lock MAZDA PROTEGE 1992 Workshop Manual

J2 TRANSAXLE
13UOJ2.01
03UOJ2-0:
03UOJ2-0:
. -
03UOJ2-0
76UO7A-22 2
!2
!3
1
.
24
7
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.1 O-0.22mm (0.0039-0.0087 in)
Maximum: 0.27mm (0.0108 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of 5th gear and the clutch hub. Replace worn or
damaged parts.
Disassembly note
Locknut
1. Mount the transaxle on the SST,
2. Lock the primary shaft with the SST.
3. Shift to 1st or 2nd gear to lock the rotation of the primary
shaft.
Caution
l Do not reuse the removed locknut.
---
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary
shafts.
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control le-
ver (arrow). Turn the shift rod counterclockwise.
2. While holding the lst-2nd shift fork with one hand and the
3rd-4th shift fork with the other, raise them both at the same
time and shift each of the clutch hub sleeves.
3. Lift the control end and remove the steel ball, and, at the
same time, remove the shift rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each
of the clutch hub sleeves.

TRANSAXLE J2
1. 3rd/4th shift fork
2. Interlock sleeve
3. Roll pin
4. Control end
5. lst/2nd shift fork
6. Roll pin
7. Control lever
8. Control rod
9. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-23
10. Secondary 4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
11. Retaining ring
12. Secondary 3rd gear
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-20
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
13 2nd gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection .,,.,~,,.,,..........,,..........,
page J2-22
14. Synchronizer ring (2nd)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
15. Retaining ring
16. Clutch hub assembly (lst/2nd)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
17. Synchronizer ring (1 st)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
18. 1st gear
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-19
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22 19. Bearing inner race
Disassem.bly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
20. Secondary shaft
Inspection ,................................. page J2-23
21. Bearing inner race
Pre-inspection ,..,.,..................... page J2-20
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
22. 4th gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
23. Synchronizer ring (4th)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
24. Retaining ring
25. Clutch hub assembly (3rd/4th)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
Inspection ..,............................... page J2-22
26. Synchronizer ring (3rd)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
27.3rd gear
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-20
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
28. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
29. Primary shaft
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-23
30. Synchronizer spring
31. Synchronizer key
32. Clutch hub
33. Clutch hub sleeve (reverse gear)
34. Synchronizer spring
35. Synchronizer key
36. Clutch hub
37. Clutch hub sleeve
03UOJ2.03! 03UOJ2-034
Pre-inspection
Thrust clearance
1. Measure the clearance between the 2nd gear and secon-
dary 3rd gear.
Clearance: 0.175-0.455mm (0.0069-0.0179 in)
Maximum : OS05mm (0.0199 in)
2. Measure the clearance between the 1 st gear and differen-
tial drive gear.
Clearance: 0.05-0.26mm (0.002-0.011 in)
Maximum : 0.33mm (0.0130 in)
03UOJ2-036
52-l 9

TRANSAXLE J2
1. Clutch hub
Assembly Note ,......................... page J2-27
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Clutch hub
Assembly Note ,......................... page J2-27
6. Synchronizer key
7. Clutch hub sleeve (reverse gear)
8. Synchronizer spring
9. Primary shaft
10. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
11. 3rd gear
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
12. Synchronizer ring (3rd)
Assembly Note.. . . . . . . . . . . . . . . . . . . page J2-28
13. Clutch hub assembly (3rd14th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
14. Retaining ring
15. Synchronizer ring (4th)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
16. 4th gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-28
17. Bearing inner race
Assembly Note.. . . . . . . . . . . . . . . . . . page J2-28
18. Secondary shaft
19. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . page J2-29 20. 1st gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
21. Synchronizer ring (1 st)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
22. Clutch hub assembly (IstMnd)
Assembly Note ,,..........,............. page J2-29
23. Retaining ring
24. Synchronizer ring (2nd)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
25.2nd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
26. Secondary 3rd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
27. Retaining ring
28. Secondary 4th gear
Assembly Note ,.,............,....,..... page J2-30
29. Bearing inner race
Assembly Note. . . . . . . . . . . . . . . . . . page J2-30
30. Control rod
31. Control lever
32. Roll pin
33. lst/2nd shift fork
34. Control end
35. Roll pin
36. Interlock sleeve
Assembly Note.. . . . . . . . . . . . . . . . page J2-30
37. 3rd/4th shift fork
03UOJ2 051
___-__ 03UOJ2-11
Assembly note
Clutch hub
Note
l Synchronizer key dimensions are as follows.
mm (in)
(l-1
12) 1\3>
_--
1stMnd 19 (0.7480) 4.25 (0.1673) -5.00 (0.1969)
3rdl4th
SthlRev. 17 (0.6693) 4.25 (0.1673) 5.00 (0.1969)
1. Install the synchronizer key springs in the clutch hub with
the hooks in the grooves to hold the three synchronizer keys
in place.
03UOJ2-052
J2-27

J2 TRANSAXLE
03UOJ2-06 3
r
03UOJ2-068 ‘4
03UOJ2-06
03UOJ2-Of
Secondary 4th gear and bearing Inner race
1. Install the secondary 4th gear and new bearing inner race.
2. Measure the clearance between the 1 st gear and differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 In)
Maximum: 0.33mm (0.0130 in)
3. Measure the clearance between the 2nd gear and secon-
dary 3rd gear.
Clearance: 0.175-0.455mm (0.0089-0.0179 in)
Maximum: 0.505mm (0.0199 in)
4. If not as specified, reassemble the secondary shaft at
sembly. -’
Interlock sleeve
1. Install both shift forks and the interlock sleeve, as in the
figure.
J2-30

TRANSAXLE J2
ShIReverse Gear and Housing Parts
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
37-52 (3.8-8.3, 27-38)
, .-- 104-122 in-lb)
H50-210 cm-ka NEW
O/NEW 8 iN m ’ --13OL-i82 in-@
@mI - *
(80-l 15 Cm-kg,
NEW 89-l 00 In-lb)
128-198
(13-20, 94-145)
1. Differential assembly
2. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
3. Primary shaft gear assembly
6. Shift fork and shift rod assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Assembly
J2-38
7. Crank lever assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly page
Note . . . . . . . . . . . . . . . . . . . . . J2-38
page 4. Spring
J2-38
8. Crank lever shaft 5. Steel ball
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
9. Pin
10. 5thlReverse shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-39
Il. 5th/Reverse shift rod and clip
Assembly Note . . . . . . . . . . . . . . . . . . . . . . page J2-39
12. Lock bolt
13. Reverse idler gear
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . page J2-39
14. Reverse idler shaft
Assembly Note.. . . . . . . . . . . . . . . page J2-39
15. Magnet
“J”“JL-“O)O
21. Secondary 5th gear 16. Clutch housing
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly
page J2-39
22. Gear sleeve Note . . . . . . . . . . . . . . . . . . . . . . . . . .
23. 5th gear page
24. Synchronizer ring (5th) J2-39
25. Clutch hub assembly (5thIReverse)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . page J2-39
26. 5thlReverse shift fork 17. Transaxle case assembly
Assembly Note .,........................ page J2-39
27. Roll pin Assembly
28. Secondary reverse synchronizer gear Note . . . . . . . . . . . . . . . . . . . . . . . . . .
29. Synchronizer ring (Reverse) page
30. Primary reverse synchronizer gear J2-39
31. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-40
32. Locknut 18. Lock bolt, ball and spring
Assembly
19. Guide bolt
Note.. . . . . . . . . . . . . . . . . page J2-40
33. Rear cover 20. Lock bolt
52-37

TRANSAXLE 52
r
03UOJ2-09:
03UOJ2-09
03UOJ2-094
03UOJ2-09!
03UOJ2-09t
fith/Reverse shift rod end, Sth/Reverse shift rod and clip
Note
l The mark (indicated by the arrow in the figure) and
the shift rod end mounting bolt hole must be in the
same direction.
1. Install the shift rod end @ and the shift rod 0, and tighten
the gate mounting bolt.
Reverse idler gear and reverse idler shaft
1. install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever
(indicated by the arrow), and, at the same time, face the
reverse idler shaft screw hole in the direction shown in the
figure.
Clutch housing and transaxle case assembly
1. Apply a thin coat of sealant to the contact surfaces of the
clutch housing and transaxle case, tighten the transaxle case
installation bolts to the specified torque.
Tlghtenlng torque:
37-52 Nsrn (3.8-5.3 m-kg, 27-38 ft-lb)
2. Insert the SST through driveshaft hole.
Secondary 5th gear
1. Install the secondary 5th gear as shown.
Clutch hub assembly (Sth/Reverse) and !%h/Reverse shift
fork
1. Install the clutch hub assembly (5thReverse) and the 5th/Re-
verse shift fork together.
52-39

52 TRANSAXLE
23UOJ2-01:
Locknut
1. Shift to 1 st gear.
2. Lock the primary shaft with the
SST.
3. Tighten new locknuts on the primary and secondary shafts.
Tightening torque:
128-198 N&m (13.0-20.0 m-kg, 94-145 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.1 O-0.22mm (0.0039-0.0087 in)
Maximum: 0.27mm (0.011 in)
6. If not as specified, reassemble the transaxle.
52-40

J2 DIFFERENTIAL
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Pre-inspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
3. inspect all parts and repair or replace as necessary.
4. Assemble in the reverse order of disassembly, referring to
Assembly Note.
5 Mwn~lre the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin
2. Pinion shaft
3. Pinion gear
Inspection for wear and cracks
Pre-inspection .,...,........,............ page J2-44
Inspection of backlash. . . . ,.,.,..,,. page J2-45
4. Thrust washer
5. Side gear
Inspect for wear and cracks
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-44
Inspection of backlash . . . . . . . . . . . . . . page J2-45
6. Thrust washer
1
J ______ Ji
7. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-45
Assembly Note, .., ,.,..,,,,....,...,..,. page J2-45
8. Speedometer drive gear
9. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note .., ..,...., . ,. . . . . . . . page J2-45
Assembly
Note.. . . . . . . ,.. . . . ..,.. . . . . . . . page J2-45
10. Ring gear and gear case assembly
Inspect ring gear for wear or damage
Pre-inspection
Backlash of side gear and pinion gear
Measure the backlash by the following procedure.
1. Install the left and right driveshafts in the differential as-
sembly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O. 1 mm (O-0.004 in)
J2-44

DIFFERENTIAL
03UOJ2-10
03UOJ2-10
03UOJ2-10
03UOJ2-
03UOJ2-
Disassembly Note
Side bearing inner race (side opposite ring gear)
Caution
l Hold the gear case with one hand so that it does
not fall.
1. Remove the bearing inner race with the SST.
Side bearing inner race (ring gear side)
Caution
l Use pads in the vise to prevent damaging the
differential assembly.
1. Remove the bearing inner race with the SST.
Assembly Note
Side bearing inner race (Side opposite rlng gear)
1. install the speedometer drive gear.
2. Install the new side bearing inner race with the
SST.
Side bearing inner race (ring gear side)
1. Install the new bearing inner race with the SST.
Backlash of Side Gear and Pinion Gear
Measure the backlash by the following procedure.
1. Install the left and right driveshafts in the differential as-
sembly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O.1 mm (O-0.004 in)
4. If not as specified, replace the differential assembly.
--I
107
52-45

FRONT AXLE M
WHEEL HUB, STEERING KNUCKLE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly and disc plate.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas-
ure the wheel bearing play.
4. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
Removal / Installation
d Maximum wheel bearing play: 0.05mm (0.002 in)
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation, check the front wheel alignment. (Refer to Section R.)
SERVIC\E, SECTION R

7 93--12? W.-L%” COTiER PIN, REPLACE
(9.5-12.9, 69-S
39-54
(4.0-5.6, 29-40) 39-64 ’ 236-319 (24.0-32.5, 174-235)
(4.4-6.0, 32-43)
66-67)
N.m (m-kg, it-lb)
23UOMX-006
1. Wheel and tire
2. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
3. Brake caliper assembly
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
4. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
5. Tie rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6 6. Lower ball joint
7. Knuckle, wheel hub, and dust cover
Inspect wheel hub for cracks and damage
Inspect knuckle spindle for cracks and
damage
Inspect dust cover for damage and dis-
tortion
Disassembly / Inspection I
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 7
M-5