oil MAZDA PROTEGE 1992 Workshop Manual

Jl TRANSAXLE
Primary Shaft Assembly
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
23UOJl.00
1. Clutch hub
9. Clutch hub assembly (3rd/4th)
2. Synchronizer key
Assembly
Note . . . . :..I . . . . . . . . . . . . . . . . . .
page Jl-35
3. Clutch hub sleeve
10. Retaining ring
4. Synchronizer spring
11. Synchronizer ring (4th)
5. Primary shaft
Assembly
Note . . . . . . . . . ,...... . . . . . . . . . .
page Jl-35
6. Searing
12. 4th gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-35 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-35
7.3rd gear
13. Bearing
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . .
page Jl -35 Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-35
8. Synchronizer ring (3rd)
Assembly Note.. . . . . . . . . . . . . III.. . . . . . . .
page J l-35
51-34

TRANSAXLE Jl
03UOJl-07 r
I
03UOJl-07
I
W
-==f =--
03UOJl-07
03UOJl-08
03UOJ l-08
Assembly note
Bearing
1, Install the bearing with a press.
3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th)
Caution
l Apply transaxle oil to the bore of 3rd gear.
1. Turn the primary shaft over and install the 3rd gear, syn-
chronizer ring (3rd) and clutch hub assembly (3rd/4th) with
a press.
Synchronizer ring (4th), 4th gear, and bearing
1. Install the retaining ring.
2. Install the synchronizer ring (4th), 4th gear, and ball bear-
ing with a press.
3. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.06-0.21 mm (0.002-0.006 in)
Maximum : 0.26mm (0.010 in)
4. Measure the clearance between 4th gear and the ball
bearing.
Clearance: 0.21-0.61 mm (0.006-0.024 in)
Maximum: 0.66mm (0.026 in)
5. If not as specified, reassemble the primary shaft assembly.
51-35

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

TRANSAXLE Jl
Assembly note
Oil seal (Speedometer gear cace)
1. Install the new oil seal with a suitable pipe.
Pipe diameter: 15mm (0.591 in)
23UOJ I-00
03UOJl-IO
03UOJl-IO!
03UOJ1.10
Roll pin (Speedometer driven gear assembly)
1. Install the new roll pin as shown in the figure.
Oil seal (Differential)
Caution
l Apply transaxle oil to the outer circumference of the
oil seal.
1. Install the new oil seal with the SST.
Adjust shim and bearing outer race (Secondary shaft
gear)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
l Apply transaxle oil to the bearing outer race.
1. Install the adjust shim(s) and the bearing outer race with
a suitable pipe.
Adjust shim and bearing outer race (Differential)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
l Apply transaxle oil to the bearing outer race.
1, Install the adjust shim(s) and the bearing outer race with
a suitable pipe.
Jl-41

Jl TRANSAXLE
03UOJl-10
-
23UOJl.01
Adjust shim (Primary shaft gear)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
1. Apply transaxle oil to the adjust shim(s) and install it.
Funnel and bearing outer race
Caution
l Apply transaxle oil to the bearing outer race.
1. Install the funnel and the bearing outer race.
Oil seal (Primary shaft gear)
Caution
* Apply transaxle oil to outer circumference of the oil
seal.
1. install the new oil seal with a suitable pipe.
Oil seal (Change rod)
Caution
l Apply transaxle oil to the oil seal lip.
1. Install the oil seal.
Boot and change rod assembly
Caution
l Install the boot with the air bleed downward as
shown in the figure.
1. Slide the boot onto the change rod assembly.
2. Install the change rod assembly into the clutch housing.
-,
Jl-42

/ cm-kg, -26-52 In-lb)
(3.8-5.3, 27-M)
Jl TRANSAXLE
INSTALLATION
1. Raise the vehicle and support it with safety stands.
2 Install in the order shown in the figure, referring to Installation Note.
3’ Add the specified amount of the specified transaxle oil. (Refer to page Jl-7.)
4: Warm up the engine and transaxle, and inspect for oil leakage and transaxle operation.
2.4-5.S N.m (30-60
9
1 8-11 N-m
o-110 cm-kg,
* h-95 In-lb)
.O,
cc.
ft-I
03UOJl-119
b)
51-48

03UOJi-12 3
03UOJl-124
L 03UOJl.126 I-
03UOJl-12
Jl TRANSAXLE
Driveshaft
Caution
l Verify that the oil seal is not damaged.
l Do not damage the oil seal
1. Insert the clip with the end-gap at the top of the groove.
2. Apply transaxle oil around the oil seal lip. Install the
driveshaft.
3. Verify that the driveshaft is correctly seated by pulling on
the shaft.
4. Connect the lower arm to the knuckle and tighten the clinch
bolt.
Tightening torque:
43-59 N-m (4.4-6.0 m-kg, 32-43 ft-lb)
Stabilizer (BP SOHC)
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension A: 17-l 9mm (0.67-0.75 in)
Tie-rod end
1. Install the locknut.
Tightening torque:
42-57 N-m (4.3-5.6 m-kg, 31-42 ft-lb)
2. Secure the locknut with a new cotter pin.
Engine mounting member
1. Install the bolts and nuts as shown.
Tightening torque
@ : 37-52 N,m (3.6-5.3 m-kg, 27-36 ft-lb)
@I: 64-89 N-m (6.5-9.1 m-kg, 47-66 ft-lb)
51-50

TRANSAXLE Jl
03UOJl-12!
03UOJi-13
2. Tighten engine mount No.4 nuts.
Tightening torque:
67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)
3. Remove the SST (Engine support).
Control rod and extension bar
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 Nern (3.2-4.7 m-kg, 23-34 ft-lb)
2. Install the change control rod to the transaxle.
Tightening torque:
16-23 N*m (1.6-2.3 m-kg, 12-17 ft-lb)
Ground
1. Connect the ground to the clutch pipe bracket.
Tightening torque:
16-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Speedometer cable
1. Add the specified oil through the speedometer gear case
mounting. (Refer to page Jl-7.)
2. Install the speedometer driven gear.
Tightening torque:
7.6-l 2 N*m (60-120 cm-kg, 69-104 in-lb)
3. Connect the speedometer cable to the speedometer driv-
en gear.
J141

J2
MANUAL TRANSAXLE
(G5M-R)
INDEX .....................................................
J2- 2
OUTLINE
................................................
J2- 3
SPECIFICATIONS
................................... J2- 3
STRUCTURAL VIEW ...............................
J2- 4
POWER FLOW
......................................
J2- 5
TROUBLESHOOTING
GUIDE.. ................... J2- 6
TRANSAXLE OIL .....................................
J2- 7
INSPECTION
.........................................
J2- 7
REPLACEMENT .....................................
J2- 7
TRANSAXLE
...........................................
J2- 6
PREPARATION ......................................
J2- 6
REMOVAL
............................................
J2-10
DISASSEMBLY
......................................
52-l 2
INSPECTION .........................................
J2-22
ASSEMBLY
...........................................
J2-26
INSTALLATION
......................................
J2-41
DIFFERENTIAL
........................................
J2-43
PREPARATION
......................................
52-43
DISASSEMBLY / INSPECTION I ASSEMBLY J2-44
SHIFT MECHANISM
.................................
52-46
OVERHAUL
..........................................
52-46
03UOJ2-001

J2 INDEX
IN
new IYLA
BACK-lx LIU, 1, w.., 1 vm q
SERVICE, SECTION
F
k’c’ 1T6AL SWITCH 8.L”
SERI /ICE, SECTION T VISCOSITY: ALL-SEASON ATF DEXRON-II,
M2C33F OR SAE75W-80
ABOVE -18% (OOF) API SERVICE
GL-4 SAE80W-90
CAPACITY: 3.35 liters (3.55 US at. 2.98 ho 41)
1. Transaxle
Removal ..,.....,.,..,....,..,.........,.... page J2-10
Disassembly ,., ,..,., . ,,...., ,.. .., .., page J2-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
Assembly . . . . . . . . . ,.,...................... page J2-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-41
52-2
2. Differential
Disassembly / Inspection I
Assembly ,..,.,.,, ,_, ,. .,. ,_. ,_. . . . page J2-44
3. Shift mechanism
Overhaul ,....,.......,..... ,........, . . . . . . page J2-46
4. Transaxle oil
inspection . . . . . . . . ..,........I....I.,..... page J2- 7
Replacement .,.,.., ,.,...,...,.. . . . . . . . . . page J2- 7 .___I’