key MAZDA 626 1987 User Guide

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

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

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

1 1 POWER BRAKE UNIT
Removal Note
Steering Shaft
To remove the mounting nuts of the power brake unit,
the steering shaft must be removed. (Refer to page
10—22 for removal and installation procedures.)
76G11X-102
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure, referring to disassembly note for specially marked
parts.
2. Inspect each part, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to assembly note for specially marked parts.
8.8—13 N-m (90-130 cm-kg, 78—112 in-lb)
1. Dust boot
2. Rear shell assembly
3. Retainer
4. Bearing
5. Dust seal
6. Retainer
7. Air filters
8. Air silencer
9. Diaphragm and plate
10. Power piston assembly
11. Retainer key
12. Valve rod and plunger as-
sembly
13. Reaction disc
76G11X-070
14. Spring
15. Push rod
16. Front shell assembly
17. Retainer
18. Seal
19. Vacuum switch (RF, RF-CX)
11-30

POWER BRAKE UNIT 1 1
76G11X-071
Disassembly Note
Front and rear shells
1. Secure the front shell studs in a vise after attach-
ing suitable nuts to them to prevent damage to the
studs.
2. Before separating the front and rear shell assem-
blies, make matching marks to be used in reas-
sembly.
3. Fit a wrench onto the rear shell studs; then fasten
two of them with suitable nuts.
4. Rotate the rear shell counterclockwise to unlock.
Caution
The rear shell is spring loaded; loosen it
carefully.
Retainer key
Depress the plunger rod fully; then remove the re-
tainer key.
86U11X-049
86U11X-050
Assembly Note
Application of Grease
Before assembly, coat the parts shown in the figure
with silicon grease.
(1) Entire surface of reaction disc
(2) Dust seal lip
(3) Push rod
(4) Diaphragm-to-shell contacting surfaces
(5) Power piston
(6) Valve plunger oil seal
Retainer key
1. Push down the plunger rod.
2. Align the groove of the valve plunger with the slot
of the power piston.
3. Insert the retainer key.
86U11X-051
11—31

TRUNK LID 14
TRUNK
LID

STRUCTURAL VIEW (SEDAN AND COUPE/MX-6)
1. Trunk lid lock
2. Trunk lid opener protector
3. Opening rod
4. Retainer
5. Trunk lid key cylinder
6. Balance spring
76G14X-040
7. Trunk lid hinge bracket
8. Trunk lid hinge
9. Trunk lid
14—5

1 4 TRUNK LID
86U14X-012
Opening rod
86U14X-013
86U14X-014
REMOVAL
Trunk Lid Opener
1. Remove the nut and the protector.
2. Remove the opening rod.
3. Remove the bolts and the trunk lid opener.
Trunk Lid Key Cylinder
Remove the retainer and the trunk lid key cylinder.
Trunk Lid
1. Remove the trunk lid installation bolts, then remove
the trunk lid.
2. Remove the balance spring.
3. Remove the rear seat. (Refer to page 14—100)
76G14X-041
14—6

REAR HATCH 1 4
REAR HATCH
STRUCTURAL VIEW
86U14X-022
1. Rear hatch
2. Upper trim
3. Side trim
4. Lower trim
5. Rear finisher
6. Rear hatch lock
7. Lock controller
8. Rear hatch outer handle
9. Stay damper
10. Key cylinder
11. Rear hatch screen
14—9