clutch MAZDA 626 1987 Workshop Manual

ASSEMBLY 7 A
STEP 2
Note
During assembly, check the thrust clearance of each gear. (Refer to page 7A—33, 35)
76G07A-029
Assembly
Install the synchronizer key spring in the clutch hub
with the hook in the groove. This holds the three syn-
chronizer keys in place.
Note
a) The sizes of the synchronizer keys are
different.
86U07A-067
Specification: mm (in)
© © ©

1st/2nd 19 (0.7480) 4.25 (0.1673) 4.25 (0.1673)
3rd/4th
5th/Rev. 17 (0.6693) 4.25 (0.1673) 4.25 (0.1673)

86U07A-068
7 A—31

7A ASSEMBLY
49 F401 331
•
49 F401 331
•
86U07A-069
"Oil groove
(four places)
76G07A-030
ZJJ
49 F40I 336 B
49 0636 145
86U07A-071
Primary Shaft
1. Install the new bearing inner race with the SST.
Note Press to 19,620 N (2,000 kg, 4,400 lb).
2. Install the 3rd gear, synchronizer ring, and clutch
hub assembly with the SST. (Refer to page
7A—33)
Note
a) Press to 19,620 N (2,000 kg, 4,400 lb).
b) Align the synchronizer ring groove and
clutch housing hub key when installing.
3. Install the retaining ring.
4. Install the synchronizer ring, 4nd gear, and bear-
ing inner race with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
5. Install both shift forks and the interlock sleeve, as
in the figure.
86U07A-072
7A-32

7A ASSEMBLY
Secondary Shaft
1. Assemble the 1st gear, synchronizer ring, and
clutch hub assembly (reverse gear), as shown in
the figure.
Note
Align the synchronizer ring, groove and clutch
housing hub key when installing.
86U07A-077
-IP Press on the clutch hub assembly (reverse gear)
with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
Install the retaining ring.
86U07A-078
4. Install the synchronizer ring and 2nd gear.
5. Install the secondary 3rd gear with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
86U07A-079
6. Install the retaining ring.
7. Install the secondary 4th gear and new bearing in-
ner race.
86U07A-080
7A-34

ASSEMBLY 7 A
Bearing Preload
Adjust the bearing preload through the use of adjust shim(s).
83U07A-099
49 G030 381
Outer race
Differential
Outer races
Secondary shaft
assembly
49 G030 382A
Transaxle case
Outer rases
Primary shaft assembly
Outer rase
49 F401 382A
Clutch housing
83U07A-033
7A-37

7 A ASSEMBLY
Outer race
Selector
76G07A-032
i "k
49 G030 381
49 G030 382A
49 G030 382A
76G07A-033
1. Install the primary and secondary shaft bearing out-
er races into the transaxle case (diaphragm springs
and shims removed).
2. After mounting the clutch housing onto the trans-
axle hanger, and set the differential bearing outer
race into the clutch housing, and tap in with a ham-
mer until it contacts the clutch housing, and tap
in with a hammer until it contacts the clutch
housing.
3. Assemble the outer races into the SST (selector)
as shown in the figure.
Note
Turn the selector to eliminate the gap indicat-
ed by the arrow in the figure.
4. Set the differential assembly onto the clutch hous-
ing, then mount the bearing outer race and the
selector on the differential.
Set the assembled selectors for the primary and
secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the
figure.
5. Set the SST (collars) in the positions shown in the
figure.
76G07A-034
6. Install the transaxle case then tighten the SST(bolts)
to the specified torque.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft—lb)
76G7A-035
7A-38

ASSEMBLY 7A
76G07A-044
76G07A-045
Bearing Preload
Check the shaft gears and the differential bearing
preload.
Note
a) Check that the correct adjust shims were
selected.
b) If the bearing preload is not within specifi-
cation, adjust again.
1. Set the primary shaft gear and the differential into
the clutch housing.
2. Install the transaxle case, and tighten to the speci-
fied torque.
Tightening torque: 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
3. Connect the SST and install it through the
driveshaft hole.
4. Measure the preload.
Preload: 1.4—2.0 N-m
(14—20 cm-kg, 12.1—17.3 in-lb)
5. Remove the SST.
6. Install the SST to the primary shaft gear.
7. Measure the preload.
Preload: 0.1—0.25 N-m
(1.0—2.5 cm-kg, 0.87—2.18 in-lb)
76G07A-046
8. Remove the SST, transaxle case, primary shaft
gear and differential.
9. Install the secondary shaft gear and transaxle case
then tighten to the specified torque.
Tightening torque: 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
10. Check the secondary shaft preload with the SST.
Preload: 0.2—0.4 N-m
(2.0—4.0 m-kg, 1.7—3.4 in-lb)
76G07A-047
7A-43

ASSEMBLY 7A
86U07A-111
r- IjjjH
Rv-jn p — it :
J^ 'ox J^ 'ox
Wh ^^o i
86U07A-112
76U07A-284
1. Install the magnet and the differential assembly.
2. Install the primary shaft gear assembly and the
secondary shaft gear assembly together.
3. Shift to 2nd gear and position the shift fork and shift
rod assembly as shown.
Insert the spring seat and spring into the reverse
lever shaft, install the steel ball, and place a scraper
knife so that it contacts the steel ball.
With the edge of the control end against the knife,
when the control end is pushed in the direction of
the arrow in the figure so that the ball goes into
the shaft, the rod will at the same time line up with
the shift rod coupling hole in the clutch housing.
6. Set each clutch hub sleeve to the neutral position,
and tap the shift rod from above so that the steel
ball goes into the center groove (of the 3 grooves
in the control end).
7. Pull the ball part of the control end forward so that
the steel ball goes into the detent in the groove.
76U07A-119
7A—45

7A ASSEMBLY
8. Fit the crank lever in between the change arm and
the control end, and connect the crank lever shaft
to the crank lever.
9. Align the pin holes of the crank lever shaft and the
clutch housing, and insert the pin.
Note
Use a new O-ring for the crank lever shaft.
86U07A-113
10. Install the gate © and the shift rod ©, and tight-
en the gate mounting bolt.
Note
The mark (indicated by the arrow in the fig-
ure) and the gate mounting bolt hole must be
in the same direction.
76U07A-121
11. Install the reverse idle gear and the reverse idle
shaft.
12. Connect the magnet to the clutch housing.
13. Align the end of the interlock sleeve with the con-
trol lever indicated by the arrow, and, at the same
time, face the reverse idle shaft screw hole in the
direction shown in the figure.
76U07A-122
14. Apply a thin coat of sealant to the contact surfaces
of the clutch housing and transmission case, tight-
en the transaxle case installation bolts to the speci-
fied torque.
Tightening torque:
18—26 N m (1.8—2.7 m-kg, 13—18.8 ft-lb)
15. Insert the SST to driveshaft coupling hole.
7A-46

INSTALLATION 7A
1. Attach rope at 2 places on the transaxle and place
a board on the jack and position the transaxle on it.
Caution
The transaxle is not well balanced; be care-
ful when positioning on the jack.
2. Move the transaxle into the place and attach the
rope (attached to the transaxle in step 1) to the
SST
86U07A-210
3. Install the transaxle onto the engine.
Note
Lift the transaxle using the jack pulling the
rope.
Tightening torque: 89—117 N-m
(9.1—11.9 m-kg, 66—85 ft-lb)
86U07A-211
4. Install the clutch pipe.
Tightening torque:
(A), (§): 19—26 N-m
(1.9—2.6 m-kg, 14—19 ft-lb)
©: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
76G07A-054
5. Install the engine mount bracket.
Tightening torque:
55—80 N-m (5.6—8.2 m-kg, 41—59 ft-lb)
76G07A-055
7A—53

INSTALLATION 7A
14. Install the clutch release cylinder.
Tightening torque: 19—26 N-m
(1.9—2.6 m-kg, 14—19 ft-lb)
76G07A-060
15. Install the gusset plates.
Tightening torque: 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
76G07A-061
16. Replace the clips at the end of the driveshafts and
joint shaft with new ones.
17. Install the joint shaft and right driveshaft as follows:
(1) Install and tighten the reamer bolts (A); then in-
stall and tighten the standard bolts (§).
Tightening torque:
® :7—10 N-m
(70—100 cm-kg, 43—61 in-lb)
(B) :42—62 Nm
(4.3—6.3 m-kg, 31—46 ft-lb)
76G07A-062
(2) Remove the SST and insert the shaft into the
transaxle.
(3) Pull the front hub outward and connect the
driveshaft to the joint shaft.
(4) Push the joint at the differential side to secure-
ly connect the driveshaft to the joint shaft.
Note
a) After installation, pull the front hub outward
to confirm that the driveshaft doesn't come
out.
b)Do not damage the oil seal.
86U07A-219
7A-55