MAZDA 626 1987 Workshop Manual

TROUBLESHOOTING GUIDE 7A
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Change lever won't Seized change lever ball Replace 7A-58 shift smoothly, or is Seized change control rod joint Replace 7A-58
hard to shift Bent change control rod Replace 7A-58
Too much play in Worn change control rod bushing Replace 7A-58 change lever Weak spring of ball or change lever Replace 7A-58 Worn bushing of ball or change lever Replace 7A—58
Difficult to shift Bent change rod Replace 7A—58
No grease in transmission control Lubricate with grease 7A-58
Insufficient oil Add oil 7A-6
Deterioration of oil quality Replace with oil of 7A-6 specified quality
Wear or play of shift fork or shift rod Replace 7 A—18
Wear of synchronizer ring Replace 7A-27
Wear of synchronizer cone of gear Replace 7A-27
Bed contact of synchronizer ring and cone of Replace 7A-27 gear
Excessive longitudinal play of gears Replace 7A-22
Wear of bearing Adjust or replace 7A—22
Wear of synchronizer key spring Replace 7A-27
Excessive shaft gear bearing preload Adjust 7A-37
Improperly adjusted change guide plate Adjust 7A-20
Won't stay in gear Bent change control rod Replace 7A-58
Worn change control rod bushing Replace 7A-58
Weak change lever ball spring Replace 7A-58
Improperly installed extension bar Tighten 7A-58
Wear of shift fork Replace 7A—22
Wear of clutch hub Replace 7A-27
Worn clutch hub sleeve Replace 7A-27
Worn gear sliding part of both shaft gears Replace 7A-26
Worn gear sliding part of each gear Replace 7A-26
Worn steel sliding groove of control end Replace 7 A—18
Weak spring pressing against steel ball Replace 7A-18
Excessive thrust clearance Replace 7A—33,35
Worn bearing Replace 7A—22
Improperly installed engine mount Tighten 7A—49
Abnormal noise Insufficient oil Add oil 7A-6
Deterioration of oil quality Replace 7A-6
Worn bearing Adjust or replace 7A-22
Worn gear sliding surface of both shaft gears Replace 7A—26
Wear of sliding surfaces of gears Replace 7A-26
Excessive thrust clearance Replace 7A—33,35
Damaged gear teeth Replace with oil of 7A-26
specified quality Foreign material in gears Replace 7A-22
Damaged differential gear, or excessive backlash Adjust or replace 7A—30
76G07A-005
7A-5

7A ON-VEHICLE MAINTENANCE
61G07X-189
61G07X-190
61G07X-191
ON-VEHICLE MAINTENANCE
TRANSAXLE OIL
Inspection
1. Park the vehicle on level ground.
2. Remove the speedometer cable dust cover, and
disconnect the cable from the speedometer driv-
en gear.
3. After removing the bolt, pull the gear case to re-
move
it
from the housing. (Insert a flat-tipped screw-
driver between the speedometer gear case and
the clutch housing, and use
it
to pry the gear case
loose if necessary.)
4. Check that the oil level is between the "F" and "L".
5. If not, add the necessary amount of the specified
oil through the gear case hole.
Replacement
1. Park the vehicle on level ground.
2. Remove the speedometer driven gear.
(See "Inspection" section above.)
3. Remove the drain plug, and drain the oil.
4. Replace the drain plug, and add the necessary
amount of the specified oil through the speedom-
eter gear case hole.
Specified oil
Type
ATF: DEXRON II
Above -18°C (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)
76G07A-006
7A—6

ON-VEHICLE MAINTENANCE 7A
DRIVESHAFT OIL SEALS
Replacement
Jack up the vehicle, support it on safety stands, and
then drain the transaxle oil. Next, use the following
procedure to replace the driveshaft oil seals:
1. Remove the front wheel(s).
2. Remove the splash shield(s).
3. Separate the front stabilizer from the lower arm.
61G07X-170
4 Remove the bolt and pull the lower arm downward.
Separate the knuckle from the lower arm ball-joint.
Note
Be careful not to damage the ball-joint dust
boot.
Remove the cotter pin then disconnect the tie-rod
end with the SST.
86U07A-009
6. Separate the driveshaft by pulling the front hub out-
ward. Do not use too much force at once, increase
the force gradually.
Note
a) Do not to allow the driveshaft ball-joint to
be bent to its maximum extent.
b) Support the driveshaft using string, wire,
etc.
86U07A-010
7. Remove the oil seal with a flat-tipped screwdriver.
86U07A-011
7A-7

7A ON-VEHICLE MAINTENANCE
86U07A-012
86U07A-013
86U07A-014
8. Tap the new oil seal into the transaxle case with
the SST.
Note
a) Tap in until the oil seal installer contacts the
case.
b)Coat the oil seal lip with transaxle oil.
9. Replace the driveshaft end clip with a new one.
Insert the clip with the gap at the top of the groove.
10. Install the driveshaft as follows:
(1) Pull the front hub outward, then
fit
the driveshaft
into the transaxle.
(2) Insert the driveshaft into the transaxle by push-
ing on the wheel hub assembly.
Note
a) Be careful not to damage the oil seal.
b) After installation is finished, pull the front
hub slowly outward to check that the
driveshaft is held securely by the clip.
11. Install the lower arm ball-joint to the knuckle, and
tighten the clinch bolt.
Tightening torque:
43—54 N-m (4.4—5.5 m-kg, 32—40 ft-lb)
12. Install the tie-rod end and new cotter pin.
Tightening torque:
29—44 N m (3.0—4.5 m-kg, 22—33 ft-lb)
86U07A-015
7 A—8

ON-VEHICLE MAINTENANCE 7A
13. Adjust and tighten the stabilizer.
Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)
Dimension: 20.1 mm (0.79 in)
86U07A-016
76G07A-007
14. Install the drain plug.
Tightening torque:
39—59 Nm (4.0—6.0 m-kg, 29—43 ft-lb)
15. Install the wheel.
Tightening torque:
88—118 Nm (9.0—12.0 m-kg, 65—87 ft-lb)
16. Add the correct quantity of the specified oil.
Type: A.T.F.: DEXRON II
Above -18°C (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—9

7A REMOVAL
REMOVAL
Fl except DOHC
76G07A-008
1. Battery
2. Main fuse block
3. Air cleaner assembly
4. Ventilation hose
5. Air hose
6. Ground(s)
7. Speedometer cable
8. Clutch release cylinder
9. Canister hose
10. Wheel
11. Splash sheild
12. Extension bar
13. Control rod
14. Stabilizer
15. Joint shaft
16. Gusset plate (rear)
17. Gusset plate (front)
18. Surge tank bracket
19. Starter
20. Under cover
21. Engine mount No.4
22. Engine mount No.2
23. Hunger rubber
24. Crossmember
7 A—10

REMOVAL 7A
DOHC
76G07A-009
1. Battery
2. Main fuse block
3. Air cleaner assembly
4. Ventilation hose
5. Air hose
6. Ground(s)
7. Speedometer cable
8. Clutch release cylinder
9. Canister hose
10. Wheel
11. Splash sheild
12. Extension bar
13. Control rod
14. Stabilizer
15. Joint shaft
16. Surge tank bracket
17. Starter
18. Engine mount No.4
19. Engine mount No.2
20. Rear member (4WS)
21. Hunger rubber
22. Crossmember
7A—11

7A REMOVAL
Carburator
76G07A-010
15. Starter
16. Engine mount No.4
17. Engine mount No.2
18. Under cover
19. Hunger rubber
20. Crossmember
1. Battery
2. Air cleaner assembly
3. Ground
4. Speedometer cable
5. Clutch release cylinder
6. Canister hose
7. Wheel
8. Splash sheild
9. Extension bar
10. Control rod
11. Stabilizer
12. Joint shaft
13. Gusset plate (rear)
14. Gusset plate (front)
7 A-12

REMOVAL 7A
RF-N and RF-CX
1. Battery
2. Air cleaner assembly
3. Vacuum hose
4. Intercooler pipe and hose
(RF-CX)
5. Electric fan
6. Speedometer cable
7. Ground(s)
8. Clutch release cylinder
9. Pressure and return hoses
(power steering)
10. Starter
11. Wheel
12. Splash shield
13. Stabilizer
14. Joint shaft
15. Extension bar
16. Control rod
76G07A-011
17. Exhaust pipe bracket
18. Water pipe
19. Gusset plate (rear)
20. Gusset plate (front)
21. Under cover
22. Engine mount No.4
23. Engine mount No.2
24. Crossmember
7 A—13

7A REMOVAL
1. Remove the battery and battery carrier.
2. Disconnect the main fuse block. (Fl)
3. Disconnect the distributor lead.
4. Remove the air cleaner assembly.
76G07A-012
5. Remove the vacuum hose, the intercooler hose
(RF-CX) and the electric fan. (RF-N and RF-CX)
86U07A-021
8. Remove the front wheels.
9. Remove the splash shields.
10. Drain the transaxle oil.
86U07A-022
7A—14