MAZDA PROTEGE 1992 Workshop Manual

TRANSAXLE J2
OUTER RACE
SELECTOR
03UOJ2-069
03UOJ2-07(
86U07A-25:
-sllzd-L-
03UOJZ071
03UOJ2-Oi 1. Install the primary and secondary shaft bearing outer races
into the transaxle case (diaphragm springs and shims
removed).
2. Mount the clutch housing onto the transaxle hanger, and
set the differential bearing outer race into the clutch housing.
Position a piece of pipe against the outer race and tap in
with a hammer until it contacts the clutch housing.
3. Set the outer races into the
SST (selector) as shown in the
figure.
Note
l Turn the selector to eliminate the gap indicated by
the arrow in the figure.
4. Set the differential assembly into the clutch housing; then
set the bearing outer race and the
SST (selector) on the
differential. Set the assembled selectors for the primary and
secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the figure.
5. Set the
SST (collars) in the positions shown in the figure.
6. Install the transaxle case and tighten the
SST (bolts) to the
specified torque.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
7. To seat the bearings, mount the SST (bars) on parts @and
@of the selector, and turn the selector so the gaps are
widened.
Then turn the
SST in the reverse direction until the gaps
are eliminated.
J2-33

J2 TRANSAXLE
Note
l Check that each shaft turns smoothly.
8. Manually expand the selector until it no longer turns by hand.
Caution
l Measure the gap around the entire circumference
of the selector.
-
9. Use a feeler gauge and measure the gap in the selector.
03UOJ2-073 10. Take the maximum reading and determine the shim to be
used as follows:
_-..
mm (in) Thickness (Shaft gears)
0.20 (0.008) 0.50
(0.020)
0.25 (0.010) 0.55
(0.022)
0.30 (0.012) 0.60 (0.024)
0.35 (0.014) 0.65
(0.026)
0.40 (0.016) 0.70
(0.028)
0.45 (0.018)
13UOJ2-01
I
03UOJ2-07
I
I 03UOJ2-0’
J2-34
Note
l Use a maximum of two shims.
< Primary shaft adjust shim >
l Subtract the diaphragm spring thickness (0.70mm,
0.0276 in) from the gap determined in Step 9.
l Select the closest thinner shim from the table.
Example
1.22mm (0.0480 in) - 0.70mm (0.0278 in)
= 0.52mm (0.0205 in)
Shim: OSOmm (0.020 in)
< Secondary shaft adjust shim >
l Subtract the diaphragm spring thickness (0.70mm,
0.0276 in) from the gap determined in Step 9.
l Select the closest thicker shim from the table.
Example
1.22mm (0.0480 in) - 0.70mm (0.0278 in)
= 0.52m.m (0.0205 in)
Shim: 0.55mm (0.022 in)
11, Install the SST.
12. Adjust the selector with the SST until the specified preload
is obtained.
Preload: 0.5 N-m (5 cm-kg, 4.3 in-lb)

TRANSAXLE
i
03UOJ2-078
-
Thickness
0.10 (0.004)
0.20 (0.008)
0.25 (0.010)
0.30 (0.012)
0.35 (0.014)
0.40 (0.016)
0.45 (0.018)
050 (0020)
0.55 (0.022)
0 60 (0.024)
0.65 (0.026)
03UOJZO7 mm (in)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
1.00 (0.039)
1.05 (0.041)
1.10 (0.043)
1.15 (0.045)
1.20 (0.047)
03UOJ2-081
, T/RAkiXiE /CA/SE/////,///
BEARING OUTER RACE
,ADJUSTMENT SHIM
__________
po3u0J2-08i
Caution
l Measure the gap around the entire circumference
of the selector
13. Use a feeler gauge to measure the gap in the selector for
the differential.
14. Add 0.15mm (0.0059 in) to the measured clearance and
select the combination of shims closest in value to that meas-
urement.
Note
l Use a maximum of two shims.
See the table below for available shim sizes.
Example: 0.32mm (0.013 in)
0.32mm (0.013 in) + 0.15mm (0.006 in) = 0.47mm
(0.019 in).
So the nearest shim (on the thick side) to 0.47mm
(0.019 in) is 0.50mm (0.020 in).
15. Remove the SST and the transaxle case.
16. Remove the selectors, the primary shaft assembly and the
-differential.
17. Remove the bearing outer races.
Assembly note
Oil seals
1. Apply transaxle oil to outer periphery.
2. Install the new oil seals with the SST.
Diaphragm spring
1. Install the diaphragm spring as shown in the figure.
Boot
1. Install the boot with the drain hole facing downward.
03UOJ2-082
J2-35

J2 TRANSAXLE
03UOJ2-OE i3
03UOJ2-120
03UOJ2-08 4
03UOJF085
Bearing preload
Verify the shaft gears and the differential bearing preload.
Note Note
l Verify that the correct adjust shims were selected. l Verify that the correct adjust shims were selected.
l If the bearing preload is not within specification, ad- l If the bearing preload is not within specification, ad-
just again. just again.
1. Set the primary shaft gear and the differential into the clutch
housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 f&lb)
3. Connect the SST and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the
preload.
Preload:
1.4-2.0 N.m (14-20 cm-kg, 12-17 in-lb)
5. Remove the SST.
6. With the transaxle facing in the direction shown in the fig-
ure, install the
SST to the primary shaft gear.
7. Measure the preload.
Preload:
0.1-0.25 N-m (1.0-2.5 cm-kg, 0.87-2.18 in-lb)
8. Remove the SST, transaxle case, primary shaft gear and
differential.
9. Install the secondary shaft gear and transaxle case then
tighten to the specified torque.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
IO. Measure the secondary shaft preload with the SST
Preload:
0.2-0.4 N.m (2.0-4.0 cm-kg, 1.7-3.5 in-lb)
J2-36

TRANSAXLE J2
ShIReverse Gear and Housing Parts
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
37-52 (3.8-8.3, 27-38)
, .-- 104-122 in-lb)
H50-210 cm-ka NEW
O/NEW 8 iN m ’ --13OL-i82 in-@
@mI - *
(80-l 15 Cm-kg,
NEW 89-l 00 In-lb)
128-198
(13-20, 94-145)
1. Differential assembly
2. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
3. Primary shaft gear assembly
6. Shift fork and shift rod assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Assembly
J2-38
7. Crank lever assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly page
Note . . . . . . . . . . . . . . . . . . . . . J2-38
page 4. Spring
J2-38
8. Crank lever shaft 5. Steel ball
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
9. Pin
10. 5thlReverse shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-39
Il. 5th/Reverse shift rod and clip
Assembly Note . . . . . . . . . . . . . . . . . . . . . . page J2-39
12. Lock bolt
13. Reverse idler gear
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . page J2-39
14. Reverse idler shaft
Assembly Note.. . . . . . . . . . . . . . . page J2-39
15. Magnet
“J”“JL-“O)O
21. Secondary 5th gear 16. Clutch housing
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly
page J2-39
22. Gear sleeve Note . . . . . . . . . . . . . . . . . . . . . . . . . .
23. 5th gear page
24. Synchronizer ring (5th) J2-39
25. Clutch hub assembly (5thIReverse)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . page J2-39
26. 5thlReverse shift fork 17. Transaxle case assembly
Assembly Note .,........................ page J2-39
27. Roll pin Assembly
28. Secondary reverse synchronizer gear Note . . . . . . . . . . . . . . . . . . . . . . . . . .
29. Synchronizer ring (Reverse) page
30. Primary reverse synchronizer gear J2-39
31. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-40
32. Locknut 18. Lock bolt, ball and spring
Assembly
19. Guide bolt
Note.. . . . . . . . . . . . . . . . . page J2-40
33. Rear cover 20. Lock bolt
52-37

J2 TRANSAXLE
03UOJ2-08
03UOJ2-09(
03UOJ2-09’
J2-38
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.
Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
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, at the same
time the rod will 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.

TRANSAXLE 52
r
03UOJ2-09:
03UOJ2-09
03UOJ2-094
03UOJ2-09!
03UOJ2-09t
fith/Reverse shift rod end, Sth/Reverse shift rod and clip
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 @ and the shift rod 0, 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.
Clutch housing and 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.
Tlghtenlng torque:
37-52 Nsrn (3.8-5.3 m-kg, 27-38 ft-lb)
2. Insert the SST through driveshaft hole.
Secondary 5th gear
1. Install the secondary 5th gear as shown.
Clutch hub assembly (Sth/Reverse) and !%h/Reverse shift
fork
1. Install the clutch hub assembly (5thReverse) and the 5th/Re-
verse shift fork together.
52-39

52 TRANSAXLE
23UOJ2-01:
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:
128-198 N&m (13.0-20.0 m-kg, 94-145 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.1 O-0.22mm (0.0039-0.0087 in)
Maximum: 0.27mm (0.011 in)
6. If not as specified, reassemble the transaxle.
52-40

TRANSAXLE J2
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. Fill the transaxle with the specified amount of the specified transaxle oil after installation.
4. Warm up the engine and transaxle, and inspect for oil leakaae and transaxle ooeration.
37-52 (3.8-5.3, 27-38) 37-52 (3.8-5.3, 27-38)
9.8-12 (1.0-1.2, 7.2-8.7)
7.8-l 2 (0.8-l .2, 5.8-8.7)
1. Transaxle
6. Tie-rod end
2. Engine mount No.4 7. Clutch release cylinder
3. Joint shaft
8. Engine mount No.2
4. Driveshaft
9. Exhaust pipe
Installation Note
10. Engine mount member
. . . . . . . . . . . . . . . . . . . . .
page J2-42 11. Control rod
5. Stabilizer
12. Extension bar
Installation Note 13. Starter
. . . . . . . . . . . . ..______. page J2-42 14. Ground
31-48 (3.2-4. ‘8
88-l 18 (g-12,65-87)
(6.5-9.1, 47-88)
37-52 (3.8-5.3, 27-38)
N.m (m-kg, Mb)
15. Neutral switch connector
16. Back-up light switch
connector
17. Speedometer
cable
18. Battery carrier
19. Battery
20. Air hose and resonance
chamber
21. Splash shield
22. Wheel and tire
52-41

J2 TRANSAXLE
ONOJZ-09
03UOJ2-11
Installation Note
Driveshaft
Caution
l Do not damage the new oil seal.
1. Install the driveshaft with the end-gap of the new clip faC-
ing upward.
Stabilizer
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension @ : 17-19mm (0.67-0.75 in)
i-/’
J2-42