MAZDA PROTEGE 1992 Workshop Manual

TRANSAXLE Jl
03UOJl-12!
03UOJi-13
2. Tighten engine mount No.4 nuts.
Tightening torque:
67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)
3. Remove the SST (Engine support).
Control rod and extension bar
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 Nern (3.2-4.7 m-kg, 23-34 ft-lb)
2. Install the change control rod to the transaxle.
Tightening torque:
16-23 N*m (1.6-2.3 m-kg, 12-17 ft-lb)
Ground
1. Connect the ground to the clutch pipe bracket.
Tightening torque:
16-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Speedometer cable
1. Add the specified oil through the speedometer gear case
mounting. (Refer to page Jl-7.)
2. Install the speedometer driven gear.
Tightening torque:
7.6-l 2 N*m (60-120 cm-kg, 69-104 in-lb)
3. Connect the speedometer cable to the speedometer driv-
en gear.
J141

Jl DIFFERENTIAL
DIFFERENTIAL
PREPARATION
SST
49 B017 1AO
Remover set,
bearing
49 8092 371
Attachment E
(Part of
49 8017 1AO)
49 F401 3308
Installer set,
bearing
49 F401 337A
Attachment C
(Part of
49 F401 3308) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
For
installation of
bearing 49 F401 366A
Plate
(Part of
49 8017 1AO)
49 0839 42%
Puller set,
bearing
49 F401 331
Body
(Part of
49 F401 3309) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
03UOJl-13 .-,
5142

DIFFERENTIAL Jl
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove the inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
3. Inspect all parts and repair or replace as necessary.
4. Assemble in the reverse order of disassembly, referring to
Assembly Note.
5. Measure the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin 7. Side bearing inner race
13UOJl-00:
Assembly Note .......................... page Jl -55 Disassembly Note.. ..................
2. Pinion shaft Inspection .................................
3. Thrust washer Assembly Note .........................
4. Pinion gear 8. Speedometer drive gear
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 9. Side bearing inner race
Inspection of backlash.. ............ page Jl-55 Disassembly Note.. ..................
5. Side gear Inspection .................................
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 10. Ring gear and ring case
Inspection of backlash.. ............ page Jl-55 Inspection .................................
6. Thrust washer
03UOJl-13 4
page Jl-54
page Jl -54
page Jl-55
page Jl -55
page Jl-54
page Jl-54
page Jl-55
page Jl-54
Preinspection
Backlash of side gear and pinion gear
Measure the backlash by the following procedure.
1. Install the left and right driveshafts in the differential as-
sem bly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O. 1 mm (O-0.004 in)
51-53

Jl DIFFERENTIAL
4. If the backlash exceeds specification, adjust by selecting
and installing thrust washers between the case and the side
gears.
Caution
l Use thrust washers with the same thickness on each
side.
-.
Thrust washer thickness: mm (in)
1 2.0 (0.079) 2.1 (0.083) 2.2 (0.087) 23UOJl-012
03UOJ2-10
1 03UOJ2-104
03UOJl-13
Jl-54
03UOJl-1: 6
Disassembly Note
Side bearing inner race (Side opposite ring gear)
Caution
l Hold the gear case with one hand so that it does
not fall.
1. Remove the bearing inner race with the SST.
Side bearing inner race (Ring gear side)
Note
l Use pads in the vise.
1. Remove the bearing inner race with the SST.
Inspection
Inspect all parts and repair or replace as necessary.
Ring gear and ring case
Note
l If the gear case is replaced, adjust the bearing
preload.
1. Inspect the ring gear for wear and cracks.
Bearing inner race
Note
l When replacing the bearing inner race, replace the
bearing outer race and inner race as a set.
l If the bearing is replaced, adjust the bearing
preload.
1. Inspect for wear and rough rotation. --

DIFFERENTIAL Jl
03UOJl-138
Assembly Note
Speedometer drive gear
1. Install the speedometer drive gear as shown in the figure.
1
03UOJl-13!
I
03UOJ2-10
I
03UOJl-14
I 03UOJl-14 .l
Side bearing inner race (Side opposite ring gear)
1. Install the speedometer drive gear.
2. Install the new side bearing inner race with the
SST.
Side bearing inner race (Ring gear side)
1. Install the new bearing inner race with the SST.
Roll pin
1, Install the new roll pin as shown in the figure to hold the
pinion shaft.
Backlash of Side Gear and Pinion Gear
Measure the backlash by the following procedure.
1. Install the driveshafts in the differential assembly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O.1 mm (O-0.004 in)
4. If not as specified, select the proper thrust washers.
(Refer to preinspection, page Jl-53.)
Jl-55

Jl SHIFT MECHANISM
SHIFT MECHANISM
OVERHAUL
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to
Assembly Note.
t
w 16-G (1.6-2.3, 12-17)
“..d
n /~~16--23 (1.6-2.3, 12-17)
1. Shift lever knob
2. Rear ashtray
3. Rear console
4. Front console
5. Boot
6. Nut
7. Washer
8. Bolt
9. Nut
10. Washer
Il. Bushing
12. Spring
Inspect for damage and weakness
Assembly Note.. . . . , . . . . . . . . . . . . . . . . . . . . page Jl -57
13. Shift lever
;45. “,Mlseat (upper)
Inspect for wear and damage
Jl-56
16. Holder
17. Ball seat (lower)
18. Nut
19. Washer
20. Pipe
21. Bushing
Inspect for wear and damage
22. Washer
23. Extension bar
Assembly Note,.. . . ., . . . . . . . . . . . . . . . . . . .
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
142
page Jl -57

SHIFT MECHANISM Jl
03UOJl-14
03UOJi-144
Assembly Note
Extension bar
1, Connect the extension bar onto the transaxle, 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.
51-57

J2
MANUAL TRANSAXLE
(G5M-R)
INDEX .....................................................
J2- 2
OUTLINE
................................................
J2- 3
SPECIFICATIONS
................................... J2- 3
STRUCTURAL VIEW ...............................
J2- 4
POWER FLOW
......................................
J2- 5
TROUBLESHOOTING
GUIDE.. ................... J2- 6
TRANSAXLE OIL .....................................
J2- 7
INSPECTION
.........................................
J2- 7
REPLACEMENT .....................................
J2- 7
TRANSAXLE
...........................................
J2- 6
PREPARATION ......................................
J2- 6
REMOVAL
............................................
J2-10
DISASSEMBLY
......................................
52-l 2
INSPECTION .........................................
J2-22
ASSEMBLY
...........................................
J2-26
INSTALLATION
......................................
J2-41
DIFFERENTIAL
........................................
J2-43
PREPARATION
......................................
52-43
DISASSEMBLY / INSPECTION I ASSEMBLY J2-44
SHIFT MECHANISM
.................................
52-46
OVERHAUL
..........................................
52-46
03UOJ2-001

J2 INDEX
IN
new IYLA
BACK-lx LIU, 1, w.., 1 vm q
SERVICE, SECTION
F
k’c’ 1T6AL SWITCH 8.L”
SERI /ICE, SECTION T VISCOSITY: ALL-SEASON ATF DEXRON-II,
M2C33F OR SAE75W-80
ABOVE -18% (OOF) API SERVICE
GL-4 SAE80W-90
CAPACITY: 3.35 liters (3.55 US at. 2.98 ho 41)
1. Transaxle
Removal ..,.....,.,..,....,..,.........,.... page J2-10
Disassembly ,., ,..,., . ,,...., ,.. .., .., page J2-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
Assembly . . . . . . . . . ,.,...................... page J2-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-41
52-2
2. Differential
Disassembly / Inspection I
Assembly ,..,.,.,, ,_, ,. .,. ,_. ,_. . . . page J2-44
3. Shift mechanism
Overhaul ,....,.......,..... ,........, . . . . . . page J2-46
4. Transaxle oil
inspection . . . . . . . . ..,........I....I.,..... page J2- 7
Replacement .,.,.., ,.,...,...,.. . . . . . . . . . page J2- 7 .___I’