MAZDA 626 1987 Workshop Manual

DISASSEMBLY 7A
STEP 4 (DIFFERENTIAL)
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
Note
a) If the bearing inner races are removed replace them with new ones.
b) Before disassembly, check the backlash of the side gears and pinion gears.
(Refer to page 7A—30)
1. Knock pin
2. Pinion shaft
3. Pinion gear
4. Thrust washer
5. Side gear
6. Thrust washer
7. Side bearing in-
ner race
8. Speedometer
drive gear
9. Side bearing in-
ner race
10. Gear case
76G07A-026
Disassemble Note
Side bearing inner race (side opposite ring gear)
Remove the race from the gear case with the SST.
Caution
Hold the gear case with one hand so that it
does not fall.
76G07A-027
Side bearing inner race (ring gear side)
Remove the race with a combination of parts from
the SST.
86U07A-055
7A-25

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

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

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
86U07A-062
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Wrths. Vvy
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86U07A-063
86U07A-064

Identification mark Thickness
0 2.0
mm
(0.079
in)

1 2.1
mm
(0.083
in)

2 2.2
mm
(0.087
in)
3. Install the thrust washers and pinion gears.
4. Install the pinion shaft.
5. Install the knock pin, then crimp it so that it cannot
come out of the gear case.
6. Install the thrust washers and the side gears.
Check and adjust using the following procedure.
7. Install the left and right driveshafts in the differen-
tial assembly.
8. Support the driveshafts on V-blocks as shown in
the figure.
9. Measure the backlash of both pinion gears.
Backlash: 0—0.1 mm (0—0.004 in)
86U07A-065
10. If the backlash is more than specified, adjust by
selecting thrust washers from the table and install
them between the case and side gears.
Note
Use the same thickness thrust washer on each
side.
7A-30

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

ASSEMBLY 7 A
6. Measure the clearance between the 3rd gear and
2nd gear.
Clearance: 0.05—0.20 mm (0.0020—0.0079 in)
Maximum: 0.25 mm (0.0098 in)
86U07A-073
7. Measure the clearance between the 4th gear and
bearing inner race.
Clearance: 0.165—0.365 mm
(0.0064—0.0144 in)
Maximum: 0.415 mm (0.0163 in)
86U07A-074
86U07A-075
8. Install the new bearing, inner race with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
Note
The styles and sizes of synchronizer rings are
different as shown in the illustration.
86U07A-076
7A—33

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