MAZDA PROTEGE 1992 Workshop Manual

TRANSAXLE 52
I I
13UOJ2.006
03UOJ2-114
, 03UOJ2-115
BE Tt
03UOJ2-047
03UOJ2-04 6
4. Measure the clearance between hub sleeve and shift fork.
Clearance mm (in)
I I Standard
I Maximum
I
I l&end I 0.08-0.228 (0.003-0.009~ I 0.728 (0.029) I
3rd14th 0.1 O-0.500 (0.004-0.020) 1.000 (0.039)
5thlRev. 0.15-0.458 (0.059-0.018) 0.958 (0.038)
Reverse idler gear and reverse lever
1. Inspect gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bush-
ing and the reverse lever.
Standard clearance:
0.1 O-0.32mm (0.004-0.013 In)
Maximum: 0.5mm (0.020 in)
Bearing
1. Inspect for damage and rough rotation.
Primary Shaft and Secondary Shaft
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for clogging.
5. Inspect the shaft gears’ runout.
Primary shaft gear runout: 0.05mm (0.002 in)
Secondary shaft gear runout: 0.015mm (0.0006 in)
Note
l If the shaft gear is replaced, adjust the bearing
preload. (Refer to page J2-32.)
J2-23

J2 TRANSAXLE
4TH
3RD
23UOJ2-015
2ND 1ST
03UOJ2-049
6. Oil clearance between shaft gears and gears.
Oil Clearance
Shaft Gear Sleeve
(Outer dia.) (inner dia.) (Outer dia.) Oil 'learanCe
1st 39.445-39.470 39.500-39.525 _
(1.553-1.554) (1.555-1.556)
2nd 34.945-34.970 35.000-35.025 _
(1.376-1.377) (1.378-1.379)
3rd 35.945-35.970 36.000-36.025 0.03-0.08
_
(1.415-1.416) (1.417-1.418) (0.001-0.003)
4th 30.945-30.970 31.000-31.025 _
(1.218-1.219) (1.220-1.221)
34.000-34.025
33.945-33.970
1 5th
-
(1.339-1.340) (1.336-1.337)
/
Speedometer Driven Gear Assembly
1. Inspect the teeth for damage and wear.
2. inspect the O-ring for damage and wear. mm (in)
_......
52-24

TRANSAXLE J2
MEMO
52-25

J2 TRANSAXLE
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. The bearing outer race and bearing inner race must be replaced as a unit.
3. Before assembly, make sure all parts are completely clean.
4. Assemble the parts within 10 minutes after applying sealant, Allow all sealant to cure at least 30 minutes
after assembly before filling the transaxle with transaxle oil.
Primary Shaft Assembly and Secondary Shaft Assembly
1. Assemble in the order shown in the figure, referring to Assembly Note.
1
1
OIL GROOVE
(FOUR PLACESj==z
L
J2-26

TRANSAXLE J2
1. Clutch hub
Assembly Note ,......................... page J2-27
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Clutch hub
Assembly Note ,......................... page J2-27
6. Synchronizer key
7. Clutch hub sleeve (reverse gear)
8. Synchronizer spring
9. Primary shaft
10. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
11. 3rd gear
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
12. Synchronizer ring (3rd)
Assembly Note.. . . . . . . . . . . . . . . . . . . page J2-28
13. Clutch hub assembly (3rd14th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
14. Retaining ring
15. Synchronizer ring (4th)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
16. 4th gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-28
17. Bearing inner race
Assembly Note.. . . . . . . . . . . . . . . . . . page J2-28
18. Secondary shaft
19. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . page J2-29 20. 1st gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
21. Synchronizer ring (1 st)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
22. Clutch hub assembly (IstMnd)
Assembly Note ,,..........,............. page J2-29
23. Retaining ring
24. Synchronizer ring (2nd)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
25.2nd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
26. Secondary 3rd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
27. Retaining ring
28. Secondary 4th gear
Assembly Note ,.,............,....,..... page J2-30
29. Bearing inner race
Assembly Note. . . . . . . . . . . . . . . . . . page J2-30
30. Control rod
31. Control lever
32. Roll pin
33. lst/2nd shift fork
34. Control end
35. Roll pin
36. Interlock sleeve
Assembly Note.. . . . . . . . . . . . . . . . page J2-30
37. 3rd/4th shift fork
03UOJ2 051
___-__ 03UOJ2-11
Assembly note
Clutch hub
Note
l Synchronizer key dimensions are as follows.
mm (in)
(l-1
12) 1\3>
_--
1stMnd 19 (0.7480) 4.25 (0.1673) -5.00 (0.1969)
3rdl4th
SthlRev. 17 (0.6693) 4.25 (0.1673) 5.00 (0.1969)
1. Install the synchronizer key springs in the clutch hub with
the hooks in the grooves to hold the three synchronizer keys
in place.
03UOJ2-052
J2-27

J2 TRANSAXLE
I
23UOJ2-OC
W-W i
W-U
(REVERSE)
I 03UOJ2-054
(FOUR PLACES)!
23UOJ2-00
r
1
03UOJ2-O!
52-m
7
1 57
Bearing inner race (primary shaft end)
1. install the new bearing inner race with the SST.
3rd gear, synchronizer ring (3rd) and clutch hub
assembly (3rd/4th)
Note
l The size of the lst, 2nd, 3rd, and 4th synchronizer
rings are the same. Be careful when installing them.
The 2nd ring has the larger cut-out as shown in the
illustration.
l Align the synchronizer ring groove and clutch hous-
ing hub key when installing.
1, Install the 3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th) with the
SST.
Synchronizer ring (4th), 4th gear and bearing inner race
1. Install the synchronizer ring (4th), 4th gear, and bearing in-
ner race with the
SST.
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05-0.20mm (0.002-0.008 in)
Maximum : 0.25mm (0.010 in)

TRANSAXLE J2
13UOJ2-006
I 03UOJ2-06f
23UOJ2.011
3. Measure the clearance between the 4th gear and bearing
inner race.
Clearance: 0.165-0.365mm (0.0065-0.0144 in)
Maximum : 0.415mm (0.0163 in)
4. If not as specified, reassemble the primary shaft assembly.
Bearing inner race (secondary shaft end)
1. Install the new bearing inner race with the SST.
1st gear, synchronizer ring (1st) and clutch hub
assembly (1 st/2nd)
Note
l Align the synchronizer ring, groove and clutch hous-
ing hub key when installing.
1. Assemble the 1 st gear, synchronizer ring (1 St), and clutch
hub assembly (lst/2nd), as shown in the figure.
2. Press the clutch hub assembly (1 st/2nd) on with the
SST.
Synchronizer ring (2nd), 2nd gear and secondary 3rd
gear
1. Install the synchronizer ring (2nd) and 2nd gear.
2. Install the secondary 3rd gear with the
SST.
23UOJ2-011
J2-29

J2 TRANSAXLE
03UOJ2-06 3
r
03UOJ2-068 ‘4
03UOJ2-06
03UOJ2-Of
Secondary 4th gear and bearing Inner race
1. Install the secondary 4th gear and new bearing inner race.
2. Measure the clearance between the 1 st gear and differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 In)
Maximum: 0.33mm (0.0130 in)
3. Measure the clearance between the 2nd gear and secon-
dary 3rd gear.
Clearance: 0.175-0.455mm (0.0089-0.0179 in)
Maximum: 0.505mm (0.0199 in)
4. If not as specified, reassemble the secondary shaft at
sembly. -’
Interlock sleeve
1. Install both shift forks and the interlock sleeve, as in the
figure.
J2-30

TRANSAXLE J2
Clutch Housing and Transaxle Case Components
1. Select the adjust shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the figure, referring to Assembly Note.
3. Verify that the bearing preload is satisfied after assembly, referring to Bearing Preload.
-s
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS EXCEPT SWITCHES
&II N.m (SO-110 cm-kg, SO-95 In-lb)
20-29
P-3,
@NEW=
O-RING, I
14-22) 11
R N.m (120-160 cm-kg,
104-l 39 in-lb)
A
=SELECTlVE ROLL PIN NE
(120-140 cm-kg,
SELECTIVE 20-29 (2-3, 14-22)
N.m (m-kg,
??I 1
1. Change rod 16. Oil seal
2. Joint
3. Oil passage
4. Back-up light switch
5. Oil seal
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
6. Adjust shim(s)
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
7. Bearing outer race
8. Adjust shims
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
9. Diaphragm springs
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
17. Gear case
18. Driven gear
19. Speedometer driven gear assembly
20. Bleeder
21. Bleeder cover assembly
22. Oil seal
23. Selector
24. Reverse gate
25. Spring
26. Boot
Assembly Note ,.,....................... page J2-35
27. Change rod assembly
28. Roll pin
10. Bearing outer races
11. Neutral switch and gasket
12. Drain plug and washer
13. Reverse lever
14. Reverse lever shaft
15. Bearing outer race 29. Change arm
30. Guide plate
31, Funnel
32. Bearing outer race
33. Oil seal
34. Bearing outer race
J2-31

TRANSAXLE
Bearing preload adjustment
Adjust the bearing preload by selecting adjust shim(s).
SST
TRANSAXLE CASE
CUTER RACES
PRIMARY SHAFT ASSEMBLY
iECONDARY SHAFT
rSSEMBLY
CLUTCH HOUSIN
SST USAGE
83U07A-03