lock MAZDA PROTEGE 1992 Workshop Manual

OUTLINE, MANUAL STEERING
OUTLINE
SPECIFICATIONS
Item
Steering wheel
Steering shaft and joint
Steering gear Outer diameter mm (in)
Lock-to-lock turns
Shaft
Joint
Power assist
Gear
Gear ratio
Rack stroke mm (in)
Power steering fluid
Fluid capacity liter (US qt, Imp qt) Manual steering Power steering 370 (14.6)
4.3 3.0
Collapsible
2cross joint
-
Engine speed sensing
Rack-and-pinion
a0 (infinite)
140 (5.51)
-
ATF Dexron@lI or M-III
-
0.8 (0.85, 0.70)
23UONX-00
MANUAL STEERING
PREPARATION
SST
49 0118 850C
Puller, ball joint For 49 1243 785
removal of tie rod
end Installer, dust
boot
49 0180 5108
Attachment,
steering worm
bearing preload
measuring For
measurement of
pinion preload 49 F032 308
Installer For
installation of dust
boot
For
installation of
oil seal
93GONX-OC
N-94

MANUAL STEERING
BOOT
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referrino to Installation Note.
N.m (m-kg, ft-lb) 7 (4.3-d&31-42)
23UONX-006
1. Cotter pin, nut
5. Tie rod end boot
2. Tie rod end/Steering knuckle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7
3. Locknut
6. Boot clip
Removal Note . . . . . . . . . . . . . . . . . . . . . page N- 7 7. Boot wire
4. Tie rod end
23UONX-00
8. Rack boot
Removal note
Tie rod end/Steering knuckle
1. Pull out the cotter pin, and loosen the nuts until the nut con-
tacts with the hole stud face.
Caution
l Leave the nuts temporarily tight not to damage the
screw thread.
2. Remove the tie rod from the knuckle arm with the SST.

MANUAL STEERING N
23UONX-050
23UONX.00 9
Locknut
1. Mark the tie rod end, the locknut, and the tie rod.
Tie rod end boot
1. Secure the tie rod end in a vise.
2. Place a chisel against the dust boot and hold it at the angle
shown.
3. Remove the boot.
Caution
l Do not scar the part where the tie rod attaches to
the dust boot.
Installation note
Tie rod end boot
1. Wipe the grease on the ball joint.
2. Put a small amount of rubber grease into the new dust boot.
q 3. Install the dust boot onto the tie rod end with the SST and
a press.
4. Wipe away any grease expelled from the dust boot.
N-7

MANUAL STEERING N
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal.
39-49 (4-5, 29-36)
Q
3-2.7, 13-20)
2.0-5.9 N.m (20-60 cm-kg, 17-52 In
N.m (m-kg. Mb)
1. Horn cap 6. Undercover
2. Locknut 7. Dust cover
3. Steering wheel 8. Fixing bolt (Intermediate shaft/Pinion shaft)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-10 9. Interlock cable (ATX only)
4. Column cover 10. Steering shaft assembly
5. Combination switch Disassembly / Assembly . . . . . . . . . . . . . page N-l 0
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section T Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
N-9

N MANUAL STEERING
Removal note
Steering wheel
Remove the steering wheel with a suitable puller.
Caution
l Do not try to remove the steering wheel by hitting
the shaft with a hammer. The column will collapse.
I
03UONX-011
Disassembly / Assembly
1. Reassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.
REPLACE
22-27 (2.2-2.8, 18-20)
@ 18-27 (1.8-2.7, 13-20)
N.m (m-kg, &lb)
311 I”hlY.nl’ L”““l .,. “,
2
1, Steering lock assembly 7. Tilt lever bracket
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 1 8. Fixing bolt (Universal joint/Intermediate shaft)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 2 9. Intermediate shaft
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
2. Coating plate 10. Fixing bolt (Steering shaft/Universal joint)
3. Bolt 11. Universal joint
4. Adjusting bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
5. Adjusting lever
12. Steering shaft assembly
6. Adjusting nut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
N-10

MANUAL STEERING N
13UONX-01
23UONX-05
POSITION
1 SGONX-Oi
23UONX.01 I1
Disassembly note
Steering lock assembly
Use a chisel to make a groove in the head of the steering lock
mounting bolts. Remove the bolts with a screwdriver; then re-
move the steering lock assembly.
Caution
l Secure the shaft in a vise protected with brass pads
or cloth.
Inspection
Check for the following and replace the assembly if necessary.
Steering shaft assembly
1. Column bushing wear.
2. Steering shaft length.
Specified length: 558.3~560.3mm (21.98-22.06 in)
3. Tilt operation.
(1) Verify that the adjusting lever moves smoothly from un-
lock position to lock position.
(2) Verify that the steering shaft is fixed firmly when the ad-
justing lever is locked.
Intermediate shaft, Universal joint
Universal joint looseness, abnormal noise, or sticking.
N-l 1

N MANUAL STEERING
1 I
13UONX-033
Steering lock assembly (ATX)
Verify that the cable connector does not move when the key
is in the LOCK position and that it moves freely with the key
in other positions.
Assembly note
Steering lock assembly
Install the steering lock assembly on the jacket. Install new
steering lock mounting bolts, and tighten them until the heads
break off.
I 13UONX-034
N-12

MANUAL STEERING N
Disassembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
23UONX-017
1. Tie rod end 12. Pinion protector
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 6 Disassembly note ,.,..,.............,... page N-16
2. Boot wire
3. Boot clip
4. Boot
5. Tie rod
Disassembly Note . . . . . . . . . . . . . . . . . . . . . .
6. Washer
7. Locknut
8. Adjusting cover
9. Spring
10. Pressure pad plate
11. Pressure pad 13. Oil seal
14. Snap ring cap
15. Snap ring
16. Pinion
page N-16 Disassembly Note ,....,,.............,. page N-l 7
17. Rack
Disassembly
Note . . . . . . . . . . . . . . . . . . . . . . page N-l 7
18. Bushing
19. Mounting bracket and rubber
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-17
20. Gear housing .
N-15

N MANUAL STEERIN
93GONX-007
23UONX-01 I
c-7
23UONX-01
63U 1 OX-089
Disassembly note
Steering gear and linkage
1, Secure the mounting part of the removed gear and linkage
in a vise.
Caution
l Be sure to insert a soft, protective material between
the part and the jaws of the vise.
Tie rod end
1. Make a matching mark on the tie rod threads for proper
reassembly.
Tie rod
1. Uncrimp the locking washer.
2. After wrapping the rack in a rag and securing it in a vise,
remove the tie rod from the rack.
Pinion protector
1. Hit the rim of pinion protector with a plastic hammer gently
from under to remove it.
I m-
I
93GONX-067
N-16

MANUAL STEERING N
Assembly
Assemble in the order shown in the figure, referring to Assembly Note.
REPLACE 1 J REPLACE
REPLACE
N.m (m-kg, ft-lb)
7% lilNXA7
----. .,. --
1. Gear housing 11. Pressure pad plate
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-20 12. Spring
2. Mounting bracket and rubber 13. Adjusting cover
Assembly Note. . . . . . . . . . . ,, ,....,.... ,, . . page N-20 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
3. Bushing 14. Locknut
4. Rack Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-20 15. Washer
5. Pinion gear Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-22
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . . page N-20 16. Tie rod
6. Snap ring Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-20 17. Boot
7. Snap ring cap Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-22
8. Oil seal 18. Boot wire
Assembly Note.. . . . . . . . . . ,.. . . . . . . . . . . . . . page N-20 19. Boot clip
9. Pinion protector 20. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21 21. Tie rod end
IO. Pressure pad Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page N-22
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page
N-21
N-19