oil MAZDA PROTEGE 1992 Workshop Manual

OUTLINE J2
OUTLINE
SPECIFICATIONS
Item
Transaxle control
Synchromesh system EnginelTransaxle
BP DOHC
GSM-R Floor shift
Forward: Synchromesh
Reverse: Selective sliding and synchromesh
T- I-
Gear ratio
I
1 st 3.307
2nd 1.833
3rd 1.310
4th 1.030
5th 0.795
Reverse 3.166
Final gear ratio 4.105
q
Oil Viscosity All-season
Above -18OC (OOF) ATF DexronYI, M2C33F or SAE75W-80
API service GL-4 SAE80W-90
Capacity liters (US qt, Imp qt) 3.35 (3.55, 2.96)
23UOJ2-001
52-3

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 OIL 52
03UOJ2-00’
03UOJ2-008
03UOJ2-00
1 9
23UOJ2-002
TRANSAXLE OIL
INSPECTION
Note
l Park the vehicle on level ground.
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Verify that the oil level is between F and L.
3. Install the speedometer driven gear.
Tightening torque:
7.8-12 Nmrn (80-120 cm-kg, 89-104 in-lb)
4. Connect the speedometer cable.
REPLACEMENT
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Remove the drain plug and washer. Drain the oil into a suit-
able container.
3. Install a new washer and the drain plug.
Tightening torque:
39-59 N*m (4.0-8.0 m-kg, 29-43 ft-lb)
4. Add the necessary amount of the specified oil through the
speedometer gear case hole.
Specified oil
Viscosity: All-season ATF Dexron@lI, M2C33F or
SAE75W-80
Above -18*C (O*F) API service GL-4
SAE 8OW-90
Capacity: 3.35 liters (3.55 US qt, 2.96 Imp qt)
5. Verify the oil level.
6. Install the speedometer driven gear and connect the
speedometer cable.
03UOJ2-011
J2-7

J2 TRANSAXLE
TRANSAXLE
PREPARATION
SST
19 GO17 5A0
removal of tie-rod
disassembly and
49 GO30 440
Holder, primary
shaft Remover, bearing
49 8001 795
‘nstaller, oil seal installation of oil
$9 GO30 370
49 F401 366A
Plate
(Part of
49 GO17 1AO) For
removal of
bearing inner
race 49 8092 373
Attachment G
(Part of
49 GO1 7
1 AO) For
removal of
bearing inner
race
49 8092 374
Attachment H
(Part of
49 GO17 1AO) For
removal of
bearing inner
race 49 0839 425C
Puller set,
bearing
49 F401 3308
Installer set,
bearing
-- For
installation of
bearing 49 F401 331
For
installation of
Body bearing inner
(Part of race
49 F401 3308)
J2-8

J2 TRANSAXLE
REMOVAL
1. Disconnect the negative battery cable.
2. Raise the vehicle and support it with safety stands.
3. Drain the transaxle oil into a suitable container.
4. Remove in the order shown in the figure, referring to Removal Note.
I
03UOJ2-0
52-l 0

TRANSAXLE J2
Clutch Housing and Transaxle Case Components
Caution
l Do not remove an oil seal if not necessary.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
ACE
1. Bearing outer race (Primary shaft) 19. Oil seal (differential)
2. Oil seal Replacement (On-vehicle) . . . . . . . . . page J2-16
3. Bearing outer race (Secondary shaft) 20. Bearing outer race (differential)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16 Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16
4. Funnel 21. Reverse lever shaft
5. Guide plate 22. Reverse lever
6. Change arm 23. Drain plug and washer
7. Roll pin 24. Neutral switch and gasket
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16 25. Bearing outer race (transaxle case)
8. Change rod assembly Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16
9. Boot 26. Diaphragm spring
10. Spring 27. Adjust shim
11. Reverse gate 28. Bearing outer race (differential)
12. Selector Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16
13. Oil seal 29. Adjust shim(s)
14. Bleeder cover 30. Oil seal (differential)
15. Bleeder Replacement (On-vehicle) . . . . . . . . . page J2-16
16. Speedometer driven gear assembly 31. Back-up light switch
Inspection ..,.,,.,......,................... page J2-24 32. Oil passage
17. Driven gear 33. Joint
18. Gear case 34. Change rod
52-l 5

J2 TRANSAXLE
J2-16
BEARING OUTE
23UOJ2-00
86U07A-04
03UOJ2-02
23UOJ2-OC
Disassembly note
Bearing outer race (transaxle case)
Note
l Since removing the bearing outer race is difficult,
use the SST.
1. Remove the bearing outer race.
Bearing outer race (secondary shaft)
1. Remove the bearing outer race by lifting out the funnel and
race together.
Roll pin
1. Align the groove for removal of the clutch housing pin with
the position of the roll pin, then tap the pin out using a pin
punch.
Bearing outer race (differential)
Caution
l Hold the SST with one hand so that it does not fall.
1. Remove the bearing outer race with a press.
Oil seal (differential)
Replacement (On-vehicle)
Jack up the vehicle and support it with safety stands. Drain
the transaxle oil. Next, use the following procedure to replace
the driveshaft oil seal:
1. Remove the front wheel.
2. Remove the splash shield.
3. Separate the front stabilizer from the lower arm.

TRANSAXLE
03UOJ2-02
03UOJ2-0:
I IO
03UOJ2-031
1
03UOJ2-121
Caution
l Do not damage the dust boots.
4. Remove the clinch bolt and pull the lower arm downward.
Separate the knuckle from the lower arm ball joint.
5. Loosen the nut and disconnect the tie-rod end with the
SST.
Caution
l Do not subject the tripod joint to shock when remov-
ing the driveshaft.
6. Disconnect the driveshaft from the transaxle by prying with
a bar between the outer ring and the transaxle.
7. Suspend the driveshaft with a rope.
8. Remove the oil seal with a screwdriver.
Note
l Tap in until the oil seal installer contacts the case.
l Coat the oil seal lip with transaxle oil.
9. Tap the new oil seal into the transaxle case with the SST.
10. Replace the driveshaft end clip with a new one. Insert the
driveshaft with the end-gap of the clip facing upward.
I I
I 03UOJ2-032
J2-17

TRANSAXLE 52
I I
13UOJ2.006
03UOJ2-114
, 03UOJ2-115
BE Tt
03UOJ2-047
03UOJ2-04 6
4. Measure the clearance between hub sleeve and shift fork.
Clearance mm (in)
I I Standard
I Maximum
I
I l&end I 0.08-0.228 (0.003-0.009~ I 0.728 (0.029) I
3rd14th 0.1 O-0.500 (0.004-0.020) 1.000 (0.039)
5thlRev. 0.15-0.458 (0.059-0.018) 0.958 (0.038)
Reverse idler gear and reverse lever
1. Inspect gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bush-
ing and the reverse lever.
Standard clearance:
0.1 O-0.32mm (0.004-0.013 In)
Maximum: 0.5mm (0.020 in)
Bearing
1. Inspect for damage and rough rotation.
Primary Shaft and Secondary Shaft
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for clogging.
5. Inspect the shaft gears’ runout.
Primary shaft gear runout: 0.05mm (0.002 in)
Secondary shaft gear runout: 0.015mm (0.0006 in)
Note
l If the shaft gear is replaced, adjust the bearing
preload. (Refer to page J2-32.)
J2-23

J2 TRANSAXLE
4TH
3RD
23UOJ2-015
2ND 1ST
03UOJ2-049
6. Oil clearance between shaft gears and gears.
Oil Clearance
Shaft Gear Sleeve
(Outer dia.) (inner dia.) (Outer dia.) Oil 'learanCe
1st 39.445-39.470 39.500-39.525 _
(1.553-1.554) (1.555-1.556)
2nd 34.945-34.970 35.000-35.025 _
(1.376-1.377) (1.378-1.379)
3rd 35.945-35.970 36.000-36.025 0.03-0.08
_
(1.415-1.416) (1.417-1.418) (0.001-0.003)
4th 30.945-30.970 31.000-31.025 _
(1.218-1.219) (1.220-1.221)
34.000-34.025
33.945-33.970
1 5th
-
(1.339-1.340) (1.336-1.337)
/
Speedometer Driven Gear Assembly
1. Inspect the teeth for damage and wear.
2. inspect the O-ring for damage and wear. mm (in)
_......
52-24