MAZDA 626 1987 Workshop Manual

INSPECTION AND REPAIR 7C
Assembly
1. Install the pressure regulator valve, spring, spring
seat, pressure regulator plug, and pressure regu-
lator sleeve.
2. Install the second lock valve and spring.
3. Install the side plate.
Tightening torque:
2.5—3.4 Nm (25—35 cm-kg, 22—30 in-lb)
76G07C-204
w
Install the 1-2 shift spring, and valve.
Install the 2-3 shift plug, spring, and 2-3 shift valve.
Install the modifier valve.
Install the side plate.
Tightening torque:
2.5—3.4 Nm (25—35 cm-kg, 22—30 in-lb)
76G07C-205
8. Install the downshift spring, and valve.
9. Install the throttle backup valve and spring.
10. Install the vacuum throttle valve.
11. Install the side plate.
Tightening torque:
2.5—3.4 N m (25—35 cm-kg, 22—30 in-lb)
76G07C-206
®—Orifice
©
1.5 mm | (0.059 in)j 1 fT—•sj-
Orifice 4> 2.0 mm
(0.079 in),
Throttle relief baii
'0
12. Install the orifice check valves (02.0 mm, (0.079
in), 1.5 mm (0.059 in)) and springs, and throttle
relief ball and spring in the lower body as shown.
76G07C-207
10,-11

7C INSPECTION AND REPAIR
—® Orifice 2.0 mm (0.079 in)
76G07C-208
76G07C-209
76G07C-210
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13. Install the orifice check valve (<£2.0 mm (0.079 in))
in the upper body as shown.
14. Install the separator plate on the lower body, and
hold it with clips; then install them onto the upper
body.
15. Tighten the mounting bolts to the specified torque.
Tightening torque:
A: 2.5—3.4 N-m (25—35 cm-kg, 22—30 in-lb)
B: 5—7 N m (50—70 cm-kg, 43—61 in-lb)
16. Install the oil strainer.
Tightening torque:
3—4 Nm (30—40 cm-kg, 26—35 in-lb)
17. Turn the valve body assembly over, and install the
sub-body.
Tightening torque:
2.5—3.4 N-m (25—35 cm-kg, 22—30 in-lb)
18. Install the manual valve.
76G07C-211
7C-78

INSPECTION AND REPAIR 7C
DIFFERENTIAL
Disassembly
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
parts.
1. Roll pin
2. Side gear
3. Side gear thrust washer
4. Pinion shaft
5. Pinion gear
Dial aauae
76G07C-212
6. Pinion gear thrust washer
7. Side bearing inner race
8. Speedometer drive gear
9. Ring gear and gear case assembly
Disassembly note
Checking backlash
Before disassembly, measure the backlash of the side
gears and pinion gears. If not within specification, re-
place the differential assembly.
Backlash:
Standard 0.025—0.1 mm (0.001—0.004 in)
Maximum 0.5 mm (0.020 in)
86U07B-323
7C-79

7C INSPECTION AND REPAIR
76G07C-213
86U07B-325
Roll pin
To remove the roll pin from the pinion shaft, place
the gear case on a vise and knock the pin out with
a suitable pin punch (04.0 mm (0.157 in) ) and
hammer.
Note
a) Use the protective plates in the vice to pre-
vent damage to the differential.
b) Insert the punch into the roll pin hole from
the ring gear side.
Side bearing inner race
1. Remove the side bearing inner race (side oppo-
site the ring gear) from the gear case with the SST.
2. Remove the side bearing inner race (ring gear side)
with a combination of parts from the SST.
86U07B-326
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn gears
2. Cracked or damaged gear case
3. Damaged bearings
86U07B-327
7C-80

INSPECTION AND REPAIR 7C
Assembly
1. Set the speedometer drive gear onto the ring gear
and case assembly.
86U07B-328
Install the side bearing inner races.
(1) Press the side bearing inner race (side oppo-
site the ring gear) onto the ring gear and case
assembly with the SST.
(2) Press on the other side bearing inner race (ring
gear side) in the same manner.
Caution
Do not reuse the bearings if they were
removed.
86U07B-329
3. Install the pinion gears and thrust washers into the
case.
4. Install the pinion shaft.
86U07B-330
5. Install the roll pin, and make a crimp so that it will
not come out of the gear case.
86U07B-331
7C-81

7C INSPECTION AND REPAIR
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Dial indicator
Pinion gear
A

86U07B-332
6. Install the thrust washers and side gears into the
gear case at the same time, then turn them back
on the pinion gear and align them with the pinion
shaft hole.
7. Check and adjust the backlash of the side gears
and pinion gears as follows:
(1) Install the left and right driveshafts in the
differential assembly.
(2) Support the driveshafts on V-blocks.
(3) Measure the backlash of both pinion gears.
Backlash:
Standard 0.025—0.1 mm (0.001—0.004 in)
Maximum 0.5 mm (0.020 in)
8.
If
the backlash is not within specification, place the
differential assembly.
86U07B-333
OUTPUT GEAR
Disassembly
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
parts.
1. Output gear
bearing
2. Output gear
bearing
3. Output gear
76G07C-214
7C—82

INSPECTION AND REPAIR 7C
76G07C-215
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Disassembly note
Output gear bearings
Remove the output gear bearings from the output
gear with the SST.
Caution
Hold the output gear with one hand so that it
does not fall.
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn output gear
2. Damaged bearing
Assembly
1. Press the output gear bearings onto the output
gear with the SST.
86U07B-336
IDLE GEAR
Disassembly
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
parts.
1. Locknut
2. Idle gear
bearing
3. Spacer
4. Idle gear
5. Adjust shim
6. Idle gear
bearing
7. Idle shaft
8. Bearing outer
race
9. Bearing outer
race
76G07C-216
7C-83

7C INSPECTION AND REPAIR
Disassembly note
Locknut
Secure the idle shaft in a vise with the SST; then re-
move the locknut.
Note
Use the protective plates in the vice to pre-
vent damage to the SST.
76G07C-217
Bearing outer race
Remove the bearing outer race from the idle gear with
the SST.
49 FT01 361
86U07B-339
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn idle gear
2. Damaged or worn bearing
86U07B-340
Assembly
1. Press the bearing outer races in with the SST.
86U07B-341
7C-84

INSPECTION AND REPAIR 7C
n Notches
m
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m
«
i * •"-=- —*
76G07C-218
49FT01 439
86U07B-345
Install the idle gear bearing onto the idle shaft, then
install the idle gear, adjust shim, spacer, and
bearing.
Note
Install the idle gear with the notches in the
teeth facing as shown.
FE engine: 2 notches
F6 engine: 3 notches
Secure the idle shaft in a vise with the SST; then
tighten the locknut to the lower limit of the tighten-
ing torque.
Tightening torque:
128 N-m (13 m-kg, 94 ft-lb)
Note
Use the protective plates in the vice to pre-
vent damage to the SST.
Check and adjust the idle gear bearing preload.
(1) Turn the idle gear assembly and SST over, and
secure the gear in the vice.
Note
Use protective plates in the vice to prevent
damage to the idle gear.
(2) Attach the SST and spring scale or a torque
wrench, and measure the preload while tight-
ening the locknut.
Tightening torque:
128—177 N-m (13—18 m-kg, 94—130 ft-lb)
Preload:
0.03—0.9 Nm
(0.3—9.0 cm-kg, 0.26—7.8 in-lb)
Value indicated on pull scale:
0.3—9 N (0.03—0.9 kg, 0.066—1.98 lb)
Note
Read the preload when the idle shaft starts to
turn.
7C—85

7C INSPECTION AND REPAIR
76G07C-221
5. If the specified preload can not be obtained with-
in the specified tightening torque, adjust it by select-
ing the proper adjust shims.
Thickness of shim
0.10 mm (0.004 in) 0.12 mm (0.005 in) 0.14 mm (0.006 in) 0.16 mm (0.0063 in) 0.20 mm (0.008 in) 0.50 mm (0.020 in)
Note
a) The maximum allowable number of shims
is 7.
b) Preload is reduced by increasing the thick-
ness of the shims, or increased by reduc-
ing the thickness of the shims.
BEARING COVER ASSEMBLY
Disassembly
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
part.
1. Oil seal
2. Bearing outer
race
3. O-ring
4. Bearing cover
76G07C-222
7C—86
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