MAZDA PROTEGE 1992 Workshop Manual

DRIVE SHAFT M
Overhaul
Caution
l Do not remove the U-shaped bearing outer races from the outer ring. (BP SOHC Left drive shaft)
l Secure the joint in a vise with protective material (such as copper plates) on the vise jaws.
l Be careful that dust or other foreign material does not enter the joint while the work is being
performed.
l Do not disassemble the wheel-side ball joint.
l Do not wash the joint unless it is being disassembled.
1. Disassemble in the order shown in the figure, referring to Disassembly Procedure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to Assembly Procedure.
I
23UOMX-030
1. Boot band 8. Band
2. Boot band 9. Dynamic damper
3. Clip 10. Boot band
4. Outer ring 11. Boot band
Inspect inside bore for wear, corrosion, and 12. Boot
scoring 13. Shaft and ball joint assembly
5. Snap ring Inspect splines for damage and wear
6. Tripod joint Inspect wheel-side joint for excessive play
7. Boot and rough rotation
M-25

M DRIVE SHAFT
03UOMX-048
II I
O?,UOMX-04
MARKS
03UOMX-050
’ TAPE
OSUOMX-OE il
M-26
03UOMX-052
Disassembly procedure
1. Pry up the locking clips of the transaxle-side boot bands
with a screwdriver.
2. Remove the bands with pliers.
3. Slide the boot along the shaft to expose the joint.
4. Mark the outer ring and the shaft for proper reassembly.
5. Remove the stopper ring.
6. Mark the shaft and tripod joint for proper reassembly.
7. Remove the snap ring with snap-ring pliers.
Caution
l Do not damage the bearing.
8. Remove the tripod joint from the shaft with a bar and a
hammer.
9. Wrap the splines of the shaft with tape to prevent damag-
ing the boot. Remove the boot.
Caution
l Do not remove the dynamic damper if not nece-
ssary.
10. Pry up the locking clip of the band with a screwdriver.
Il. Remove the band with pliers. Remove the dynamic damper.

DRIVE SHAFT M
I
I 03UOMX-053
DIFFERENTIAL SIDE WHEEL SIDE
23UOMX-03 1
03UOMX.05
23UOMX :-032
23UOMX
Caution
l Do not remove the wheel side boot if not necessary.
12. Pry up the locking clips of the wheel-side boot bands with
a screwdriver.
13. Remove both bands with pliers. Remove the boot.
Assembly procedure
Caution
l The wheel-side and transaxle-side boots are
different.
mm (in)
I c3
80.8
I 89.0 85.2
(3.18) (3.50)
I I 94.1
(3.35) (3.70)
1. Wrap the splines of the transaxle-side shaft, and install the
wheel-side boot.
Caution
l Always use new bands.
l The bands should be mounted in the direction op-
posite the forward revolving direction of the drive
shaft.
2. Install the dynamic damper and new band.
3. Fold the band back by pulling on the end of it with pliers.
4. Lock the end of the band by bending the locking clip.
5. Install the wheel-side boot.
Caution
l Do not damage the bearing.
6. Align the marks and install the tripod joint with a bar and
a hammer.
7. Install the new snap ring with snap-ring pliers.
M-27

DRIVE SHAFT
8. Apply the specified grease included in the kit to the tripod
joint, outer ring, and boot. Install the outer ring.
9. If the wheel-side boot was removed, fill with the specified
grease included in the kit.
Specified grease
!J@z)
B6 SOHC BP SOHC BP DOHC
Right Left Right
Left Right Left
side side side side side side
DIFFEREN- 2;&y’ 140 (4.94) 145 (5.12)
TIAL SIDE y;L44;)
YELLOW YELLOW YELLOW
WHEEL SIDE 70 (2.47) 140 (4.94) 90 (3.18)
BLACK BLACK BLACK
23UOMX-03
I I
I
23UOMX-0:
M-28
Caution
l Be sure the boots are not dented or twisted.
. Carefully lift up the small end of the boots to release
any trapped air.
10. Install the boots.
11. Measure the length of the drive shaft.
Standard length: mm (in)
B6 SOHC BP SOHC BP DOHC
MTX 1 ATX MTX 1 ATX MTX 1 ATX
light side 919.3 918.7
630.7
(36.19) (36.17) (24.83)
640.2 621.2 637.1
(25.20) (24.46) (25.08)
I Left side
I 637.8
(25.11)
12. Fold the new bands back by pulling on the ends with pliers.
13. Lock the ends of the bands by bending the locking clips.

N
STEERING SYSTEM
INDEX ......................................................
MANUAL STEERING ............................... ;I g
ENGINE SPEED SENSING POWER
STEERING (ESPS) ................................. N- 3
OUTLINE ..................................................
SPECIFICATIONS .................................... ;I ::
MANUAL STEERING ..................................
PREPARATION ....................................... ;I ;
TROUBLESHOOTING GUIDE.. .................. N- 5
BOOT ................................................... N- 6
STEERING WHEEL AND COLUMN.. .......... N- 6
STEERING GEAR AND LINKAGE .............. N-13
ENGINE SPEED SENSING POWER
STEERING .............................................. N-23
PREPARATION ....................................... N-23
TROUBLESHOOTING GUIDE.. .................. N-25
AIR BLEEDING ....................................... N-26
STEERING WHEEL AND COLUMN.. .......... N-26
POWER STEERING FLUID.. ...................... N-27
STEERING GEAR AND LINKAGE .............. N-30
POWER STEERING OIL PUMP.. ................ N-37
DRIVE BELT ........................................... N-41
23UONX-001

INDEX
MANUAL STEERING
STEERING WHEEL PLAY
NON-TILT
23UONX-00.
1. Boot 3. Steering gear and linkage
Removal / Installation page N- 6 Removal / Installation..
................ page N-l 3 ..................
2. Steering wheel and column Disassembly ............................... page N-15
Inspection (On-vehicle)
............... page N- 8 Inspection ................................... page N-17
Removal I Installation.. ................
page N- 9 Assembly .................................... page N-19
Disassembly / Assembly.. ........... page
N-l 0
Inspection ...................................
page N-l 1
_’
N-2

INDEX
ENGINE SPEED SENSING POWER STEERING (ESPS)
FLUID
ATF M STEERING WHEEL PLAY
O-30mm (O-l .18 in)
SPECIFICATION
-IIt or Dexron@lI
I T nFFl FCTIC-IN
--. --w. .-.. NEW: 8.0-9.0mm (0.31-0.35 in)
USED: 9.0-lO.Omm (0.35-0.39 in)
LIMIT: 11.5mm (0.45 in)
23UONX-00
1. Boot
4. Drive belt
Removal / installation
.................. page N- 6 Inspection ................................... page N-41
2. Steering gear and linkage Adjustment .................................
page N-42
Removal / Installation.. ................ page N-30 Replacement .............................. page N-42
Disassembly / Inspection.. ..........
page N-31 5. Power steering fluid
Assembly..
.................................. page N-34 Air bleeding ................................ page N-26
3. Power steering oil pump Inspection.. .................................
page N-27
Removal I Installation
.................. page N-37 6. Steering wheel and column
Disassembly / Inspection I Inspection (On-vehicle).
.............. page N-26
Assembly ..................................
page N-38 Removal / Installation..
................ page N- 9
Disassembly / Assembly ............. page
N-l 0
Inspection ................................... page N-l 1
N-3

OUTLINE, MANUAL STEERING
OUTLINE
SPECIFICATIONS
Item
Steering wheel
Steering shaft and joint
Steering gear Outer diameter mm (in)
Lock-to-lock turns
Shaft
Joint
Power assist
Gear
Gear ratio
Rack stroke mm (in)
Power steering fluid
Fluid capacity liter (US qt, Imp qt) Manual steering Power steering 370 (14.6)
4.3 3.0
Collapsible
2cross joint
-
Engine speed sensing
Rack-and-pinion
a0 (infinite)
140 (5.51)
-
ATF Dexron@lI or M-III
-
0.8 (0.85, 0.70)
23UONX-00
MANUAL STEERING
PREPARATION
SST
49 0118 850C
Puller, ball joint For 49 1243 785
removal of tie rod
end Installer, dust
boot
49 0180 5108
Attachment,
steering worm
bearing preload
measuring For
measurement of
pinion preload 49 F032 308
Installer For
installation of dust
boot
For
installation of
oil seal
93GONX-OC
N-94

MANUAL STEERING N
TROUBLESHOOTING GUIDE
Problem
Possible cause Action PagelSectio
Steering feels heavy
Poor lubrication, foreign material in mechanism, stuck or Lubricate or replace N- 6
(Vehicle jacked up) damage of steering ball joint
Improper steering gear preload
Replace gear -
Damaged steering gear
Replace N-13
Malfunction of steering shaft joint
Replace N-10
Malfunction of steering gear Replace N-13
Cracked or worn steering gear mounting rubber Replace N- 6
Malfunction of suspension -
Section R Steering wheel pulls
Damaged steering linkage
Replace N-13 to one side Damaged wheel or tire -
Section Q
Malfunction of braking system -
Section P
Malfunction of suspension -
Section R General instability
Worn or damaged steering joints Replace N- 6 while drlvlng Improper steering gear preload Adjust
Damaged steering linkage
Replace N-13
Damaged wheel or tire -
Section Q
Malfunction of suspension -
Section R Steering feels
Malfunction of steering gear
Replace N-13 unstable Malfunction of steering joints
Replace N- 6
Malfunction of steering linkage
Replace N-13
Excessive steering
Worn steering gear
Replace N-13 wheel play Worn or damaged steering joints
Replace N- 6 Loose steering gear mounting bolts
Replace N-13 Poor steering wheel
Stuck or damaged steering joints
Replace N- 6
return Improper steering gear preload
Replace gear
Damaged wheel or tire -
Section Q
Malfunction of suspension -
Section R Shimmy
Damaged steering linkage Replace N-13 (Steering wheel Loose steering gear mounting bolts Tighten N-13 vibrates left/right) Stuck or damaged steering joints Replace N- 6
Damaged or worn front wheel bearing Replace Section M
Damaged wheel or tire -
Section Q
Malfunction of suspension -
Section R Abnormal noise from
Loose steering gear mounting bolts
Tighten N-13 steering system Malfunction of steering gear Replace N-13
Obstruction near steering column Replace -
Loose steering linkage Tighten N-13
Worn steering joints Replace N- 6
23UONX-OC
N-5

MANUAL STEERING
BOOT
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referrino to Installation Note.
N.m (m-kg, ft-lb) 7 (4.3-d&31-42)
23UONX-006
1. Cotter pin, nut
5. Tie rod end boot
2. Tie rod end/Steering knuckle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7
3. Locknut
6. Boot clip
Removal Note . . . . . . . . . . . . . . . . . . . . . page N- 7 7. Boot wire
4. Tie rod end
23UONX-00
8. Rack boot
Removal note
Tie rod end/Steering knuckle
1. Pull out the cotter pin, and loosen the nuts until the nut con-
tacts with the hole stud face.
Caution
l Leave the nuts temporarily tight not to damage the
screw thread.
2. Remove the tie rod from the knuckle arm with the SST.