differential MAZDA PROTEGE 1992 User Guide

Jl TRANSAXLE
51-38
03UOJ l-08!
RACE
OWOJ i-09
ONJOJl-09 , _.
03UOJ I-09
Example: 0.22mm (0.009 in)
0.22mm (0.009 in) + 0.03mm (0.001 in)
= 0.25mm (0.010 in)
0.22mm (0.009 in) + 0.08mm (0.003 in)
= 0.30mm (0.012 in)
Range: 0.25mm (0.010 in)-0.30mm (0.012 in)
Select the 0.30mm (0.012 in).
Adjustment shim thickness:
mm (in)
0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.012)
0.35 (0.014) 0.40 (0.016) 0.45 (0.018) 0.50 (0.020)
93GOJ I-524
Differential
1. Install the bearing outer race into the clutch housing.
2. Set the differential assembly into the clutch housing.
Note
l Turn A and B until the gap shown in the figure is
eliminated.
3. Install the transaxle case side bearing outer race to the SST
(selector).
4. Set the
SST (collars) in the positions shown in the figure.
5. Tighten the
SST (bolts) to the specified torque.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)

TRANSAXLE Jl
03UOJl-09:
03UOJi-09
03UOJl-09
03UOJl-09
03UOJl-0:
Note
l Turn the bars until the SST (selector) can no longer
be moved.
6. To seat the bearings, mount the bars on parts @ and @I
of the selector, and turn the selector so the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.
8. Install the
SST to the differential pinion gear through the
transaxle case.
9. Turn the
SST with a torque wrench. Adjust the SST (selec-
tor) with the bars until the specified preload is obtained.
Preload:
0.03-0.74 N#m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
10. Remove the SST.
11. Measure the clearance around the entire circumference of
the
SST (selector).
12. Select the proper adjust shim(s) to be used for the differen-
tial by referring to the table and selecting the shim which
is nearest (on the thick side) to the largest measured clear-
ance in the selector.
Adjust shim thickness:
0.20 (0.008)
0.25 (0.010)
0.40 (0.016)
0.45 (0.018) mm (in)
0.30 (0.012) 0.35 (0.014)
0.50 (0.020) 0.55 (0.022)
13. Remove the SST (bolts).
14. Remove the transaxle case and the
SST (collars).
Jl-39

Jl TRANSAXLE
,
,,
03UOJi-09
03UOJl-10
Jl-40
OSUOJl-1C
15. Remove the bearing outer race from the SST (selector).
16. install the selected shim(s) and bearing outer race to the
transaxle case.
-’
Bearing preload (Differential)
Measure the preload as follows.
1. Set the differential assembly into the clutch housing.
2. Install the transaxle case onto the clutch housing.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
3. Install the SST to the differential side gear through the trans-
axle case.
4. Measure the bearing preload.
Preload:
0.03-0.74 N,m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
5. If not as specified, readjust the bearing preload.
6. Remove the SST.
7. Remove the transaxle case and differential assembly.

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

TRANSAXLE Jl
1. Control rod
2. Control end
3. lstl2nd shift fork
4. Control lever
5. Interlock sleeve
6.3rd/4th shift fork
7. Clutch hub
8. Synchronizer key
9. Clutch hub sleeve
10. Synchronizer spring
11. Clutch housing
12. Differential assembly
13. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-45
14. Primary shaft gear assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . , . page J 1-45
15. Spring
16. Steel ball
17. Shift fork and shift rod assembly
Assembly Note.. . . . . . . . . . . , . . . . . . . . . , . . , page J 1-45
18. Crank lever assembly
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
19. Crank lever shaft
Assembly Note.. . . . . . . . . . . , , . . . . . . . . . . . . page Jl -46
20. Pin
21. 5th shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page 31-46
22. 5th shift rod
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-46
23. Reverse idler gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
24. Reverse idler shaft
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . page Jl -46
25 Magnet
26. Transaxle case assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl -47
27. Neutral switch
28. Back-up light switch
29. Lock bolt and washer
30. Secondary 5th gear
31. Gear sleeve
32. 5th gear
33. Synchronizer ring (5th)
34. Clutch hub assembly (5th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
35. 5th shift fork
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
36. Stop plate
37. Locknut (Secondary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
38. Locknut (Primary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-47
39. Rear cover
13UOJl-005
Assembly note
Primary shaft gear assembly and secondary shaft gear
assembly
1. Install the primary shaft gear assembly and the secondary
shaft gear assembly together.
03UOJl-115 Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
03UOJ2-088
51-45

Jl DIFFERENTIAL
DIFFERENTIAL
PREPARATION
SST
49 B017 1AO
Remover set,
bearing
49 8092 371
Attachment E
(Part of
49 8017 1AO)
49 F401 3308
Installer set,
bearing
49 F401 337A
Attachment C
(Part of
49 F401 3308) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
For
installation of
bearing 49 F401 366A
Plate
(Part of
49 8017 1AO)
49 0839 42%
Puller set,
bearing
49 F401 331
Body
(Part of
49 F401 3309) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
03UOJl-13 .-,
5142

DIFFERENTIAL Jl
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove the inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Preinspection.
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. Measure the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin 7. Side bearing inner race
13UOJl-00:
Assembly Note .......................... page Jl -55 Disassembly Note.. ..................
2. Pinion shaft Inspection .................................
3. Thrust washer Assembly Note .........................
4. Pinion gear 8. Speedometer drive gear
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 9. Side bearing inner race
Inspection of backlash.. ............ page Jl-55 Disassembly Note.. ..................
5. Side gear Inspection .................................
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 10. Ring gear and ring case
Inspection of backlash.. ............ page Jl-55 Inspection .................................
6. Thrust washer
03UOJl-13 4
page Jl-54
page Jl -54
page Jl-55
page Jl -55
page Jl-54
page Jl-54
page Jl-55
page Jl-54
Preinspection
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-
sem bly.
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)
51-53

Jl DIFFERENTIAL
4. If the backlash exceeds specification, adjust by selecting
and installing thrust washers between the case and the side
gears.
Caution
l Use thrust washers with the same thickness on each
side.
-.
Thrust washer thickness: mm (in)
1 2.0 (0.079) 2.1 (0.083) 2.2 (0.087) 23UOJl-012
03UOJ2-10
1 03UOJ2-104
03UOJl-13
Jl-54
03UOJl-1: 6
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)
Note
l Use pads in the vise.
1. Remove the bearing inner race with the SST.
Inspection
Inspect all parts and repair or replace as necessary.
Ring gear and ring case
Note
l If the gear case is replaced, adjust the bearing
preload.
1. Inspect the ring gear for wear and cracks.
Bearing inner race
Note
l When replacing the bearing inner race, replace the
bearing outer race and inner race as a set.
l If the bearing is replaced, adjust the bearing
preload.
1. Inspect for wear and rough rotation. --

DIFFERENTIAL Jl
03UOJl-138
Assembly Note
Speedometer drive gear
1. Install the speedometer drive gear as shown in the figure.
1
03UOJl-13!
I
03UOJ2-10
I
03UOJl-14
I 03UOJl-14 .l
Side bearing inner race (Side opposite ring 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.
Roll pin
1, Install the new roll pin as shown in the figure to hold the
pinion shaft.
Backlash of Side Gear and Pinion Gear
Measure the backlash by the following procedure.
1. Install the driveshafts in the differential assembly.
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, select the proper thrust washers.
(Refer to preinspection, page Jl-53.)
Jl-55

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