oil MAZDA PROTEGE 1992 Workshop Manual

J2 TRANSAXLE
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. The bearing outer race and bearing inner race must be replaced as a unit.
3. Before assembly, make sure all parts are completely clean.
4. Assemble the 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.
Primary Shaft Assembly and Secondary Shaft Assembly
1. Assemble in the order shown in the figure, referring to Assembly Note.
1
1
OIL GROOVE
(FOUR PLACESj==z
L
J2-26

TRANSAXLE J2
Clutch Housing and Transaxle Case Components
1. Select the adjust shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the figure, referring to Assembly Note.
3. Verify that the bearing preload is satisfied after assembly, referring to Bearing Preload.
-s
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS EXCEPT SWITCHES
&II N.m (SO-110 cm-kg, SO-95 In-lb)
20-29
P-3,
@NEW=
O-RING, I
14-22) 11
R N.m (120-160 cm-kg,
104-l 39 in-lb)
A
=SELECTlVE ROLL PIN NE
(120-140 cm-kg,
SELECTIVE 20-29 (2-3, 14-22)
N.m (m-kg,
??I 1
1. Change rod 16. Oil seal
2. Joint
3. Oil passage
4. Back-up light switch
5. Oil seal
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
6. Adjust shim(s)
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
7. Bearing outer race
8. Adjust shims
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
9. Diaphragm springs
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
17. Gear case
18. Driven gear
19. Speedometer driven gear assembly
20. Bleeder
21. Bleeder cover assembly
22. Oil seal
23. Selector
24. Reverse gate
25. Spring
26. Boot
Assembly Note ,.,....................... page J2-35
27. Change rod assembly
28. Roll pin
10. Bearing outer races
11. Neutral switch and gasket
12. Drain plug and washer
13. Reverse lever
14. Reverse lever shaft
15. Bearing outer race 29. Change arm
30. Guide plate
31, Funnel
32. Bearing outer race
33. Oil seal
34. Bearing outer race
J2-31

TRANSAXLE
i
03UOJ2-078
-
Thickness
0.10 (0.004)
0.20 (0.008)
0.25 (0.010)
0.30 (0.012)
0.35 (0.014)
0.40 (0.016)
0.45 (0.018)
050 (0020)
0.55 (0.022)
0 60 (0.024)
0.65 (0.026)
03UOJZO7 mm (in)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
1.00 (0.039)
1.05 (0.041)
1.10 (0.043)
1.15 (0.045)
1.20 (0.047)
03UOJ2-081
, T/RAkiXiE /CA/SE/////,///
BEARING OUTER RACE
,ADJUSTMENT SHIM
__________
po3u0J2-08i
Caution
l Measure the gap around the entire circumference
of the selector
13. Use a feeler gauge to measure the gap in the selector for
the differential.
14. Add 0.15mm (0.0059 in) to the measured clearance and
select the combination of shims closest in value to that meas-
urement.
Note
l Use a maximum of two shims.
See the table below for available shim sizes.
Example: 0.32mm (0.013 in)
0.32mm (0.013 in) + 0.15mm (0.006 in) = 0.47mm
(0.019 in).
So the nearest shim (on the thick side) to 0.47mm
(0.019 in) is 0.50mm (0.020 in).
15. Remove the SST and the transaxle case.
16. Remove the selectors, the primary shaft assembly and the
-differential.
17. Remove the bearing outer races.
Assembly note
Oil seals
1. Apply transaxle oil to outer periphery.
2. Install the new oil seals with the SST.
Diaphragm spring
1. Install the diaphragm spring as shown in the figure.
Boot
1. Install the boot with the drain hole facing downward.
03UOJ2-082
J2-35

TRANSAXLE J2
ShIReverse Gear and Housing Parts
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
37-52 (3.8-8.3, 27-38)
, .-- 104-122 in-lb)
H50-210 cm-ka NEW
O/NEW 8 iN m ’ --13OL-i82 in-@
@mI - *
(80-l 15 Cm-kg,
NEW 89-l 00 In-lb)
128-198
(13-20, 94-145)
1. Differential assembly
2. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
3. Primary shaft gear assembly
6. Shift fork and shift rod assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Assembly
J2-38
7. Crank lever assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly page
Note . . . . . . . . . . . . . . . . . . . . . J2-38
page 4. Spring
J2-38
8. Crank lever shaft 5. Steel ball
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
9. Pin
10. 5thlReverse shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-39
Il. 5th/Reverse shift rod and clip
Assembly Note . . . . . . . . . . . . . . . . . . . . . . page J2-39
12. Lock bolt
13. Reverse idler gear
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . page J2-39
14. Reverse idler shaft
Assembly Note.. . . . . . . . . . . . . . . page J2-39
15. Magnet
“J”“JL-“O)O
21. Secondary 5th gear 16. Clutch housing
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly
page J2-39
22. Gear sleeve Note . . . . . . . . . . . . . . . . . . . . . . . . . .
23. 5th gear page
24. Synchronizer ring (5th) J2-39
25. Clutch hub assembly (5thIReverse)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . page J2-39
26. 5thlReverse shift fork 17. Transaxle case assembly
Assembly Note .,........................ page J2-39
27. Roll pin Assembly
28. Secondary reverse synchronizer gear Note . . . . . . . . . . . . . . . . . . . . . . . . . .
29. Synchronizer ring (Reverse) page
30. Primary reverse synchronizer gear J2-39
31. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-40
32. Locknut 18. Lock bolt, ball and spring
Assembly
19. Guide bolt
Note.. . . . . . . . . . . . . . . . . page J2-40
33. Rear cover 20. Lock bolt
52-37

TRANSAXLE J2
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. Fill the transaxle with the specified amount of the specified transaxle oil after installation.
4. Warm up the engine and transaxle, and inspect for oil leakaae and transaxle ooeration.
37-52 (3.8-5.3, 27-38) 37-52 (3.8-5.3, 27-38)
9.8-12 (1.0-1.2, 7.2-8.7)
7.8-l 2 (0.8-l .2, 5.8-8.7)
1. Transaxle
6. Tie-rod end
2. Engine mount No.4 7. Clutch release cylinder
3. Joint shaft
8. Engine mount No.2
4. Driveshaft
9. Exhaust pipe
Installation Note
10. Engine mount member
. . . . . . . . . . . . . . . . . . . . .
page J2-42 11. Control rod
5. Stabilizer
12. Extension bar
Installation Note 13. Starter
. . . . . . . . . . . . ..______. page J2-42 14. Ground
31-48 (3.2-4. ‘8
88-l 18 (g-12,65-87)
(6.5-9.1, 47-88)
37-52 (3.8-5.3, 27-38)
N.m (m-kg, Mb)
15. Neutral switch connector
16. Back-up light switch
connector
17. Speedometer
cable
18. Battery carrier
19. Battery
20. Air hose and resonance
chamber
21. Splash shield
22. Wheel and tire
52-41

J2 TRANSAXLE
ONOJZ-09
03UOJ2-11
Installation Note
Driveshaft
Caution
l Do not damage the new oil seal.
1. Install the driveshaft with the end-gap of the new clip faC-
ing upward.
Stabilizer
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension @ : 17-19mm (0.67-0.75 in)
i-/’
J2-42

M FRONT AXLE
FRONT AXLE
PREPARATION
SST -’
.9 0118 850C
Uler, ball joint
19 8026 1AO
Uler, wheel hub
19 GO30 727
Attachment A
Part of
19 8026 1AO)
$9 F027 OAl
nstaller set,
oearing
49 F027 005
Attachment 62
(Part of
49 F027 OAl)
49 F027 009
Attachment
68 & 77
(Part of
49 F027 OAl) For
removal of tie rod
end
For
disassembly and
assembly of
wheel hub
For
removal of front
wheel hub
For
installation of
bearing
For
removal of wheel
bearing
For
installation of dust
cover 19 F026 103
qemoving plate !iiLzil
a-
l
49 GO33 102
Handle
(Part of
49 8026 IAO)
49 GO33 107
Installer, dust
cover
49 F027 003
Handle
(Part of
49 F027 OAl)
49 F027 007
Attachment 72
(Part of
49 F027 OAI)
49 VOOI 795
Installer, oil seal :or
disassembly of
vheel bearing
-01
,emoval of front
Nheel hub
-or
nstallation of dust
:over
For
removal and
installation of
wheel bearing
For
installation of
wheel bearing
For
installation of oil
seal
23UOMX-I
M-4

FRONT AXLE M
Disassembly / Inspection / Assembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to
Assembly Note.
REPLACE
1. Oil seal 5. Dust cover
Assembly Note .......................... page M-10 Disassembly Note ...................... page M- 8
2. Wheel hub assembly Assembly Note .......................... page M- 9
Disassembly Note ......................
page M- 7 6. Knuckle
Assembly Note ..........................
page M- 9 7. Hub bolt
3. Retaining ring Disassembly Note ......................
page M- 8
4. Wheel bearing Assembly Note .......................... page M- 9
Disassembly Note..
.................... page M- 8
Assembly Note .......................... page M- 9
23UOMX-00’
Disassembly note
Wheel hub assembly
1. Remove the wheel hub assembly with the SST.
M-7

M FRONT AXLE, REAR AXLE
03UOMX-0
OII seal
Caution
l Use a new oil seal, and apply grease to the lip of
the seal.
l Install the oil seal flush with the knuckle.
1. Install the new oil seal with the SST.
REAR AXLE
PREPARATION
SST
I
I
49 0259 7708 For
removal and
Wrench, flare nut
w installation of
brake pipe
23lJOMX.011
M-10

DRIVE SHAFT M
DRIVE SHAFT
PREPARATION
SST
49 HO34 2A0
Lower arm bush-
ing puller & in-
staller For
support of
bracket 49 HO34 201
49 HO34 2AO)
49 F026 102
Installer, bearing For
removal of
bearing and left
dust seal 49 GPQn
7~16 U”” I “V
Installer, oil seal For
installation of
right dust seal
and bearing
49 MOO5 795
Installer set, oil
seal For
installation of left
dust seal 49 MOO5 796
Body
(Part of
49 MOO5 795) For
installation of left
dust seal
I
23UOMX-01
49 0118 850C
Puller, ball joint For
removal of tie rod
end
M-17