boot MAZDA PROTEGE 1992 Owner's Manual

SHIFT MECHANISM
1. Change lever knob
2. Rear console
3. Front console
4. Boot
5. Nut
6. Washer
7. Bolt
8. Cover
9. Nut
10. Washer
11. Bushing
12. Spring
Inspect for damage and weaked
Assembly note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-47
13. Change lever
14. Ball seat (Upper)
15. Boot
Inspect for wear or damage 16. Holder
17. Ball seat (lower)
18. Nut
19. Washer
20. Pipe
21. Bushing
Inspect for wear or damage
22. Washer
23. Extension bar
Assembly note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-47
24. Insulator
Inspect for damage and cracks
25. Nut
26. Bolt
27. Bushing
Inspect for wear and damage
28. Change control rod
Inspect for bending
03UOJ2-109
CHAGE CONT
03UOJ2-111
Assembly Note
Extension bar
1. Connect the extension bar to the transaxle, and then mount
it to the floor.
Tightening torque:
16-23 N+m (1.6-2.3 m-kg, 12-17 ft-lb)
Spring
1. Verify that the hooked part of the spring is properly seated
in the bracket groove.
J2-47

OUTLINE, TROUBLESHOOTING GUIDE M
OUTLINE
SPECIFICATIONS
Engine/Transaxle
86 SOHC
I BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX
Front axle
Bearing play axial direction Rear axle
Bearina olav axial direction I
mm (in) 0.05 (0.002)
mm (in) I 0.05 (0.002) Drive shaft
j Inside Tripod ioint
I Joint type I -
Outside I Ball ioint 1
Right side 919.3 (36.19)
918.7 (36.17) 630.7 (24.83)
Length of shaft
mm (in)
Left side 637.8 (25.11)
640.2 (25.20) 621.2 637.1
(24.46) (25.08)
Shaft diameter mm (in) Right side 21.5 (0.85) 23.0 (0.91)
Left side
21.5 (0.85)
23.0 (0.91)
23UOMX-003
TROUBLESHOOTING GUIDE
FRONT AXLE Problem
Steering wheel
vibration
Steering wheel pulls
or one-sided braking
Excessive steering
wheel play
Abnormal noise
Grease leakage from
boot Possible Cause Action
Worn or damaged wheel bearing
Excessive wheel bearing play
Worn or damaged wheel bearing
Excessive wheel bearing play
Excessive wheel bearing play Replace
Tighten or replace
Replace
Tighten or replace
Tighten or replace
Bent drive shaft or joint shaft
Worn or damaged wheel bearing
Worn drive shaft or joint shaft splines
Insufficient grease in joint or on splines of drive shaft
insufficient grease in joint or splines of joint shaft
Nom drive shaft tripod joint Replace
Replace
Replace
Replenish or replace
Add or replace
Replace
Damaged or broken boot
Faulty boot band
Excessive grease Replace
Replace
Reoair Page M- 7
M- 5,7
M- 7
M- 5,7
M- 57
M-18, 22
M- 7
M-18, 22
M-22, 25
M-18
M-25
M-25
M-25
M-25
23UOMX-004
REAR AXLE Problem Possible Cause Action Page
Steering wheel
Worn or damaged wheel bearing
Replace M-11, 14 vibration
Excessive wheel bearing play Tighten or replace M-11, 14 Steering wheel pulls
Worn or damaged wheel bearing Replace M-11, 14 or one-sided braking Excessive wheel bearing play Tighten or replace M-11, 14 Excessive steering
Excessive wheel bearing play Tighten or replace M-11, 14 wheel olav
Abnormal noise
Worn or damaged wheel bearing Replace M-11, 14
23UOMX-005
M-3

M FRONT AXLE
23UOMX-0:
Removal note
Tie rod end
Caution
l Do not damage the dust boot.
1. Loosen the nut and disconnect the tie-rod end with the SST.
Installation note
Tie rod end
Caution
l Do not damage the dust boot.
1. Install the nut and secure it with the new cotter pin.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
Locknut
1, Install a new locknut and stake it, as shown.
Tightening torque:
235-319 Nnrn (24.0-32.5 m-kg, 174-235 ft-lb)
03UOMX-010
M-6

DRIVE SHAFT M
r
I
23UOMX-039
03UOMX-030
I
03UOMX-03
ii I I
23UOMX-04
03UOMX-03
Removal note
Tie rod end
Caution
l Do not damage the dust boot.
1. Loosen the nut and disconnect the tie rod end with the SST.
Joint shaft
Caution
l Do not damage the oil seal.
1. Remove the joint shaft.
Installation note
Joint shaft
Caution
l Do not damage the oil seal.
1. Install the joint shaft.
2. Tighten the bolts in the order shown.
Tightening torque:
42-62 N*m (4.3-6.3 m-kg, 31-46 ft-lb)
Tie rod end
Caution
l Do not damage the dust boot.
1. Install the nut and secure it with the new cotter pin.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
Stabilizer
1. Install the stabilizer bolt.
Dimension A: 17-19mm (0.67-0.75 in)
M-19

DRIVE SHAFT M
23UOMX-02,
I
23UOMX
Assembly procedure
1. Install the new Right dust seal with the SST.
2. Install the new bearing with the SST.
3. Install the new Left dust seal with the SST.
4. Install the joint shaft with the SST.
5. Install the new clip.
DRIVE SHAFT (TRIPOD JOINT)
Preinspection
Drive shaft
1. Check the dust boot on the drive shaft for cracks, damage,
leaking grease, and a loose boot band.
2. Check the drive shaft for bending, cracks, and wear of joints
or splines.
3. Repair or replace the drive shaft if necessary.
M-21

DRIVE SHAFT M
23UOMX-04
23UOMX-02
I
23UOMX-02
/
I
23UOMX-029
23UOMX-04
Removal note
Tie rod end
Caution
l Do not damage the dust boot.
1. Loosen the nut and disconnect the tie rod end with the SST.
Drive shaft
Caution
l Do not damage the dust cover or oil seal.
1. Remove the drive shaft from the transaxle with a pry bar.
Note
l If the drive shaft is stuck in the front wheel hub, in-
stall a miscellaneous nut until it is flush with the end
of the shaft. Tap the nut with a copper hammer to
remove the drive shaft.
Installation note
Drive shaft
Caution
l Do not damage the dust cover or oil seal.
1. install the drive shaft with the end-gap of clip facing upward.
Tie rod end
Caution
l Do not damage the dust boot.
1, Install the nut and secure it with the new cotter pin.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
M-23

DRIVE SHAFT M
Overhaul
Caution
l Do not remove the U-shaped bearing outer races from the outer ring. (BP SOHC Left drive shaft)
l Secure the joint in a vise with protective material (such as copper plates) on the vise jaws.
l Be careful that dust or other foreign material does not enter the joint while the work is being
performed.
l Do not disassemble the wheel-side ball joint.
l Do not wash the joint unless it is being disassembled.
1. Disassemble in the order shown in the figure, referring to Disassembly Procedure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to Assembly Procedure.
I
23UOMX-030
1. Boot band 8. Band
2. Boot band 9. Dynamic damper
3. Clip 10. Boot band
4. Outer ring 11. Boot band
Inspect inside bore for wear, corrosion, and 12. Boot
scoring 13. Shaft and ball joint assembly
5. Snap ring Inspect splines for damage and wear
6. Tripod joint Inspect wheel-side joint for excessive play
7. Boot and rough rotation
M-25

M DRIVE SHAFT
03UOMX-048
II I
O?,UOMX-04
MARKS
03UOMX-050
’ TAPE
OSUOMX-OE il
M-26
03UOMX-052
Disassembly procedure
1. Pry up the locking clips of the transaxle-side boot bands
with a screwdriver.
2. Remove the bands with pliers.
3. Slide the boot along the shaft to expose the joint.
4. Mark the outer ring and the shaft for proper reassembly.
5. Remove the stopper ring.
6. Mark the shaft and tripod joint for proper reassembly.
7. Remove the snap ring with snap-ring pliers.
Caution
l Do not damage the bearing.
8. Remove the tripod joint from the shaft with a bar and a
hammer.
9. Wrap the splines of the shaft with tape to prevent damag-
ing the boot. Remove the boot.
Caution
l Do not remove the dynamic damper if not nece-
ssary.
10. Pry up the locking clip of the band with a screwdriver.
Il. Remove the band with pliers. Remove the dynamic damper.

DRIVE SHAFT M
I
I 03UOMX-053
DIFFERENTIAL SIDE WHEEL SIDE
23UOMX-03 1
03UOMX.05
23UOMX :-032
23UOMX
Caution
l Do not remove the wheel side boot if not necessary.
12. Pry up the locking clips of the wheel-side boot bands with
a screwdriver.
13. Remove both bands with pliers. Remove the boot.
Assembly procedure
Caution
l The wheel-side and transaxle-side boots are
different.
mm (in)
I c3
80.8
I 89.0 85.2
(3.18) (3.50)
I I 94.1
(3.35) (3.70)
1. Wrap the splines of the transaxle-side shaft, and install the
wheel-side boot.
Caution
l Always use new bands.
l The bands should be mounted in the direction op-
posite the forward revolving direction of the drive
shaft.
2. Install the dynamic damper and new band.
3. Fold the band back by pulling on the end of it with pliers.
4. Lock the end of the band by bending the locking clip.
5. Install the wheel-side boot.
Caution
l Do not damage the bearing.
6. Align the marks and install the tripod joint with a bar and
a hammer.
7. Install the new snap ring with snap-ring pliers.
M-27

DRIVE SHAFT
8. Apply the specified grease included in the kit to the tripod
joint, outer ring, and boot. Install the outer ring.
9. If the wheel-side boot was removed, fill with the specified
grease included in the kit.
Specified grease
!J@z)
B6 SOHC BP SOHC BP DOHC
Right Left Right
Left Right Left
side side side side side side
DIFFEREN- 2;&y’ 140 (4.94) 145 (5.12)
TIAL SIDE y;L44;)
YELLOW YELLOW YELLOW
WHEEL SIDE 70 (2.47) 140 (4.94) 90 (3.18)
BLACK BLACK BLACK
23UOMX-03
I I
I
23UOMX-0:
M-28
Caution
l Be sure the boots are not dented or twisted.
. Carefully lift up the small end of the boots to release
any trapped air.
10. Install the boots.
11. Measure the length of the drive shaft.
Standard length: mm (in)
B6 SOHC BP SOHC BP DOHC
MTX 1 ATX MTX 1 ATX MTX 1 ATX
light side 919.3 918.7
630.7
(36.19) (36.17) (24.83)
640.2 621.2 637.1
(25.20) (24.46) (25.08)
I Left side
I 637.8
(25.11)
12. Fold the new bands back by pulling on the ends with pliers.
13. Lock the ends of the bands by bending the locking clips.