differential MAZDA 626 1987 User Guide

ASSEMBLY 7A
8. Measure the clearance between the 1st gear and
differential drive gear.
Clearance: 0.05—0.28 mm (0.0020—0.0110 in)
Maximum: 0.33 mm (0.0199 in)
86U07A-081
9. Measure the clearance between the 2nd gear and
secondary 3rd gear.
Clearance:
0.175—0.455 mm (0.0069—0.0179 in)
Maximum: 0.505 mm (0.0199 in)
86U07A-082
7A-35

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

7A ASSEMBLY
11. Install the SST.
76G07A-039
76G07A-040
76G07A-041

Thickness (Differential)
mm
(in)
0.10 (0.004) 0.70 (0.026)
0.15 (0.006) 0.75 (0.028)
0.20 (0.008) 0.80 (0.030)
0.25 (0.010) 0.85 (0.032)
0.30 (0.012) 0.90 (0.034)
0.35 (0.014) 0.95 (0.036)
0.40 (0.016) 1.00 (0.038)
0.45 (0.018) 1.05 (0.040)
0.50 (0.020) 1.10 (0.042)
0.60 (0.022) 1.15 (0.044)
0.65 (0.024) 1.20 (0.046)

12. Adjust the selector with the SST until the specified
preload is obtained.
Preload:
0.5 N-m (5 cm-kg, 4.3 in-lb)
13. Use a feeler gauge to measure the gap in the selec-
tor for the differential.
Note
Measure the gap around the entire circumfer-
ence of the selector
76G07A-042
14. Add 0.15 mm (0.0059 in) to the measured clear-
ance and select the combination of shims whose
thickness added is nearest higher than that valve.
See the table for available shim sizes.
Example: 0.32 mm (0.013 in)
0.32 mm (0.013 in) + 0.15 mm (0.006 in) =
0.47 mm (0.019 in).
So the nearest shim (on the thick side) to 0.47
mm (0.019 in) is 0.50 mm (0.020 in).
Note
Use a maximum of two shims.
15. Remove the SST and transaxle case.
16. Remove the primary shaft assembly and the
differential.
17. Remove the bearing outer races.
7A—40

ASSEMBLY 7A
86U07A-102
86U07A-103
76G07A-043
Assembly
1. Install the neutral switch.
2. Install the drain plug.
3. Install the back-up lamp switch.
4. Install the new oil seals with the SST.
5. Install the differential adjust shim(s) and the bear-
ing outer race with a suitable pipe.
6. Install the adjust shims, diaphragm springs, fun-
nel, and bearing outer races.
Note
Install the diaphragm spring as shown in the
figure.
7. Install the bearing outer races with a suitable pipe.
86U07A-105
7A—41

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
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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

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

7A INSTALLATION
76G07A-063
76G07A-064
18. Install the left driveshaft as follows:
(1) Pull the front hub outward and insert the
driveshaft into the transaxle.
(2) Push the joint at the differential side to connect
the driveshaft to the differential side gear.
Note
a) Do not damage the oil seal.
b) After installation, pull the front hub outward
to confirm that the driveshaft doesn't come
out.
19. Install the lower arm ball joints to the knuckles and
tighten the bolts and nuts.
Tightening torque: 43—54 N-m
(4.4—5.5 m-kg, 32—40 ft-lb)
20. Install the under cover, (except DOHC)
Note
Before installation, fill the notches with sili-
con as shown in the figure.
Tightening torque: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
21. Install the stabilizer bar control links as follows.
(1) Install the stabilizer bar control link.
(2) Adjust protrusion to 20.1 mm (0.79 in)
(3) Tighten bolt to specified torque.
Tightening torque: 16—23 N-m
(1.6—2.3 m-kg , 12—17 ft-lb)
76G07A-065
76G07A-066
22. Install the tie-rod ends and new cotter pine.
Tightening torque: 29—44 N-m
(3.0—4.5 m-kg, 22—33 ft-lb)
23. Install the splash shields.
Tightening torque: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
24. Install the front wheels.
Tightening torque: 88—118 N-m
(9.0—12.0 m-kg, 65—87 ft-lb)
—56

7B
AUTOMATIC TRANSAXLE
(Electronically Controlled and 4-Speed)
OUTLINE 7B— 2
SPECIFICATIONS 7B— 2
COMPONENT LOCATION 7B— 3
STRUCTURAL VIEW 7B— 5
OPERATION OF COMPONENTS 7B— 6
FLUID PASSAGE LOCATION 7B— 9
TROUBLESHOOTING (G4A-EL) 7B— 12
GENERAL NOTE 7B— 12
STEP 1
(WARNING CODE RETRIEVAL) 7B— 15
STEP 2
(PRELIMINARY INSPECTION) 7B— 22
STEP 3 (SIGNAL INSPECTION) 7B— 24
STEP 4 (STALL TEST) 7B— 27
STEP 5 (TIME LAG TEST) 7B— 30
STEP 6 (OIL PRESSURE TEST) 7B— 31
STEP 7 (ROAD TEST) 7B— 34
TROUBLESHOOTING (G4A-HL) 7B— 41
GENERAL NOTE 7B— 41
STEP 1
(PRELIMINARY INSPECTION) 7B— 44
STEP 2 (ELECTRICAL
SYSTEM INSPECTION) 7B— 47
STEP 3 (STALL TEST) 7B— 49
STEP 4 (TIME LAG TEST) 7B- 52
STEP 5 (ROAD TEST) 7B— 53
STEP 6 (OIL PRESSURE TEST) 7B— 58
ELECTRICAL SYSTEM
COMPONENTS 7B— 63
MODE SWITCH (G4A-EL) 7B— 63
HOLD SWITCH (G4A-EL) 7B— 63
OD OFF SWITCH (G4A-HL) 7B— 64
INHIBITOR SWITCH 7B- 65
WATER TEMPERATURE SWITCH 7B— 66
FLUID TEMPERATURE SWITCH
(G4A-EL) 7B— 66
BRAKE LIGHT SWITCH
(G4A-EL) 7B— 66
KICK-DOWN SWITCH (G4A-HL) 7B— 67
PULSE GENERATOR (G4A-EL) 7B- 68
VEHICLE SPEED SENSOR
(G4A-EL) 7B— 68
CRUISE CONTROL SWITCH
(CRUISE CONTROL UNIT) 7B— 68
IDLE SWITCH AND THROTTLE
SENSOR (G4A-EL) 7B— 68
OD RELEASE SOLENOID
VALVE (G4A-HL) 7B— 68
SOLENOID VALVES (G4A-EL) 7B— 69
NO LOAD SIGNAL (G4A-EL) 7B— 69
MODE, AND HOLD INDICATOR
LIGHT (G4A-EL) 7B— 69
OD OFF INDICATOR LIGHT
(G4A-HL) 7B— 69
EC-AT CONTROL UNIT
(G4A-EL) 7B— 69
ON-VEHICLE MAINTENANCE 7B— 71
AUTOMATIC TRANSAXLE
FLUID (ATF) 7B— 71
SELECTOR LEVER 7B— 72
THROTTLE CABLE 7B— 73
CONTROL VALVE BODY 7B— 77
OIL STRAINER 7B— 79
ADJUSTMENT OF 2-4 BRAKE
BAND 78— 80
REPLACEMENT OF
DRIVESHAFT OIL SEAL 7B— 80
OIL COOLER 7B— 81
GOVERNOR (G4A-HL) 7B— 82
REMOVAL 7B— 83
PRECAUTION 7B— 83
DISASSEMBLY 7B— 88
DISASSEMBLY-STEP 1 7B— 88
DISASSEMBLY-STEP 2 7B— 94
DISASSEMBLY-STEP 3 7B— 99
DISASSEMBLY-STEP 4 7B—103
INSPECTION AND REPAIR 7B—107
PRECAUTION 7B—107
TORQUE CONVERTER 7B—107
OIL PUMP 7B—108
CLUTCH ASSEMBLY 7B—113
SMALL SUN GEAR AND
ONE-WAY CLUTCH 7B—122
ONE-WAY CLUTCH AND
CARRIER HUB ASSEMBLY 7B-126
3-4 CLUTCH 7B—128
2-3 ACCUMULATOR 7B—132
GOVERNOR ASSEMBLY
(G4A-HL) 7B-133
LOW AND REVERSE BRAKE 7B—134
2-4 BRAKE BAND 7B—135
BAND SERVO 7B—135
OTHER INSPECTION 7B—135
CONTROL VALVE BODY
(G4A-EL) 7B-136
CONTROL VALVE BODY
(G4A-HL) 7B-155
DIFFERENTIAL 7B—177
OUTPUT GEAR 7B—181
IDLE GEAR 7B—182
BEARING COVER ASSEMBLY 7B—185
BEARING HOUSING 7B—186
ASSEMBLY 7B-187
PRECATION 7B—187
ASSEMBLY-STEP 1 7B—187
ASSEMBLY-STEP 2 7B—197
ASSEMBLY-STEP 3 7B—202
ASSEMBLY-STEP 4 7B—208
INSTALLATION 7B—215
TORQUE SPECIFICATIONS 7B—215
HYDRAULIC CIRCUIT (G4A-EL) 7B—221
HYDRAULIC CIRCUIT (G4A-HL) 7B—239
76G07B-001