differential MAZDA PROTEGE 1992 Workshop Manual

OUTLINE, TROUBLESHOOTING GUIDE D
OUTLINE
SPECIFICATIONS
Engine
Item
--
Lubrication system
Type
011 pump
Relief pressure kPa (kg/cm2, psi)
_~__
Type Oil filter
Relief pressure differential kPa (kg/cm2, psi)
Oil pressure switch activation pressure
kPa (kg/cm’, psi)
Total (dry engine)
liters (US qt, Imp qt)
Oil capacity Oil pan liters (US qt, Imp qt)
Oil filter liter (US qt, Imp qt)
Engine oil
Above -25OC (-13’F)
Viscosity number
Below 0% (32OF) BP SOHC BP DOHC
B6 SOHC
Force-fed type
Trochoid gear
343-441 (3.5-4.5, 50-64) m I, Full-flow, paper element
78-l 18 (0.8-l .2, 1 l-i 7)
25 (0.25, 3.6)
3.4 (3.6, 3.0) 4.0 (4.2, 3.5)
3.0 (3.2, 2.6) 3.6 (3.8, 3.2)
0.17 (0.18, 0.15)
API service SG Energy ConservingII (ECII) Only
SAE low-30
SAE 5W-30
23UODX-005
TROUBLESHOOTING GUIDE
Problem
Engine hard starting
Excessive oil
consumption
Oil pressure drop
Warming lamp
illuminates while
engine is running Possible Cause
Improper engine oil
Insufficient engine oil
Oil working up or down
011 leakage
Insufficient oil
Oil leakage
Worn and/or damaged oil pump gear
Worn plunger (inside oil pump) or weak spring
Clogged oil strainer
Excessive main bearing or connecting rod bearing
clearance
Oil pressure drop
Malfunction of oil pressure switch
Malfunction of electrical system Remedy
Replace
Add oil
Refer to Section B
Repair
Add oil
Repair
Replace
Replace
Clean
Refer to Section B
As described above
Refer to Section T
Refer to Section T Page
D- 7
D- 7
-
D- 7
-
D-13, 14
D-13, 14
-
-
23UODX-015
D-5

Jl
MANUAL TRANSAXLE
(F5M-R)
INDEX ..................................................... Jl- 2
OUTLINE ................................................ Jl- 3
SPECIFICATIONS ................................... Jl- 3
STRUCTURAL VIEW ............................... Jl- 4
POWER FLOW ...................................... Jl- 5
TROUBLESHOOTING GUIDE.. ................... Jl- 6
TRANSAXLE OIL ..................................... Jl- 7
INSPECTION ......................................... Jl- 7
REPLACEMENT ..................................... Jl- 7
TRANSAXLE ........................................... Jl- 6
PREPARATION ...................................... Jl- 6
REMOVAL ............................................ 51-10
DISASSEMBLY ...................................... Jl-14
INSPECTION ......................................... 51-27
ASSEMBLY ........................................... Jl-30
INSTALLATION ...................................... Jl-46
DIFFERENTIAL ........................................ Jl-52
PREPARATION ...................................... 51-52
DISASSEMBLY I INSPECTION / ASSEMBLY Jl-53
SHIFT MECHANISM ................................. Jl-56
OVERHAUL .......................................... Jl-56
OWOJl-001

Jl INDEX
INDEX
BACK-UP LdHT SWITCH
SERVICE, SECTION T VISCOSITY: SAE 75W-90
CAPACITY : 2.68 liters (2.83 US qt, 2.36 Imp qt)
03UOJl-00
1, Transaxle 2. Differential
Removal.. ..................................
page Jl-IO Disassembly I Inspection I
Disassembly ................................ .............................. page Jl-14 Assembly page Jl-53
Inspection ..................................
page J 1-27 3. Shift mechanism
Assembly .................................. page J l-30 Overhaul ...................................
page Jl-56
Installation ................................. page Jl -48 4. Transaxle oil
Inspection. .................................
page Jl- 7
Replacement ............................. page Jl- 7

Jl OUTLINE
1. Primary 1 st gear 6. Primary reverse gear
2. Primary 2nd gear 7. Secondary 1st gear
3. Primary 3rd gear 8. Secondary 2nd gear
4. Primary 4th gear 9. Secondary 3rd gear
5. Primary 5th gear 10. Secondary 4th gear 11. Secondary 5th gear
12. Secondary reverse gear
13. Reverse idler gear
14. Differential
51-4

Jl TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem
Shift lever won’t shift
smoothly or is hard
to shift
Too much play in
shift lever
I------
Difficult to shift
Won’t stay in gear
Abnormal noise
I
Possible cause
Seized shift lever ball
Seized change control rod joint
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
Worn shift lever ball bushing
Bent change rod
No grease in transaxle control
Insufficient oil
Deterioration of oil quality
Wear or play of shift fork or shift rod
Worn synchronizer ring
Worn synchronizer cone of gear
Bad contact of synchronizer ring and cone of gear
Excessive longitudinal play of gears
Worn bearing
Worn synchronizer key spring
Excessive primary shaft gear bearing preload
improperly adjusted change guide plate
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
improperly installed extension bar
Worn shift fork
Worn clutch hub
Worn clutch hub sleeve
Worn gear sliding part of both shaft gears
Worn gear sliding part of each gear
Worn steel sliding groove of control end
Weak spring pressing against steel ball
Excessive thrust clearance
Worn bearing
Improperly installed engine mount
Insufficient oil
Deterioration of oil quality
Worn bearing
Worn sliding surfaces of gears or shafts
Excessive gear backlash
Damaged gear teeth
Foreign material in gears
Damaged differential gear or excessive backlash Remedy Replace
Replace
Replace
Replace
Replace
Replace
Replace
Lubricate with grease
Add oil
Replace with oil of
specified quality
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Replace
Replace
Replace
Tighten
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Tighten
Add oil
Replace
Adjust or replace
Replace
Replace
Replace with oil of
specified quality
Replace
Adjust or replace Page Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl- 7
Jl- 7
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-36
Jl-17
Jl-56
Jl-56
Jl-56
Jl-56
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-14
Jl-14
Jl-22, 24
Jl-22, 24
Jl-48
Jl- 7
Jl- 7
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-53
03UOJl-OC --
-../
51-6

TRANSAXLE Jl
1, Rear cover
2. Locknut (Primary shaft)
Disassembly Note .,......,,.,......... page Jl-15
3. Stop plate
4. Locknut (Secondary shaft)
Disassembly Note ,..,....,,.,......... page Jl-15
5. 5th shift fork
6. Clutch hub assembly (5th)
Inspection . . . . . . . . . . . . . . . . ..*............... page J l-29
7. Synchronizer ring (5th)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-27
8. 5th gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-28
9. Gear sleeve
Inspection . . . . . . . . . . . . . . . . ..*...*........... page Jl-28
10. Secondary 5th gear
11. Lock bolt and washer
12. Back-up light switch
13. Neutral switch
14. Transaxle case assembly
15. Magnet
16. Reverse idler shaft
17. Reverse idler gear
Inspection.. . . , . . . . . . . . . . . . . . . , , . , . . . . . . . . . . page J l-27
L ,
03UOJl-022
I
I I
03UOJl-023
18. 5th shift rod
19. 5th shift rod end
20. Pin
21. Crank lever shaft
22. Crank lever assembly
23. Shift fork and shift rod assembly
Disassembly Note ,.................... page Jl-16
24. Steel ball
25. Spring
26. Primary shaft gear assembly
27. Secondary shaft gear assembly
28. Differential assembly
29. Clutch housing
30. Synchronizer spring
31. Clutch hub sleeve
32. Synchronizer key
33. Clutch hub
34. 3rd/4th shift fork
35. Interlock sleeve
36. Control lever
37. lstl2nd shift fork
38. Control rod
39. Control end
03UOJl-021
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06-0.26mm (0.0024-0.0102 in)
Maximum : 0.31 mm (0.0122 in)
2. If the clearance exceeds the the maximum, check the con-
tact surfaces of 5th gear and the clutch hub. Replace worn
or damaged parts.
Disassembly note
Locknut
1, Mount the transaxle on the SST.
Jl-15

TRANSAXLE Jl
Clutch Housing and Transaxle Case Components
Caution
l Do not remove oil seals unless necessary.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
-
.ACE
23UOJl-O(
1. Speedometer driven gear 17. Boot 28. Adjust shim
assembly 18. Oil seal (Change rod) 29. Adjust shim
2. Oil seal (Differential) Disassembly Note 30. Bearing outer race
Disassembly Note ,.,,,..,............. page Jl-18 (Differential)
..................... page Jl-19 19. Bushing Disassembly Note
Replacement (On-vehicle) 20. Oil seal (Primary shaft) ..................... page Jl-19
.....................
page Jl-20 Disassembly Note 31. Adjust shim (Differential)
3. Pivot ..................... page Jl-19 Disassembly Note
4. Bleeder 21. Bearing outer race ..................... page Jl-19
5. Bleeder cover Disassembly Note 32. Transaxle case
6. Gasket ..................... page Jl-18 33. Roll pin
7. Roll pin 22. Funnel 34. O-ring
8. Blind plug Disassembly Note 35. Driven gear
Disassembly Note ..................... page Jl-18 36. Packing
..................... page Jl-18 23. Bearing outer race 37. Oil seal
9. Reverse lever shaft (Differential) (Speedometer gear cace)
Disassembly Note Disassembly Note Disassembly Note
..................... page Jl-18 ..................... page Jl-19 ..................... page Jl-19
10. Lever set spring 24. Clutch housing 38. Gear case
11. Reverse lever 25. Oil passage 39. Joint
Inspection ....... page Jl-27 26. Oil seal (Differential) 40. Change rod
12. Guide plate assembly Disassembly Note
13. Roll pin ..................... page Jl-19
14. Selector Replacement (On-vehicle)
15. Change arm ..................... page Ji-20
16. Change rod assembly 27, Bearing outer race
Jl-17

TRANSAXLE
L I
03UOJl-030
03UOJl-03 81
-”
/
23UOJl-004
03UOJ l-03
03UOJl.0:
Oil seal (Primary shaft)
Caution
l Do not damage the clutch housing.
1. Remove the oil seal with a screwdriver.
Oil seal (Differential)
1. Remove the oil seal with a screwdriver.
Bearing outer race (Differential)
1. Remove the bearing outer race with the SST.
Bearing outer race and adjust shim (Differential)
1. Install the SST to the bearing outer race.
2. Remove the bearing outer race and adjust shim.
Oil seal (Speedometer gear case)
1. Remove the oil seal as shown in the figure.
Jl-19

TRANSAXLE Jl
03UOJ 1.04!
03UOJ 1.041
03UOJl-047
, , .” ,,,,,..
03UOJl-04t
03UOJ l-04!
Preinspection
1st gear thrust clearance
1, Measure the clearance between 1 st gear and the differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 in)
Maximum: 0.33mm (0.013 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 1 st gear, differential drive gear of the secon-
dary shaft gear, and clutch hub assembly (1 st/2nd). Replace
worn or damaged parts.
2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary
3rd gear.
Clearance: 0.18-0.51 mm (0.007-0.020 in)
Maximum: 0.58mm (0.022 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 2nd gear, secondary 3rd gear, and clutch
hub assembly (1 stMnd). Replace worn or damaged parts.
Disassembly note
Bearing inner race and secondary 4th gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race and secondary 4th gear with
the
SST.
Secondary 3rd gear and 2nd gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the secondary 3rd gear and 2nd gear with the
SST.
Clutch hub assembly (lst/2nd), synchronizer ring (1st)
and 1st gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the clutch hub assembly (1 st/2nd), synchronizer
ring (1st) and 1st gear with the
SST.
Jl-25

TRANSAXLE

I
\m/ 7.8-11 N-m
1. Change
rod
2. Joint
3. Bearing outer race
4. Funnel
Assembly Note 11. Oil passage
29. Guide plate assembly
12. Oil
seal (Differential) 30.
Gear case
Assembly Note 31, Oil seal
,.................... page Jl -41 (Speedometer gear cace)
13. Transaxle case Assembly Note
. . . . . . . . . . . . . . . . . . . . .
page Jl-42
5. Bearing outer race
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-42
6. Bearing outer race
(Differential)
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-41
7. Adjust shim (Differential)
Assembly Note
. . . . . . . . . . . . . . . ...*.. page Jl-41
8. Bearing outer race
(Secondary shaft gear)
Assembly Note
,..*.,...............
page Jl -41
9. Adjust shim
(Secondary shaft gear)
Assembly Note
. . . . . . ...*. . . . . . . . . . . page Jl-41
IO. Adjust shim
(Primary shaft gear)
Assembly Note
14. Reverse lever . . . . . . . . . . . . . . . . . . . . . page Jl-41
15. Lever set spring 32. Packing
16. Reverse lever shaft 33. O-ring
17. Roll pin 34. Drive gear
18. Blind plug 35. Roll pin
19. Oil seal (Primary shaft gear) (Speedometer driven gear
Assembly Note assembly)
. . . . . . . . . . . . . . . . . . . . . page Jl-42 Assembly Note
20. Gasket ..,......*. ..,,...... page Jl-41
21. Bleeder cover 36. Speedometer driven gear
22. Bushing assembly
23. Oil seal (Change rod) 37. Bleeder
Assembly Note 38. Pivot
..,..,...,........... page Jl-42 39. Oil seal (Differential)
24. Boot Assembly Note
Assembly Note . . . . . . . . . . . . . . . . . ...* page Jl-41
.,.,.,............... page Jl-42 40. Clutch housing
25. Change rod
Assembly Note
. ..*.................
page J l-42 .,................... page Jl-42
26. Change arm
27. Selector
28. Roll pin
Jl-36