MAZDA PROTEGE 1992 Workshop Manual

OUTLINE J2
OUTLINE
SPECIFICATIONS
Item
Transaxle control
Synchromesh system EnginelTransaxle
BP DOHC
GSM-R Floor shift
Forward: Synchromesh
Reverse: Selective sliding and synchromesh
T- I-
Gear ratio
I
1 st 3.307
2nd 1.833
3rd 1.310
4th 1.030
5th 0.795
Reverse 3.166
Final gear ratio 4.105
q
Oil Viscosity All-season
Above -18OC (OOF) ATF DexronYI, M2C33F or SAE75W-80
API service GL-4 SAE80W-90
Capacity liters (US qt, Imp qt) 3.35 (3.55, 2.96)
23UOJ2-001
52-3

J2 OUTLINE
03UOJ2-OC
1, Primary 1 st gear
2. Primary 2nd gear
3. Primary 3rd gear
4. Primary 4th gear
5. Primary 5th gear
J2-4
6. Primary reverse gear
7. Secondary 1st gear
8. Secondary
2nd gear 9. Secondary 3rd gear
10. Secondary 4th gear Il. Secondary 5th gear
12. Secondary reverse gear
13. Reverse idler gear
14. Differential

OUTLINE J2
POWER FLOW
3RD
5TH 2ND
4TH
AC---.
-
w
REVERSE
03UOJ2-00
J2-!

J2 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Shift lever won’t shift
Seized shift lever ball Replace J2-46
smoothly or is hard Seized change control rod joint Replace JZ-46
to shift Bent change control rod Replace J2-46
Too much play in Worn change control rod bushing Replace J2-46
shift lever Weak shift lever ball spring Replace J2-46
Worn shift lever ball bushing Replace J2-46
Difficult to shift Bent change control rod Replace J2-46
No grease in transaxle control Lubricate with grease J2-46
Insufficient oil Add oil J2- 7
Deterioration of oil quality Replace with oil of J2- 7
specified quality
Wear or play of shift fork or shift rod Replace J2-13
Worn synchronizer ring Replace J2-18
Worn synchronizer cone of gear Replace J2-18
Bad contact of synchronizer ring and cone of gear Replace J2-18
Excessive longitudinal play of gears Replace J2-18
Worn bearing Replace J2-18
Worn synchronizer key spring
Replace J2-18
Excessive primary shaft gear bearing preload Adjust J2-32
Improperly adjusted change guide plate
Adjust J2-15
Won’t stay in gear Bent change control rod Replace J2-46
Worn change control rod bushing Replace J2-46
Weak shift lever ball spring Replace J2-46
Improperly installed extension bar Tighten J2-46
Worn shift fork Replace J2-18
Worn clutch hub Replace J2-18
Worn clutch hub sleeve Replace J2-18
Worn gear sliding part of both shaft gears Replace J2-18
Worn gear sliding part of each gear Replace J2-18
Worn steel sliding groove of control end Replace J2-13
Weak spring pressing against steel ball Replace J2-13
Excessive thrust clearance Replace J2-18
Worn bearing Replace J2-18
Improperly installed engine mount
Tighten J2-41
Abnormal noise Insufficient oil Add oil J2- 7
Deterioration of oil quality
Replace J2- 7
Worn bearing Adjust or replace J2-18
Worn sliding surfaces of gears or shafts Replace J2-18
Excessive gear backlash Replace J2-18
Damaged gear teeth Replace with oil of J2-18
specified quality
Foreign material in gears Replace J2-18
Damaged differential gear or excessive backlash Adjust or replace J2-44
J2-6

TRANSAXLE OIL 52
03UOJ2-00’
03UOJ2-008
03UOJ2-00
1 9
23UOJ2-002
TRANSAXLE OIL
INSPECTION
Note
l Park the vehicle on level ground.
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Verify that the oil level is between F and L.
3. Install the speedometer driven gear.
Tightening torque:
7.8-12 Nmrn (80-120 cm-kg, 89-104 in-lb)
4. Connect the speedometer cable.
REPLACEMENT
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Remove the drain plug and washer. Drain the oil into a suit-
able container.
3. Install a new washer and the drain plug.
Tightening torque:
39-59 N*m (4.0-8.0 m-kg, 29-43 ft-lb)
4. Add the necessary amount of the specified oil through the
speedometer gear case hole.
Specified oil
Viscosity: All-season ATF Dexron@lI, M2C33F or
SAE75W-80
Above -18*C (O*F) API service GL-4
SAE 8OW-90
Capacity: 3.35 liters (3.55 US qt, 2.96 Imp qt)
5. Verify the oil level.
6. Install the speedometer driven gear and connect the
speedometer cable.
03UOJ2-011
J2-7

J2 TRANSAXLE
TRANSAXLE
PREPARATION
SST
19 GO17 5A0
removal of tie-rod
disassembly and
49 GO30 440
Holder, primary
shaft Remover, bearing
49 8001 795
‘nstaller, oil seal installation of oil
$9 GO30 370
49 F401 366A
Plate
(Part of
49 GO17 1AO) For
removal of
bearing inner
race 49 8092 373
Attachment G
(Part of
49 GO1 7
1 AO) For
removal of
bearing inner
race
49 8092 374
Attachment H
(Part of
49 GO17 1AO) For
removal of
bearing inner
race 49 0839 425C
Puller set,
bearing
49 F401 3308
Installer set,
bearing
-- For
installation of
bearing 49 F401 331
For
installation of
Body bearing inner
(Part of race
49 F401 3308)
J2-8

TRANSAXLE
49 F401 335A
Attachment A
(Part of
49 F401 3308)
49 GO30 380C
Shim selector set
49 GO30 382A
Selector 458
(Part of
49 GO30 380C)
49 F401 384 49 F401 384
Collar
/ / Collar
(Part of (Part of
49 GO30 380C) 49 GO30 380C)
49 FTOl 515A
Adapter, preload
(Part of
49 GO30 380C)
49 8017 102
Adapter, preload
49 GO30 455
Holder, diff. side
gear For
installation of
bearing inner
race
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
molding side gear 49 F401 3368
Attachment B
(Part of
49 F401 330B)
49 GO30 381
Selector for $168
1
(Part of
49 GO30 380C)
49 F401 382A
Selector (Bearing
size 452)
(Part of
49 GO30 380C)
49 GO19 021
Bolt set
(Part of
49 GO30 380C)
49 F401 385
49 GO17 202
Adapter, preload For
installation of
bearing inner
race
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
bearing preload
For
adjustment of
Dearing preload
03UOJZ01
52-9

J2 TRANSAXLE
REMOVAL
1. Disconnect the negative battery cable.
2. Raise the vehicle and support it with safety stands.
3. Drain the transaxle oil into a suitable container.
4. Remove in the order shown in the figure, referring to Removal Note.
I
03UOJ2-0
52-l 0

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
03UOJZ018
Driveshaft
Caution
l Do not shock the tripod joint when removing the
driveshaft.
1. Separate the driveshaft from the transaxle by prying with
a bar inserted between the outer ring and the transaxle.
2. Suspend the driveshaft with a rope.
Transaxle
1. Lean the engine toward the transaxle.
2. Support the transaxle with a jack.
3. Remove the transaxle mounting bolts.
4. Remove the transaxle.
DISASSEMBLY
Precaution
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry
with compressed air. Clean out all holes and passages with compressed air, and verify that there are no
obstructions.
3. Wear eye protection when using compressed air to clean components.
03UOJ2-020
J2-12