key MAZDA PROTEGE 1992 User Guide

Jl TRANSAXLE
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
0 REPLACE-
/
1. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
2. Secondary 4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
3. Retaining ring
4. Secondary 3rd gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
5.2nd gear
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (2nd)
Inspection.. . . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . . page J l-27
7. Retaining ring
8. Clutch hub assembly (lst/2nd)
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-29 9. Synchronizer ring (1 st)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. ,,..... . . . . . . . . . . . . . . . . . . . . . . . . . page J l-27
10. 1st gear
Disassembly Note ..,..,,.,,,....,..,.. page Jl-25
Inspection ..,................,.............. page J l-29
11. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . , . . . . page Jl -26
12. Secondary shaft
Inspection., , , . , . , . . , , . . . . . . . . , . , . . . . . , . . . . . page J l-28
13. Synchronizer spring
14. Clutch hub sleeve
15. Synchronizer key
16. Clutch hub
Jl-24

TRANSAXLE
1ST 2ND
03UOJl-06 03UOJl-06
9MUOJX-05
03UOJl-05
1st Gear and 2nd Gear
1. Measure the clearance between the shaft gears and the
gears.
Oil Clearance mm (in)
Shaft (A) Gear (B) Sleeve (C) Oil (D)
(outer diameter) (inner diameter) (outer diameter)
Clearance
39.45-39.47 39.50-39.52 03 =(B)-(A)
’ st Gear (1.553-l 554) (1,555-l ,556) - 0.03-0.07
(0.001-0.003)
35.15-35.17 35.20-35.22 PI = (B)-(A)
2nd Gear (1.384-I ,385) (1,386-l ,387) - 0.03-0.07
(0.001-0.003)
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
Clutch hub assembly
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the individual gear teeth for damage, wear, and
cracks.
3. Inspect the synchronizer key for damage, wear, and cracks.
4. Measure the clearance between the hub sleeve and the shift
fork.
mm (in)
1 stMnd Standard clearance
0.1 O-O.36
(0.004-0.014) Maximum
0.86 (0.034)
I 3rd14th
I 0.20-0.50
(0.008-0.020)
I 1 .oo (0.039)
I
5th 0.40-0.75
(0.016-0.030) 1.25 (0.049)
51-29

Jl TRANSAXLE
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. Verify that all parts are completely clean before assembly.
3. Assemble parts within 10 minutes after applying sealant.
Allow all sealant to cure at least 30 minutes after assembly before filling the transaxle with transaxle oil.
4. The bearing outer race and bearing inner race must be replaced as a unit.
03UOJl-063
OBUOJl-06
-.--___
l-----o1
r-o-i
q----j H
I4
OBUOJI-065
03UOJl-06
SYNCHRONIZER RING
CLUTCH HUB SLEEVE

SYNCHRONIZER KEY 6
I
03UOJ l-067
51-30
Clutch hub assembly
Note
l Synchronizer ring diameters are as follows.
1st and 2nd
3rd and 4th
5th mm (in)
61.7 (2.429)
61.7 (2.429)
49.7 (1.957)
l Synchronizer key dimensions are as follows.
mm (in)
0 0
0
1 stl2nd 19.00 (0.748)
4.25 (0.167) 5.00 (0.197)
3rdl4th 17.00 (0.669)
4.25 (0.167) 5.00 (0.197)
5th
17.00 (0.669) 5.55 (0.219)
5.00 (0.197)
1. Install the synchronizer key springs in the clutch hub with
the hooks in the grooves to hold the three synchronizer keys
in place.
2. Align the synchronizer ring grooves with the synchronizer
key during assembly.

TRANSAXLE Jl
Secondary Shaft Assembly
1. Assemble in the order shown in the figure, referring to Assembly Note.
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
6 REPLACE=
P
10. Retaining ring
11. Synchronizer ring (2nd) 1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Secondary shaft
6, Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
7. 1st gear
Assembly Note.., . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
8. Synchronizer ring (1st)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J l-32
9. Clutch hub assembly (lst/2nd)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
23UOJl-00
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
12.2nd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
13. Secondary 3rd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
14. Retaining ring
15. Secondary 4th gear
Assembly Note ,......................... page Jl-32
16. Bearing inner race
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . page Jl -32
Jl-31

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
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

J2 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Shift lever won’t shift
Seized shift lever ball Replace J2-46
smoothly or is hard Seized change control rod joint Replace JZ-46
to shift Bent change control rod Replace J2-46
Too much play in Worn change control rod bushing Replace J2-46
shift lever Weak shift lever ball spring Replace J2-46
Worn shift lever ball bushing Replace J2-46
Difficult to shift Bent change control rod Replace J2-46
No grease in transaxle control Lubricate with grease J2-46
Insufficient oil Add oil J2- 7
Deterioration of oil quality Replace with oil of J2- 7
specified quality
Wear or play of shift fork or shift rod Replace J2-13
Worn synchronizer ring Replace J2-18
Worn synchronizer cone of gear Replace J2-18
Bad contact of synchronizer ring and cone of gear Replace J2-18
Excessive longitudinal play of gears Replace J2-18
Worn bearing Replace J2-18
Worn synchronizer key spring
Replace J2-18
Excessive primary shaft gear bearing preload Adjust J2-32
Improperly adjusted change guide plate
Adjust J2-15
Won’t stay in gear Bent change control rod Replace J2-46
Worn change control rod bushing Replace J2-46
Weak shift lever ball spring Replace J2-46
Improperly installed extension bar Tighten J2-46
Worn shift fork Replace J2-18
Worn clutch hub Replace J2-18
Worn clutch hub sleeve Replace J2-18
Worn gear sliding part of both shaft gears Replace J2-18
Worn gear sliding part of each gear Replace J2-18
Worn steel sliding groove of control end Replace J2-13
Weak spring pressing against steel ball Replace J2-13
Excessive thrust clearance Replace J2-18
Worn bearing Replace J2-18
Improperly installed engine mount
Tighten J2-41
Abnormal noise Insufficient oil Add oil J2- 7
Deterioration of oil quality
Replace J2- 7
Worn bearing Adjust or replace J2-18
Worn sliding surfaces of gears or shafts Replace J2-18
Excessive gear backlash Replace J2-18
Damaged gear teeth Replace with oil of J2-18
specified quality
Foreign material in gears Replace J2-18
Damaged differential gear or excessive backlash Adjust or replace J2-44
J2-6

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

52 TRANSAXLE
INSPECTION
Inspect all parts and repair or replace as necessary.
05UOJX-023
-’
03UOJ2-04
I
-
03UOJ2-11
13UOJ2-00
9MUOJX-05
52-22
Gears
1. Inspect synchronizer cones for wear.
2. Inspect individual gear teeth for damage, wear, and cracks.
3. Inspect synchronizer ring matching teeth for damage and
wear.
Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear,
and cracks.
2. Inspect taper surface for wear and cracks.
Note
l Set the synchronizer ring squarely in the gear; then
measure around the circumference.
3. Measure the clearance between the synchronizer ring and
flank surface of the gear.
Standard clearance: 1.5mm (0.059 in)
Minimum: 0.8mm (0.032 in)
Clutch hub assembly
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the individual gear teeth for damage, wear, and
cracks,
3. Inspect the synchronizer key for damage, wear, and cracks.

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