clutch MAZDA 626 1987 Workshop Manual

TECHNICAL DATA 30
6. CLUTCH
Item Engine model F6 F8 FE FE DOHC RF-N RF-CX
Clutch control

Type Hydraulic
Master cylinder inner diameter mm (in) 15.87 (0.625)
Release cylinder inner diameter mm (in) 19.05 (0.750)
Clutch fluid type DOT-3
or
DOT-4, FMVSS 116,
or
SAE J1703

Clutch pedal

Type Suspended
Pedal ratio LHD 6.00 Pedal ratio RHD 5.96
Full stroke mm (in) 135 (5.31)
Height mm (in) 216.5-221.5 (8.524—8.720)
Free play mm (in) 5—13 (0.20—0.51)
Distance
to
floor when clutch LHD 68 (2.7)
or
more
fully disengaged mm (in) RHD 85 (3.3)
or
more

Flywheel

Deflection mm (in) 0.2 (0.008) max.
Grinding limit mm (in) 0.5 (0.020) max.

Clutch disc

Type Single
dry
plate
General 3434 (350, 770) 3846 (392, 862) 4316 (440, 968) 3846 (392, 862)
—

Set load N (kg,
lb)
ECE (Except UK)
—
4022
(410, 902) 4611 (470, 1034) 4022 (410, 902)
UK
—
3846
(392, 862)
4611
(470, 1034)
4316
(440, 968) 3846
I
4022
(392, 862)|(410, 902)
Runout mm (in) 1.0 (0.039) max.
Wear limit mm (in) 0.3 (0.012) from rivet head
Outer diameter mm (in) 200 (7.874) 215
(8.465) 225 (8.858)
Inner diameter mm (in) 130 (5.118) 150 (5.906)
Flywheel side 3.5 (0.14)
Facing thickness Pressure plate
side
General 4.1 (0.16)
-

mm (in) Pressure plate
side ECE (Except UK)
—
3.8 (0.15) Pressure plate
side UK
—
4.1
ro.16)
3.8 (0.15) 4.1 (0.16) 3.8
(0.15)
Clutch cover

Type
Diaphragm spring

Runout mm (in) 0.05 (0.0020) max.
Grindina limit mm (in) 0.5 (0.020)

30—25

30 TECHNICAL DATA
7A. MANUAL TRANSAXLE
Engine model FE DOHC Ffl FE FE
B
valve F8 Item —— Leaded UriBsded Ffl 12 valve Carb. Fl F8 RF-N RF-CX

Transmission
Shift
lever
position Floor shift
Gear ratio
First 3.307
Second 1.833
Third 1.310
Fourth 1.030
Fifth 0.837
1,233
0.970
0.795
0.914

1.161
0.861

0.755 0.680
Reverse 3.166
Oil capacity liters US qt, Imp
qt)
3.35 (3.6, 3.0)
Fluid type
ATF: DEXRON-II
Above 0°F: API GL-4
or
GL-5
SAE80W—90
or
SAE90

Clearance

Clearance
of
lever and reverse idle
gear
mm (in)

Standard 0.1—0.32 (0.004-0.013) Clearance
of
lever and reverse idle
gear
mm (in)
Wear limit 0.5 (0.020)
Clearance
of
shift fork and clutch hub sleeve
mm (in)

Standard 0.2—0.4 (0.008-0.016) Clearance
of
shift fork and clutch hub sleeve
mm (in)
Wear limit 0.5 (0.020)
Clearance
of
synchronizer ring
and

gear
mm
(in)
Standard 1.5 (0.059) Clearance
of
synchronizer ring
and

gear
mm
(in) Wear limit 0.8 (0.021)
Gear thrust clearance
mm (in)
First Standard 0.05—0.28 (0.002-0.011)
Gear thrust clearance
mm (in)
First Limit 0.3 (0.020)
Gear thrust clearance
mm (in)
Second Standard 0.18—0.46 (0.007-0.018)
Gear thrust clearance
mm (in)
Second Limit 0.5 (0.02) Gear thrust clearance
mm (in) Third Standard 0.05-0.20 (0.002-0.008)
Gear thrust clearance
mm (in) Third Limit 0.25 (0.010)
Gear thrust clearance
mm (in)
Fourth Standard 0.17—0.37 (0.0064—0.014)
Gear thrust clearance
mm (in)
Fourth Limit 0.4 (0.016)
Bearing preload
of
primary shaft gear
Primary shaft
0.1-0.25 N-m (1.0-2.5 cm-kg, 0.86-2.18 in-lb) Secondary shaft 0.2-0.4 N-m (2.0—4.0 cm-kg, 1.7-3.4 in-lb)
Bearing preload adjust shim mm (in) 0.25 (0.010), 0.30 (0.012), 0.35 (0.014), 0.40 (0.016), 0.45 (0.018), 0.50 (0.020), 0.55 (0.022), 0.60 (0.024), 0.65 (0.026), 0.70 (0.028), 0.75 (0.030), 0.80 (0.031)

Drive and differential

Final gear
TvDe

Reduction ratio
Side
bearina Dreload

Helical aear
4.1051 3.850 4.1051 3.850
4.150

1.4-2.0 N
m
(14—20 cm-kg, 12-17 in-lb)
Bearing preload adjust shim mm (in)
0.10 (0.004), 0.15 (0.006), 0.20 (0.008), 0.25 (0.010), 0.30 (0.012), 0.35 (0.014), 0.40 (0.016), 0.45 (0.018), 0.50 (0.020), 0.55 (0.022), 0.60 (0.024), 0.65 (0.026), 0.70 (0.028), 0.75 (0.030), 0.80 (0.031), 0.85 (0.033), 0.90 (0.035), 0.95 (0.037), 1.00 (0.039), 1.05 (0.041), 1.10 (0.043), 1.15 (0.045), 1.20 (0.047)
Backlash
of
side aear and
Dinion
aear mm (in) 0-0.1 (0-0.004)

30—26

30 TECHNICAL DATA
Model G4A-EL G4A-HL (4-speed)
Item (EC-AT) FE engine F8 engine
Forward clutch

Number
of
drive/driven plate 3/3
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Forward clutch clearance mm (in) 1.0—1.2 (0.040—0.047)
Retaining plate sizes mm (in) 5.9 (0.232), 6.1 (0.240), 6.3 (0.248),
6.5 (0.256), 6.7 (0.264),
8.9
(0.350)

Coasting clutch

Number
of
drive/driven plates 2/2
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Coasting clutch clearance mm (in) 1.0-1.2 (0.040—0.047)
Retaining plate sizes mm (in) 4.6 (0.181), 4.8 (0.189), 5.0 (0.197),
5.2 (0.205), 5.4 (0.213), 5.6 (0.220)
Return spring free length mm (in) 29.8 (1.173)

Reverse clutch

Number
of
drive/driven plates 2/2
Driven plate thickness mm (in) Standard 1.6 (0.063) Driven plate thickness mm (in) Minimum 1.4 (0.055)
Reverse clutch clearance mm (in) 2.1—2.4 (0.083—0.094)
Retaining plate sizes mm (in) 6.6 (0.260),
6.8
(0.268), 7.0 (0.276), 7.2 (0.283), 7.4 (0.291), 7.6 (0.299)

3-4 clutch

Number
of
drive/driven plates 5/5 4/4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
3-4 clutch clearance mm (in) 1.3-1.5 (0.051-0.059)
Retaining plate sizes mm (in) 3.8 (0.150), 4.0 (0.157), 4.2 (0.165), 4.4 (0.173), 4.6 (0.181), 4.8 (0.189)
4.8 (0.819), 5.0 (0.197), 5.2 (0.205), 5.4 (0.213), 5.6 (0.220)
Return spring free length mm fin) 33.2 (1.307)

Low and reverse brake

Number
of
drive/driven Dlates 3/3 4/4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Low and reverse brake clearance mm (in) 2.1-2.4 (0.083-0.094)
Retaining plate sizes mm (in) 6.8 (0,268), 7.0 (0.276), 7.2 (0.283), 7.4 (0.291), 7.6 (0.299), 7.8 (0.307)
10.0 (0.394), 10.2 (0.402), 10.4 (0.410),
10.6 (0.417), 10.8 (0.425)
Return spring free length mm (in) 20.5 (0.807)
Sun gear drum bushing mm (in) Maximum 33.425 (1.316)
Small sun gear bushing mm (in) Maximum 24.021 (0.946)

Carrier hub

Clearance between pinion washer and planet carrier
mm (in)
Maximum 0.2-0.7 (0.008-0.028)

Servo

Free length
of
return spring mm (in) Standard 43.25 (1.703) 42.0 (1.654) 43.25 (1.703)

2-3 accumulator valve

2-3 accumulator valve spring mm (in) Standard 83.3
mm
(3.280) 76.0 (2.992)

30—30

30 TECHNICAL DATA
Item Engine model FE engine F6 engine
Front clutch

Number
of
driven and drive plates 3
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Front clutch clearance mm (in) 1.6-1.8 (0.063-0.071)
Retaining plate sizes mm (in) 5.2 (0.205), 5.4 (0.213), 5.6 (0.220),
5.8 (0.228), 6.0 (0.236), 6.2 (0.244)
Return spring free length mm (in) 26.2 (1.031)
Drum bushing inner diameter mm (in) Standard 44.000-44.025 (1.732-1.733) Drum bushing inner diameter mm (in) Maximum 44.075 (1.735)
Front clutch drum end play mm (in) 0.5-0.8 (0.197-0.0315)
End play adjust shims mm (in) 1.3 (0.0512), 1.5 (0.0591), 1.7 (0.0669), 1.9 (0.0748), 2.1 (0.0827), 2.3 (0.0906),
2.5
(0.0984), 2.7 (0.1063)

Rear clutch

Number
of
driven and drive plates 4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Rear clutch clearance mm (in) 0.8--1.0 (0.0315- 0.0394)
Retaining plate sizes mm (in) 4.8 (0.189), 5.0 (0.197), 5.2 (0.205), 5.4 (0.213),
5.6 (0.220), 5.8 (0.228), 6.0 (0.236), 6.2 (0.244)
Return spring free length mm (in) 26.2 (1.031)

Low and reverse brake

Number
of
low and reverse brake plates 4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Low and reverse brake clearance mm (in) 0.8-1.05 (0.032-0.041)
Retaining plate sizes mm (in) 4.6 (0.181),
4.8
(0.189), 5.0 (0.197), 5.2 (0.205), 5.4 (0.213), 5.6 (0.220)
Return spring free length mm (in) 27.7 (1.091)

Servo

Return sprina free lenath mm (in) 48.0 (1.89) 45.5 (1.79)

Governor

Primary spring mm (in) Outer diameter 9.0 (0.354) Primary spring mm (in) Free lenath 17.2 (0.667)
Secondary spring mm (in) Outer diameter 9.25 (0.364) Secondary spring mm (in) Free lenath 13.2 (0.520)

One-wav clutch

Bushing diameter mm (in) Standard 129.987-130.013 (5.118--5.119) Bushing diameter mm (in) Maximum 130.063 (5.121)

Control valve SDrinas
Spring name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in)

Throttle backup spring 7.3 (0.287) 36.0 (1.417) 0.8 (0.031)
Downshift sorina 5.55 (0.219) 21.9 (0.862) 0.55 (0.022)
2-3 shift spring 6.9 (0.272) 41.0 (1.614) 0.7 (0.028)
1-2 shift spring 6.4 (0.252) 31.63 (1.245) 0.4 (0.016)
Second lock spring 5.55 (0.219) 33.5 (1.319) 0.55 (0.022)
Pressure reaulator sprina 11.7 (0.461) 43.0 (1.693) 1.2 (0.047)
Throttle relief ball spring 7.0 (0.276) 11.2 (0.441) 0.9 (0.035)
Orifice check valve sprina 5.0 (0.197) 15.5 (0.610) 0.23 (0.009)

30-34

40
SPECIAL TOOLS
GENERAL INFORMATION 40— 2
ENGINE 40- 3
CLUTCH AND MANUAL TRANSAXLE 40- 5
AUTOMATIC TRANSAXLE 40— 6
FRONT AND REAR AXLE 40— 7
STEERING 40— 8
BRAKE 40— 9
SUSPENSION 40— 9
CHECKER AND OTHERS 40—10 76G40X-001

SPECIAL TOOLS 40
CLUTCH AND MANUAL TRANSAXLE
40—5

40 SPECIAL TOOLS
AUTOMATIC TRANSAXLE
TOOL NUMBER & DESCRIPTION PRIORITY ILLUSTRATION

49 G019 0A7A
Compressor set, Return spring
A
49 G019 0A5A
Shim selector set A
a

x|mJen
It
49 0378 400A
Gauge set,
oil

pressure
A

lal

49 G019 011
Bearing installer A
mm H

49 FT01
376

Lifter, servo
piston
(3AT)
A
49 S120 785
Dsut boots
installer
A
49 FT01
377

Replacer,
low
reverse piston (3A1)
A

fl
jr "

49 FT 01
374

Holder,
one
way clutch position (3AT1
A

TOOL NUMBER & DESCRIPTION PRIORITY ILLUSTRATION

49 G032 355
Adjust gauge (3 AT) B
49 G019 9A2
Tester set, EC-AT
(EC-AT)
A
J3||
i®
49 G019 013
Bearing
remover
A

©5

49 G019 022
Attachment
K
A
49 FT01
439

Holder, idle
gear shaft
A
49 G019 012
Leak checker A

I

49 G019 0A2
Turbine shaft holder A

•o

49 0378 375
Compressor, clutch spring (3AT)
A i

U
40-6