MAZDA PROTEGE 1992 Workshop Manual

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
03UOJl-07
- --
51-32
03UOJl-06!
Assembly note
Bearing inner race
1. Install the new bearing inner race with the SST.
1 st gear, synchronizer ring (1 st) and clutch hub assembly
(lst/2nd)
1. Install the 1 st gear, synchronizer ring (1 st) and clutch hub
assembly (lstl2nd) with the SST.
Synchronizer ring (2nd), 2nd gear, and secondary 3rd
gear
1. Install the synchronizer ring (2nd), 2nd gear, and secon-
dary 3rd gear with the SST.
Secondary 4th gear
1. install the secondary 4th gear with the SST.
Bearing inner race (4th gear)
1. Install the new bearing inner race with the SST.

TRANSAXLE Jl
03UOJl-07,
03UOJl-07
2. Measure the clearance between 1 st gear and the differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 in)
Maximum : 0.33mm (0.013 in)
3. Measure the clearance between 2nd gear and the secon-
dary 3rd gear.
Clearance: 0.18-0.51 mm (0.007-0.020 in)
Maximum : 0.56mm (0.022 in)
4. If not as specified, reassemble the secondary shaft as-
sembly.
51-33

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
03UOJl-07 r
I
03UOJl-07
I
W
-==f =--
03UOJl-07
03UOJl-08
03UOJ l-08
Assembly note
Bearing
1, Install the bearing with a press.
3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th)
Caution
l Apply transaxle oil to the bore of 3rd gear.
1. Turn the primary shaft over and install the 3rd gear, syn-
chronizer ring (3rd) and clutch hub assembly (3rd/4th) with
a press.
Synchronizer ring (4th), 4th gear, and bearing
1. Install the retaining ring.
2. Install the synchronizer ring (4th), 4th gear, and ball bear-
ing with a press.
3. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.06-0.21 mm (0.002-0.006 in)
Maximum : 0.26mm (0.010 in)
4. Measure the clearance between 4th gear and the ball
bearing.
Clearance: 0.21-0.61 mm (0.006-0.024 in)
Maximum: 0.66mm (0.026 in)
5. If not as specified, reassemble the primary shaft assembly.
51-35

TRANSAXLE

I
\m/ 7.8-11 N-m
1. Change
rod
2. Joint
3. Bearing outer race
4. Funnel
Assembly Note 11. Oil passage
29. Guide plate assembly
12. Oil
seal (Differential) 30.
Gear case
Assembly Note 31, Oil seal
,.................... page Jl -41 (Speedometer gear cace)
13. Transaxle case Assembly Note
. . . . . . . . . . . . . . . . . . . . .
page Jl-42
5. Bearing outer race
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-42
6. Bearing outer race
(Differential)
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-41
7. Adjust shim (Differential)
Assembly Note
. . . . . . . . . . . . . . . ...*.. page Jl-41
8. Bearing outer race
(Secondary shaft gear)
Assembly Note
,..*.,...............
page Jl -41
9. Adjust shim
(Secondary shaft gear)
Assembly Note
. . . . . . ...*. . . . . . . . . . . page Jl-41
IO. Adjust shim
(Primary shaft gear)
Assembly Note
14. Reverse lever . . . . . . . . . . . . . . . . . . . . . page Jl-41
15. Lever set spring 32. Packing
16. Reverse lever shaft 33. O-ring
17. Roll pin 34. Drive gear
18. Blind plug 35. Roll pin
19. Oil seal (Primary shaft gear) (Speedometer driven gear
Assembly Note assembly)
. . . . . . . . . . . . . . . . . . . . . page Jl-42 Assembly Note
20. Gasket ..,......*. ..,,...... page Jl-41
21. Bleeder cover 36. Speedometer driven gear
22. Bushing assembly
23. Oil seal (Change rod) 37. Bleeder
Assembly Note 38. Pivot
..,..,...,........... page Jl-42 39. Oil seal (Differential)
24. Boot Assembly Note
Assembly Note . . . . . . . . . . . . . . . . . ...* page Jl-41
.,.,.,............... page Jl-42 40. Clutch housing
25. Change rod
Assembly Note
. ..*.................
page J l-42 .,................... page Jl-42
26. Change arm
27. Selector
28. Roll pin
Jl-36

TRANSAXLE Jl
Shim selection
Adjust the bearing preload and select the shim(s) as follows.
Primary shaft assembly
1, Set the primary shaft assembly into the clutch housing.
2. Install the transaxle case to the clutch housing and tighten
the bolts to the specified torque.
Tightening torque:
19-26 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
03UOJl-083 3. Mount a dial indicator to the transaxle hanger and meas-
ure the primary shaft thrust clearance.
03UOJl-064
03UOJl-Of%!
03UOJl-086
Clearance: 0.005-0.1 OOmm (0.0002-0.0039 in)
4. Select the closest shim on the thin side from the table.
Adjustment shim thickness: mm (in)
0.1 (0.004) 0.2 (0.008) 0.3 (0.012)
1 0.4 (0.016)
0.5 (0.020) 0.6 (0.024)
Secondary shaft bearing preload
1. Install the funnel and bearing outer race into the clutch
housing.
2. Set the secondary shaft into the clutch housing.
3. Install the secondary shaft bearing outer race into the trans-
axle case.
4. Install the transaxle case to the clutch housing and tighten
the bolts to the specified torque.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
5. Mount a dial indicator to the transaxle case and measure
the secondary shaft end play.
6. Select the shim as follows.
(a) Add 0.03mm (0.0012 in) to the thrust clearance.
(b) Add 0.08mm (0.0031 in) to the thrust clearance.
(c) Select the thickest shim in the range from (a) to (b) from
the table.
I
13UOJl.004
Jl-37

Jl TRANSAXLE
51-38
03UOJ l-08!
RACE
OWOJ i-09
ONJOJl-09 , _.
03UOJ I-09
Example: 0.22mm (0.009 in)
0.22mm (0.009 in) + 0.03mm (0.001 in)
= 0.25mm (0.010 in)
0.22mm (0.009 in) + 0.08mm (0.003 in)
= 0.30mm (0.012 in)
Range: 0.25mm (0.010 in)-0.30mm (0.012 in)
Select the 0.30mm (0.012 in).
Adjustment shim thickness:
mm (in)
0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.012)
0.35 (0.014) 0.40 (0.016) 0.45 (0.018) 0.50 (0.020)
93GOJ I-524
Differential
1. Install the bearing outer race into the clutch housing.
2. Set the differential assembly into the clutch housing.
Note
l Turn A and B until the gap shown in the figure is
eliminated.
3. Install the transaxle case side bearing outer race to the SST
(selector).
4. Set the
SST (collars) in the positions shown in the figure.
5. Tighten the
SST (bolts) to the specified torque.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)

TRANSAXLE Jl
03UOJl-09:
03UOJi-09
03UOJl-09
03UOJl-09
03UOJl-0:
Note
l Turn the bars until the SST (selector) can no longer
be moved.
6. To seat the bearings, mount the bars on parts @ and @I
of the selector, and turn the selector so the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.
8. Install the
SST to the differential pinion gear through the
transaxle case.
9. Turn the
SST with a torque wrench. Adjust the SST (selec-
tor) with the bars until the specified preload is obtained.
Preload:
0.03-0.74 N#m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
10. Remove the SST.
11. Measure the clearance around the entire circumference of
the
SST (selector).
12. Select the proper adjust shim(s) to be used for the differen-
tial by referring to the table and selecting the shim which
is nearest (on the thick side) to the largest measured clear-
ance in the selector.
Adjust shim thickness:
0.20 (0.008)
0.25 (0.010)
0.40 (0.016)
0.45 (0.018) mm (in)
0.30 (0.012) 0.35 (0.014)
0.50 (0.020) 0.55 (0.022)
13. Remove the SST (bolts).
14. Remove the transaxle case and the
SST (collars).
Jl-39

Jl TRANSAXLE
,
,,
03UOJi-09
03UOJl-10
Jl-40
OSUOJl-1C
15. Remove the bearing outer race from the SST (selector).
16. install the selected shim(s) and bearing outer race to the
transaxle case.
-’
Bearing preload (Differential)
Measure the preload as follows.
1. Set the differential assembly into the clutch housing.
2. Install the transaxle case onto the clutch housing.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
3. Install the SST to the differential side gear through the trans-
axle case.
4. Measure the bearing preload.
Preload:
0.03-0.74 N,m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
5. If not as specified, readjust the bearing preload.
6. Remove the SST.
7. Remove the transaxle case and differential assembly.