint
shaft in the same manner.
86U07A-026
7 A—15

7A DISASSEMBLY
DISASSEMBLY
STEP 1
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
76G07A-016
76G07A-017
24. Crank lever shaft
25. O-ring
26. Crank lever assembly
27. Shift fork and shift rod as-
sembly
28. Steel ball
29. Spring
30. Primary shaft gear as-
sembly
31. Secondary shaft gear as-
sembly
32. Differential assembly
33. Clutch housing
1. Rear cover
2. Lock nut
3. Lock nut
4. Primary reverse synchroniz-
er gear
5. Secondary reverse syn-
chronizer gear
6. Roll pin
7. Shift fork
8. Clutch hub assembly
9. Synchronizer ring
10. 5th gear
11. Gear sleeve
12. Secondary 5th gear
13. Lock bolt
14. Guide bolt
15. Lock bolt, ball and spring
16. Transaxle case
17. Magnet
18. Reverse idle shaft
19. Reverse idle gear
20. Lock bolt
21. Shift rod (5th and reverse)
and clip
22. Gate
23. Pin
7 A—18

DISASSEMBLY 7 A
Disassembly Note
Transaxle
Mount the transaxle on the SST.
86U07A-037
Lock nut
1. Lock the primary shaft with the SST.
2. Shift to 1st or 2nd gear.
3. Remove the lock nut.
86U07A-038
Shift rod
rj 'ic^rv
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the
control lever, then turn the shift rod counter-
clockwise.
2. While holding the 1st-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.
86U07A-039
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.
76U07A-227
7A-19

DISASSEMBLY 7 A
Disassembly Note
Bearing outer race (primary shaft)
Remove the bearing outer race with the SST.
86U07A-041
Bearing outer race (secondary shaft)
Remove the bearing outer race by lifting out the fun-
nel and race together.
86U07A-042
Roll pin
Align the groove for removal of the clutch housing
pin with the position of the roll pin, then tap the pin
out using a pin punch.
76G07A-020
Bearing outer race (differential)
Remove the bearing outer race with the SST.
86U07A-044
7A-21

7 A DISASSEMBLY
STEP 3
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
Note
a) Replace the bearings with new ones whenever they are disassembled.
b) Before disassembly, check the thrust clearance of all gears. (Refer to page 7A—33, 35.)
76G07A-021
1. Shift fork (3rd and 4th 13. 2nd gear 26. 4th gear
gears) 14. Synchronizer ring 27. Synchronizer ring
2. Interlock sleeve 15. Retaining ring 28. Retaining ring
3. Roll pin 16. Clutch hub assembly 29. Clutch hub assembly (3rd
4. Control end 17. Synchronizer spring and 4th gears)
5. Shift fork (1st and 2nd 18. Synchronizer key 30. Synchronizer spring
gears) 19. Clutch hub 31. Synchronizer key
6. Roll pin 20. Clutch hub sleeve (reverse 32. Clutch hub
7. Control lever gear) 33. Clutch hub sleeve
8. Control rod 21. Synchronizer ring 34. Synchronizer ring
9. Bearing outer race 22.
1
st gear 35. 3rd gear
10. Secondary 4th gear 23. Bearing inner race 36. Bearing inner race
11. Retaining ring 24. Secondary shaft 37. Primary shaft
12. Secondary 3rd gear 25. Bearing inner race
IK—22

DISASSEMBLY 7A
Disassembly Note
Secondary Shaft
Bearing inner race (secondary 4th gear end)
Remove the bearing inner race and secondary 2nd
gear with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-022
Secondary 3rd gear and 2nd gear
1. Remove the retaining ring.
2. Shift the gears to 1st gear.
3. Remove the secondary 3rd gear and 2nd gear with
the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
86U07A-047
1st gear
1. Remove the retaining ring.
2. Remove the clutch hub assembly (reverse gear)
and 1st gear as shown in the figure.
Caution
Hold the shaft with one hand so that it does
not fall.
86U07A-048
Bearing inner race
Remove the bearing inner race with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-023
7 A—23

7A DISASSEMBLY
Primary Shaft
Bearing inner race (4th gear end)
1. Remove the retaining ring.
2. Remove the bearing inner race with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-024
Clutch hub assembly (3rd/4th)
1. Remove the retaining ring.
2. Remove the clutch hub assembly with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
86U07A-051
Bearing inner race
Remove the bearing inner race with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-025
7A-24

INSPECTION 7A
86U07A-057
Synchronizer Ring
1. Engagement with gear
2. Worn or damaged teeth
3. Worn or damaged tapered surface
4. Clearance from side of gear
Clearance: 1.5 mm (0.059 in)
Minimum: 0.8 mm (0.031 in)
Note
a) Press the synchronizer ring uniformly
against the gear and measure around the
circumference.
b) If the clearance is less than specified, re-
place the synchronizer ring or gear.
Clutch Hub
1. Worn or damaged splines.
2. Worn or damaged synchronizer key groove.
3. Worn end surface.
4. Operation of the hub sleeve when it is installed.
63U07A-070
Clutch Hub Sleeve
1. Worn or damaged hub splines.
2. Worn or damaged sleeve fork groove.
3. Clearance between sleeve and shift fork.
Standard: 0.2—0.458 mm (0.008—0.018 in)
Limit: 0.5 mm (0.020 in)
63U07A-071
Synchronizer Key and Spring
1. Worn key.
2. Bent spring.
63U07A-072
Ik—21

7A INSPECTION
86U07A-058
63U07A-074
63U07A-075
Reverse Idle Gear
1. Worn or damaged bushing.
2. Worn or damaged teeth.
3. Worn or damaged release lever coupling groove.
4. Clearance between sleeve and reverse lever.
Standard: 0.095—0.318 mm (0.004—0.013 in)
Maximum: 0.5 mm (0.020 in)
Clutch Housing, Transaxle Case, Rear Cover,
and Differential Gear Case
Cracks or damage.
Caution
If the clutch housing, transaxle case, or
differential gear case is replaced, adjust the
bearing preload of the shaft gears and the
preload of the differential side bearings.
Bearing
1. Roughness or noise while turning
2. Worn or damaged outer race or rollers
Caution
a) Replace the bearing, the outer race, and the
inner race as a unit.
b)lf the bearing is replaced, adjust the
preload.
Speedometer Driven Gear Assembly
1. Worn or damaged teeth.
2. Worn or damaged O-ring.
Ring Gear Speedometer Drive Gear
Worn or damaged teeth.
Oil Seal
Damaged or worn lip.
63U07A-076
7A—28