MAZDA 626 1987 Workshop Manual

CLUTCH AND FLYWHEEL 6
CLUTCH AND FLYWHEEL
REMOVAL
Components
Gasoline: 96—103 N-m (9.8—10.5 m-kg, 71—76 ft-lb)
Diesel: 177—186 N-m (18—19 m-kg, 130—137 ft-lb)
18-26 N-m (1.8—2.7 m-kg, 13—20 ft-lb)
1. Clutch release bearing
2. Clutch release fork
3. Clutch cover
76G06X-024
4. Clutch disc
5. Pilot bearing
6. Flywheel
7. Ring gear
1. Remove the transaxle. (Refer to Section 7).
2. Attach the SST to the engine, and remove the
clutch cover and clutch disc.
B6U06X-030
6-15

6 CLUTCH AND FLYWHEEL
3. Remove the pilot bearing from the crankshaft with
the SST.
Note
Do not remove the bearing if it is not neces-
sary.
86U06X-031
4. Remove the flywheel.
86U06X-032
5. Remove the release bearing.
6. Remove the release fork.
86U06X-033
INSPECTION
Check the following and repair or replace any faulty
parts.
Clutch Cover
1. Clutch disc for scoring, cracks, or discoloration.
Note
Minor scratches or discoloration should be re-
moved with sandpaper.
2. Diaphragm spring and cover for damage.
86U06X-034
6-16

CLUTCH AND FLYWHEEL 6
86U06X-035
86U06X-036
76G06X-025
Clutch Disc
1. Facing surface for hardening or presence of oil.
Note Use sandpaper if the trouble is minor.
2. Loose facing rivets.
3. Worn clutch disc.
Measure the depth to the rivet heads with a slide
caliper.
Depth: 0.3 mm (0.012 in) min.
4. Runout of clutch disc.
Runout: 1.0 mm (0.039 in) max.
5. Wear or rust on the splines.
Remove any minor rust.
Clutch Release Bearing
1. Turn the bearing both directions and check for any
binding or abnormal noise.
2. Worn or damaged diaphragm spring or release
fork contact surface.
Caution
The clutch release bearing is a sealed bear-
ing and must not be washed.
3. Sliding condition of bearing.
Install the bearing on the clutch housing extension
and check for smooth movement.
63U06X-025
6-17

6 CLUTCH AND FLYWHEEL
Clutch Release Fork
Cracked or bent clutch release fork.
67U06X-035
4BG06X-028
4BG06X-029
Flywheel
1. Surface marks, scoring or discoloration of clutch
contact surface.
Note
If the problem is minor, repairs can be made
by cleaning with sandpaper.
2. Damaged or worn ring gear teeth.
If necessary, replace the ring gear as follows:
(1) Heat the ring gear with a blowtorch, then tap
around the gear to remove
it
from the flywheel.
(2) Heat the new ring gear to 250—300°C
(480—570°F), then fit it onto the flywheel.
Caution
The bevelled side of the ring gear must face
toward the engine side.
3. Runout of flywheel
(1) To measure, set a dial indicator on the clutch
disc contact surface, and turn the flywheel.
Runout: 0.2 mm (0.008 in) max.
(2) If the runout exceeds specification repair by
grinding.
Grinding limit: 0.5 mm (0.020 in) max.
86U06X-037
6-18

CLUTCH AND FLYWHEEL 6
INSTALLATION
1. Apply clutch grease (Mori While TA No.2 or
equivalent organic molybdenum grease) to the
clutch release bearing and fork, indicated by the
shaded lines in the figure.
86U06X-038
2. Install the clutch release fork and release bearing.
86U06X-039
Gasoline Diesel
}
.iSlf
49 E301 060 g^M 1/ j> •«] 49 V101 060
76G06X-026
3. Install the flywheel, then attach the SST and tight-
en the flywheel installation bolts.
Tightening torque:
Gasoline 96—103 N-m
(9.8—10.5 m-kg, 71—76 ft-lb)
Diesel 177—186 N-m
(18—19 m-kg, 130—137 ft-lb)
Caution
If reusing the flywheel bolts, clean the threads
to remove old sealant, and apply new sealant.
If old sealant cannot be removed, replace the
bolts.
4. Install the pilot bearing in the flywheel using a suit-
able bar and a hammer.
Caution
a) Tap it in until distance A in the figure is
3.8—4.2 mm (0.150—0.165 in).
b) Put a small amount of clutch grease (Mori
White TA No.2 or equivalent organic
molybdenum grease).
86U06X-041
6—19

6 CLUTCH AND FLYWHEEL
86U06X-042
86U06X-043
5. Clean the clutch disc splines and primary shaft
splines, then apply clutch grease (Mori White TA
No. 2 or equivalent organic molybdenum
grease).
6. Install the clutch disc with the SST.
Note
Install the clutch so that it faces in the direc-
tion shown in the figure.
7. Install the SST, and tighten the clutch, cover di-
agonally and evenly.
Tightening torque: 18—26 N-m
(1.8—2.7 m-kg, 13—20 ft-lb)
8. Install the transaxle. (Refer to Section 7A.)
76G06X-027
6-20

MANUAL TRANSAXLE
OUTLINE 7 A— 2
STRUCTURAL VIEW 7A— 2
CROSS-SECTIONAL VIEW 7A— 3
SPECIFICATIONS 7A— 4
TROUBLESHOOTING GUIDE 7A— 5
ON-VEHICLE MAINTENANCE 7A— 6
TRANSAXLE OIL 7A— 6
DRIVESHAFT OIL SEALS 7A— 7
REMOVAL 7A—10
DISASSEMBLY 7A—18
STEP 1 7A—18
STEP 2 7A—20
STEP 3 7A—22
STEP 4 7A—25
INSPECTION 7A—26
ASSEMBLY 7A—29
STEP 1 7A—29
STEP 2 7A—31
STEP 3 7A—36
STEP 4 7A—44
INSTALLATION 7A—49
TRANSAXLE CONTROL 7A—58
76G07A-001

7A OUTLINE
OUTLINE
STRUCTURAL VIEW
76G07A-002
1. Primary shaft gear assembly
2. Secondary shaft gear assembly
3. Differential assembly
4. Clutch housing
5. Primary reverse synchronizer gear
6. Secondary reverse synchronizer gear
7. Reverse idle gear
8. Transaxle case
7A—2

CROSS-SECTIONAL VIEW
OUTLINE 7 A
4 speed
76G07A-003
7A—3

7A OUTLINE
SPECIFICATIONS
•Engine model
Item ——
FE DOHC F6 FE 12-valve
FE 8-valve F8 RF-N RF-CX •Engine model
Item —— Leaded Unleaded F6 FE 12-valve Carb. Fl F8 RF-N RF-CX
Transaxle control Floor shift
Synchromesh system Forward synchromesh, Reverse selective sliding and synchromesh
Gear ratio
1st 3.307
Gear ratio
2nd 1.833
Gear ratio 3rd 1.310 1.233 1.161 Gear ratio
4th 1.030 0.970 0.914 0.861
Gear ratio
5th 0.837 0.795 0.755 0.680
Gear ratio
Reverse 3.166
Final gear ratio 4.105 3.850 4.105 3.850 4.105
Oil Type
ATF: DEXRON-II Above -18°C (0°F): API: GL-4 or GL-5 SAE 80W-90 or SAE 90 Oil
Capacity 3.35 liters (3.6 US qt, 3.9 Imp qt)
76G07A-004
7A—4