wheel MAZDA PROTEGE 1992 Owner's Guide

CLUTCH UNIT
REMOVAL / INSTALLATION
Note
l Remove the clutch release cylinder with the clutch pipe connected.
l Do not remove the pilot bearing if not necessary.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
96-l 03
Kt.6-10.5. 71-761
(MOLYBDENUM SULFIDE)
N-m (m-kg, R-lb:
911 Im-4Y.fi,r
1. Clutch release cylinder
2. Transaxle
Service . . . . . . . . . . . . . . . . . . . . . . . . . ,....... Sections Jl , J2
3. Boot
4. Release bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-l 7
5. Clutch release fork
6. Clutch cover
Removal Note ..,...........,,,.........,, page H-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-l 7
Installation Note .,......................., page
H-l 7
7. Clutch disc
Removal Note ............................ page H-16
Inspection.. ................................. page H-l 7
Installation Note .......................... page H-l 7
8. Pilot bearing
Inspection ................................... page H-18
Removal Note ............................ page H-16
Installation Note.. ........................ page H-16
9. Flywheel
Removal Note ............................ page H-16
Inspection ................................... page H-18
Installation Note .......................... page H-16
H-15

H CLUTCH UNIT
/ 6fs 23UOHX-015
Removal Note
Clutch cover and disc
1. Install the SST or equivalent.
2. Loosen each bolt one turn at a time in a crisscross pattern
until spring tension is released. Then remove the clutch COV-
er and disc.
‘6
I
23UOHX-016
23UOHX-01
Pilot bearing
1. Remove the pilot bearing with the SST if necessary.
Flywheel
Note
l After removing the flywheel, inspect for oil leakage
past the crankshaft rear oil seal.
If necessary, replace the oil seal.
(Refer to Section B.) -J
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel.
Installation Note
Flywheel
1. Wipe the bolts clean and apply sealant to the bolt threads.
2. Install the flywheel and the
SST or equivalent.
3. Tighten the bolts in the pattern shown.
Tightening torque:
96-103 N,m (9.6-10.5 m-kg, 71-76 ft-lb)
Pilot bearing
Note
l Install the pilot bearing flush with the flywheel.
1. Install the new bearing with a suitable pipe.
Bearing outer diameter: 35mm (1.376 in) .-’

CLUTCH UNIT, RELEASE BEARING, CLUTCH COVER, CLUTCH DISC H
L
13UOHX-01;
03UOHX-03 8
23UOHX-018
5
03UOHX-032
03UOHX-03
Clutch disc
1. Clean the clutch disc splines and main drive gear splines;
then apply organic molybdenum sulfide grease.
2. Hold the clutch disc in position with the
SST.
Clutch cover
1. Install the SST or equivalent.
2. Align the dowel holes with the flywheel dowels.
3. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque:
18-26 Nom (1.8-2.7 m-kg, 13-20 ft-lb)
RELEASE BEARING
INSPECTION
Note
l The clutch release bearing Is a sealed bearlng and
must not be washed in solvent.
1. Turn the bearing while applying force in the axial direction.
If the bearing sticks or has excessive resistance, replace it.
CLUTCH COVER
INSPECTION
Note
l Minor scoring or burning should be removed with
emery paper.
1. Inspect the contact surface of the clutch disc for scoring,
cracks, and burning. Repair or replace as necessary.
2. Inspect the contact surface of the clutch release bearing
for wear and cracks.
If there is wear or cracks, replace the clutch cover.
CLUTCH DISC
INSPECTION
Note
l Use sandpaper if the trouble is minor.
1. Inspect the lining surface for burning and oil contamination.
Replace the clutch disc if it is badly burned or oil soaked.
2. Inspect for loose facing rivets and rubbers.
Replace the clutch disc if either is loose.
H-17

CLUTCH DISC, PILOT BEARING, FLYWHEEL
9
13UOHX-020
03UOHX-03
03UOHX-0:
3. Measure the thickness of the lining at a rivet head on both
sides with vernier calipers.
Replace the clutch disc if its thickness is less than minimum.
Thickness: 0.3mm (0.012 in) min.
4. Measure the clutch disc runout with a dial indicator.
Replace the clutch disc if runout is excessive.
Runout: 0.7mm (0.027 in) max.
PILOT BEARING
INSPECTION
1. Turn the bearing while applying force in the axial direction.
If the bearing sticks or has excessive resistance, replace it.
---
FLYWHEEL
INSPECTION
Note
l Minor scoring or burning should be removed with
emery paper.
1. Inspect the contact surface of the clutch disc for scoring,
cracks, and burning; repair or replace as necessary.
2. Inspect the ring gear teeth for wear and damage. If neces-
sary, replace the ring gear.
3. Measure the flywheel runout with a dial indicator. Replace
the flywheel if runout is excessive.
Runout: 0.2mm (0.008 in) max.

TRANSAXLE Jl
1. Wheel and tire
2. Splash shield
3. Air hose and resonance chamber
4. Battery
5. Battery carrier
6. Speedometer cable
7. Back-up light switch connector
8. Neutral switch connector
9. Ground
10. Starter
11. Extension bar
12. Control rod
13. Engine mount member
Removal Note . . . . . . . . . . . . . . . . . . . . . . 14. Exhaust pipe
15. Engine mount No.2
16. Clutch release cvlinder
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-1 1
17. Tie-rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
18. Stabilizer (BP SOHC)
19. Driveshaft
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
20. Engine mount No.4
21. Transaxle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
page Jl-11
03UOJl-012
Removal Note
Engine mount member
1. Suspend the engine with the SST and remove the engine
mount member.
03UOJ2-015 Clutch release cylinder
Caution
l Do not damage the clutch pipe.
1. Remove the bolts shown.
2. Lay aside the clutch release cylinder and the clutch pipe
when removing the transaxle.
03UOJl-013
,Jl-11

Jl TRANSAXLE
r
03UOJ2-026
03UOJl-03:
Oil seal
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.
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 inserted between the outer ring and the transaxle.
7. Suspend the driveshaft with a rope.
03UOJl-036
8. Remove the oil seal with a screwdriver.
03UOJ2-03’
03UOJi-03;
51-20
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.

TRANSAXLE Jl
1. Transaxle
Installation Note ..,......,.............. page Jl-49
2. Engine mount No.4
3. Driveshaft
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
4. Stabilizer (BP SOHC)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
5. Tie-rod end
Installation Note ,........,..,........... page Jl-50
6. Clutch release cylinder
7. Engine mount No.2
8. Exhaust pipe
9. Engine mounting member
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-50
10. Control rod
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51 11. Extension bar
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51
1 12. Starter
13. Ground
Installation Note .,..,...,......,........ page Jl-5
14. Neutral switch connector
15. Back-up light switch connector
16. Speedometer cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-5
17. Battery carrier
18. Battery
19. Air hose and resonance chamber
20. Splash shield
21. Wheel and tire 1
Installation Note
Transaxle
1. Set the transaxle on a jack and lift it into place.
Install tne transaxle oorts.
Tightening torque:
64-69 N*rn (6.5-9.1 m-kg, 47-66 ft-lb)
Loosely tighten engine mount No.4 bolts.
Jl-49

TRANSAXLE J2
1. Wheel and tire 14. Exhaust pipe
2. Splash shield 15. Engine mount No.2
3. Air hose and resonance chamber 16. Clutch release cylinder
4. Battery Removal Note .,...........,....,.,...... page J2-11
5. Battery carrier 17. Tie-rod end
6. Speedometer cable Removal Note . . . . . . . . . . . . . . . . ..*........ page J2-11
7. Back-up light switch connector 18. Stabilizer
8. Neutral switch connector 19. Driveshaft
9. Ground Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-12
10. Starter 20. Joint shaft
11. Extension bar 21. Engine mount No.4
12. Control rod 22. Transaxle
13. Engine mount member Removal Note ..,..,....*................ page J2-12
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-1 1
03UOJ2-014
-
03UOJ2-01
Removal Note
Engine mount member
1. Suspend the engine with the SST and remove the engine
mount member.
Clutch release cylinder
Caution
l Do not damage the clutch pipe.
1. Remove the bolts shown.
2. Lay aside the clutch release cylinder and the clutch pipe.
I ,
03UOJ2-016
Tie-rod end
1. Remove the cotter pin.
Caution
l Do not damage the dust boot.
2. Loosen the nut and disconnect the tie-rod end with the SST.
I I
03UOJ2-017
52-l 1

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 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