MAZDA PROTEGE 1992 Workshop Manual

TRANSAXLE Jl
Assembly note
Oil seal (Speedometer gear cace)
1. Install the new oil seal with a suitable pipe.
Pipe diameter: 15mm (0.591 in)
23UOJ I-00
03UOJl-IO
03UOJl-IO!
03UOJ1.10
Roll pin (Speedometer driven gear assembly)
1. Install the new roll pin as shown in the figure.
Oil seal (Differential)
Caution
l Apply transaxle oil to the outer circumference of the
oil seal.
1. Install the new oil seal with the SST.
Adjust shim and bearing outer race (Secondary shaft
gear)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
l Apply transaxle oil to the bearing outer race.
1. Install the adjust shim(s) and the bearing outer race with
a suitable pipe.
Adjust shim and bearing outer race (Differential)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
l Apply transaxle oil to the bearing outer race.
1, Install the adjust shim(s) and the bearing outer race with
a suitable pipe.
Jl-41

Jl TRANSAXLE
03UOJl-10
-
23UOJl.01
Adjust shim (Primary shaft gear)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
1. Apply transaxle oil to the adjust shim(s) and install it.
Funnel and bearing outer race
Caution
l Apply transaxle oil to the bearing outer race.
1. Install the funnel and the bearing outer race.
Oil seal (Primary shaft gear)
Caution
* Apply transaxle oil to outer circumference of the oil
seal.
1. install the new oil seal with a suitable pipe.
Oil seal (Change rod)
Caution
l Apply transaxle oil to the oil seal lip.
1. Install the oil seal.
Boot and change rod assembly
Caution
l Install the boot with the air bleed downward as
shown in the figure.
1. Slide the boot onto the change rod assembly.
2. Install the change rod assembly into the clutch housing.
-,
Jl-42

TRANSAXLE Jl
MEMO
Jl-43

Jl TRANSAXLE
Sth/Reverse Gear and Housing Parts
1. Assemble in the order shown in the figure, referrina to Assembly Note.
@ 2Q-

(2.0. -25
-2.5, 14-W)
PACKING.
0
-d-25 ._-..
,.-
-- -- --.
,152)
r I ew-am (13-21, 94-152) cl.9
ROLL PIN: NEW
N.m (m-kg, it-lb)
fill w ‘. 1
u.wJJl-11
51-44

TRANSAXLE Jl
1. Control rod
2. Control end
3. lstl2nd shift fork
4. Control lever
5. Interlock sleeve
6.3rd/4th shift fork
7. Clutch hub
8. Synchronizer key
9. Clutch hub sleeve
10. Synchronizer spring
11. Clutch housing
12. Differential assembly
13. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-45
14. Primary shaft gear assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . , . page J 1-45
15. Spring
16. Steel ball
17. Shift fork and shift rod assembly
Assembly Note.. . . . . . . . . . . , . . . . . . . . . , . . , page J 1-45
18. Crank lever assembly
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
19. Crank lever shaft
Assembly Note.. . . . . . . . . . . , , . . . . . . . . . . . . page Jl -46
20. Pin
21. 5th shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page 31-46
22. 5th shift rod
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-46
23. Reverse idler gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
24. Reverse idler shaft
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . page Jl -46
25 Magnet
26. Transaxle case assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl -47
27. Neutral switch
28. Back-up light switch
29. Lock bolt and washer
30. Secondary 5th gear
31. Gear sleeve
32. 5th gear
33. Synchronizer ring (5th)
34. Clutch hub assembly (5th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
35. 5th shift fork
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
36. Stop plate
37. Locknut (Secondary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
38. Locknut (Primary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-47
39. Rear cover
13UOJl-005
Assembly note
Primary shaft gear assembly and secondary shaft gear
assembly
1. Install the primary shaft gear assembly and the secondary
shaft gear assembly together.
03UOJl-115 Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
03UOJ2-088
51-45

Jl TRANSAXLE
I I 03UOJ2-089
03UOJ2-091 3
03UOJ2-09
2. Insert the spring seat and spring into the reverse lever shaft,
install the steel ball, and place a scraper so that it contacts
the steel ball.
3. With the edge of the control end against the scraper, when
the control end is pushed in the direction of the arrow in
the figure so that the ball goes into the shaft, the rod will
at the same time line up with the shift rod coupling hole in
the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap
the shift rod from above so that the steel ball goes into the
center groove (of the 3 grooves in the control end).
5. Pull the ball part of the control end forward so that the steel
ball goes into the detent in the groove.
Crank lever assembly and crank lever shaft
Note
l Use a new O-ring for the crank lever shaft.
1. Fit the crank lever between the change arm and the con-
trol end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch
housing, and insert the new pin. -’
5th shift rod end and 5th shift rod
Note
l The mark (indicated by the arrow in the figure) and
the shift rod end mounting bolt hole must be in the
same direction.
1. Install the shift rod end (1) and the shift rod (2), and tighten
the gate mounting bolt.
Reverse idler gear and reverse idler shaft
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever
(indicated by the arrow), and, at the same time, face the
reverse idler shaft screw hole in the direction shown in the
figure.
Jl-46

TRANSAXLE Jl
- 23UOJl-01
03UOJl-11
03UOJl-14
I 03UOJl-11
Transaxle case assembly
1, Apply a thin coat of sealant to the contact surfaces of the
clutch housing and transaxle case, tighten the transaxle case
installation bolts to the specified torque.
Tightening torque:
19-26 Nom (1.9-2.6 m-kg, 14-19 ft-lb)
Clutch hub assembly (6th) and 6th shlft fork
1. Install the clutch hub assembly (5th) and the 5th shift fork
together.
Locknut
1. Shift to 1 st gear.
2. Lock the primary shaft with the
SST.
3. Tighten new locknuts on the primary and secondary shafts.
Tightening torque:
126-206 N*m (13.0-21 m-kg, 94-152 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06-0.26mm (0.0024-0.0102 in)
Maximum : 0.31 mm (0.0122 in)
6. If not as specified, reassemble the transaxle.
Jl-47

/ cm-kg, -26-52 In-lb)
(3.8-5.3, 27-M)
Jl TRANSAXLE
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’ Add the specified amount of the specified transaxle oil. (Refer to page Jl-7.)
4: Warm up the engine and transaxle, and inspect for oil leakage and transaxle operation.
2.4-5.S N.m (30-60
9
1 8-11 N-m
o-110 cm-kg,
* h-95 In-lb)
.O,
cc.
ft-I
03UOJl-119
b)
51-48

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

03UOJi-12 3
03UOJl-124
L 03UOJl.126 I-
03UOJl-12
Jl TRANSAXLE
Driveshaft
Caution
l Verify that the oil seal is not damaged.
l Do not damage the oil seal
1. Insert the clip with the end-gap at the top of the groove.
2. Apply transaxle oil around the oil seal lip. Install the
driveshaft.
3. Verify that the driveshaft is correctly seated by pulling on
the shaft.
4. Connect the lower arm to the knuckle and tighten the clinch
bolt.
Tightening torque:
43-59 N-m (4.4-6.0 m-kg, 32-43 ft-lb)
Stabilizer (BP SOHC)
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension A: 17-l 9mm (0.67-0.75 in)
Tie-rod end
1. Install the locknut.
Tightening torque:
42-57 N-m (4.3-5.6 m-kg, 31-42 ft-lb)
2. Secure the locknut with a new cotter pin.
Engine mounting member
1. Install the bolts and nuts as shown.
Tightening torque
@ : 37-52 N,m (3.6-5.3 m-kg, 27-36 ft-lb)
@I: 64-89 N-m (6.5-9.1 m-kg, 47-66 ft-lb)
51-50