oil MAZDA 626 1987 Workshop Manual

7A DISASSEMBLY
STEP 2
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
76G07A-018
76G07A-019
1. Bearing outer race 15. Selector 28. Roll pin
2. Oil seal 16. Oil seal 29. Reverse lever shaft
3. Bearing outer race 17. Bolt 30. Reverse lever
4. Funnel 18. Bleeder cover 31. Drain plug and washer
5. Bolts 19. Bleeder 32. Neutral switch and gasket
6. Guide plate 20. Bolt 33. Bearing outer race
7. Pipe 21. Speedometer driven gear 34. Diaphragm spring
8. Bolt assembly 35. Adjust shim
9. Change arm 22. O-ring 36. Bearing outer race
10. Roll pin 23. Roll pin 37. Adjust shim
11. Change rod 24. Driven gear 38. Oil seal
12. Boot 25. Gear case 39. Back-up light switch
13. Spring 26. Oil seal 40. Oil passage
14. Reverse gate 27. Bearing outer race
7A-20

7A INSPECTION
INSPECTION
Check the following parts, and replace if necessary.
1st, 2nd, 3rd, 4th, and 5th gears
1. Worn or damaged synchronizer cone.
2. Worn or damaged hub sleeve coupling.
3. Worn or damaged teeth.
4. Worn or damaged inner surface or end surface of
gears.
63U07A-064
Primary Shaft Gear and Primary Gear
1. Worn teeth
2. Primary shaft gear run-out
Run-out: 0.05 mm (0.002 in) max.
Note
If the shaft gear is replaced, adjust the bear-
ing preload. (Refer to page 7A—37)
76G07A-028
Secondary Shaft Gear
1. Worn or damaged gear contact surface.
2. Worn or damaged splines.
3. Worn teeth.
4. Clogged oil passage.
5. Secondary shaft gear run-out.
Standard run-out: 0.015 mm (0.0006 in)
63U07A-068
6. Oil clearance between secondary gear shaft and
gears.
Standard: 0.03—0.08 mm (0.001—0.003 in)
Caution
If the shaft gear is replaced, adjust the bear-
ing preload.
63U07A-069
7A-26

7A INSPECTION
86U07A-058
63U07A-074
63U07A-075
Reverse Idle Gear
1. Worn or damaged bushing.
2. Worn or damaged teeth.
3. Worn or damaged release lever coupling groove.
4. Clearance between sleeve and reverse lever.
Standard: 0.095—0.318 mm (0.004—0.013 in)
Maximum: 0.5 mm (0.020 in)
Clutch Housing, Transaxle Case, Rear Cover,
and Differential Gear Case
Cracks or damage.
Caution
If the clutch housing, transaxle case, or
differential gear case is replaced, adjust the
bearing preload of the shaft gears and the
preload of the differential side bearings.
Bearing
1. Roughness or noise while turning
2. Worn or damaged outer race or rollers
Caution
a) Replace the bearing, the outer race, and the
inner race as a unit.
b)lf the bearing is replaced, adjust the
preload.
Speedometer Driven Gear Assembly
1. Worn or damaged teeth.
2. Worn or damaged O-ring.
Ring Gear Speedometer Drive Gear
Worn or damaged teeth.
Oil Seal
Damaged or worn lip.
63U07A-076
7A—28

ASSEMBLY 7 A
ASSEMBLY
Note
a) Wash all parts.
b) Apply oil to all friction surfaces.
c) Use new roll pins and retaining rings.
STEP 1 (DIFFERENTIAL)
86U07A-059
Assembly
1. Install the speedometer drive gear and the new
bearing inner race with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
2. Install the new bearing inner race with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
86U07A-061
7A-29

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

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

7 A ASSEMBLY
86U07A-106
86U07A-107
86U07A-108
8. Install the new breather.
9. Install the new change rod oil seal.
10. Install the change rod ©, the boot the spring

(3),
the reverse gate @, and selector ©, as shown.
11. Install the new roll pin.
12. Install the change arm.
Tightening torque: 12—14 N-m
(120—140 cm-kg, 104—122 in-lb)
13. Install the guide plate.
Tightening torque:
©8—11 N-m
(80—115 cm-kg, 69—100 in-lb)
(1)22—33 N-m
(2.25—3.35 m-kg, 16—25 ft-lb)
14. Install reverse lever, and reverse lever shaft.
15. Install the new roll pin.
16. Install the speedometer driven gear assembly.
86U07A-109
7A-42

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)
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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

INSTALLATION 7A
25. Install the grounds to the transaxle case.
Tightening torque:
8—11 N-m (80—115 cm-kg, 69—100 in-lb)
26. Connect the speedometer cable.
76G07A-067
76G07A-068
76G07A-069
76G07A-070
27. Install the intercooler pipe and hose. (RF-CX)
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
28. Install the brake vacuum pipe. (RF-CX)
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
29. Connect the brake vacuum hose. (RF-CX)
30. Install the air cleaner assembly and connect the
air flow meter connector.
Tightening torque:
16—27 Nm (1.6—2.8 m-kg, 12—20 ft-lb)
31. Connect the distributor lead.
32. Connect the main fuse block.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
33. Install the battery carrier and battery.
34. Add the correct quantity of the specified transaxle
oil.
Specified
Type
A.T.F.: DEXRON II
Above 0°F:
API: GL-4 or GL-5
SAE 80W-90 or SAE 90
Capacity:
3.35 liters (3.6 US qt, 3.0 Imp qt)
7A-57