MAZDA PROTEGE 1992 Workshop Manual

MANUAL STEERING N
23UONX-050
23UONX.00 9
Locknut
1. Mark the tie rod end, the locknut, and the tie rod.
Tie rod end boot
1. Secure the tie rod end in a vise.
2. Place a chisel against the dust boot and hold it at the angle
shown.
3. Remove the boot.
Caution
l Do not scar the part where the tie rod attaches to
the dust boot.
Installation note
Tie rod end boot
1. Wipe the grease on the ball joint.
2. Put a small amount of rubber grease into the new dust boot.
q 3. Install the dust boot onto the tie rod end with the SST and
a press.
4. Wipe away any grease expelled from the dust boot.
N-7

N MANUAL STEERING
03UONX-01:
03UONX-01
23UONX-010
STEERING WHEEL AND COLUMN
On-vehicle inspection
Steering wheel play
With the wheels in the straight-ahead position, gently turn the
steering wheel to the left and right to determine if play is with-
in specification.
Play: O-30mm (O-l. 18 in)
Note
l if play exceeds specification, either the steering
joints are worn or the backlash of the steering gear
is excessive.
Looseness of steering wheel and column
Move the steering wheel in directions @ , @ , and @ to check
for column bearing wear, steering shaft joint play, steering
wheel looseness. and column looseness.
Steering wheel effort
1. With the vehicle on a hard level surface, move the steering
wheel to put the wheels in the straight-ahead position.
2. Attach a pull scale to the outer of the steering wheel, and
then starting with the wheels in the straight-ahead position,
check the steering effort required to turn the steering wheel
to the left and to the right.
3. If the measured effort exceeds specification, check the fol-
lowing: rotation-starting torque of the pinion, rotation torque
of each ball joint, and seizure of each joint.
Steering wheel effort: 108 N (11 kg, 24.2 lb) or less
Note
l Measure after turning the steering wheel to the left
and right 5 times or more.

MANUAL STEERING N
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal.
39-49 (4-5, 29-36)
Q
3-2.7, 13-20)
2.0-5.9 N.m (20-60 cm-kg, 17-52 In
N.m (m-kg. Mb)
1. Horn cap 6. Undercover
2. Locknut 7. Dust cover
3. Steering wheel 8. Fixing bolt (Intermediate shaft/Pinion shaft)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-10 9. Interlock cable (ATX only)
4. Column cover 10. Steering shaft assembly
5. Combination switch Disassembly / Assembly . . . . . . . . . . . . . page N-l 0
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section T Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
N-9

N MANUAL STEERING
Removal note
Steering wheel
Remove the steering wheel with a suitable puller.
Caution
l Do not try to remove the steering wheel by hitting
the shaft with a hammer. The column will collapse.
I
03UONX-011
Disassembly / Assembly
1. Reassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.
REPLACE
22-27 (2.2-2.8, 18-20)
@ 18-27 (1.8-2.7, 13-20)
N.m (m-kg, &lb)
311 I”hlY.nl’ L”““l .,. “,
2
1, Steering lock assembly 7. Tilt lever bracket
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 1 8. Fixing bolt (Universal joint/Intermediate shaft)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 2 9. Intermediate shaft
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
2. Coating plate 10. Fixing bolt (Steering shaft/Universal joint)
3. Bolt 11. Universal joint
4. Adjusting bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
5. Adjusting lever
12. Steering shaft assembly
6. Adjusting nut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
N-10

MANUAL STEERING N
13UONX-01
23UONX-05
POSITION
1 SGONX-Oi
23UONX.01 I1
Disassembly note
Steering lock assembly
Use a chisel to make a groove in the head of the steering lock
mounting bolts. Remove the bolts with a screwdriver; then re-
move the steering lock assembly.
Caution
l Secure the shaft in a vise protected with brass pads
or cloth.
Inspection
Check for the following and replace the assembly if necessary.
Steering shaft assembly
1. Column bushing wear.
2. Steering shaft length.
Specified length: 558.3~560.3mm (21.98-22.06 in)
3. Tilt operation.
(1) Verify that the adjusting lever moves smoothly from un-
lock position to lock position.
(2) Verify that the steering shaft is fixed firmly when the ad-
justing lever is locked.
Intermediate shaft, Universal joint
Universal joint looseness, abnormal noise, or sticking.
N-l 1

N MANUAL STEERING
1 I
13UONX-033
Steering lock assembly (ATX)
Verify that the cable connector does not move when the key
is in the LOCK position and that it moves freely with the key
in other positions.
Assembly note
Steering lock assembly
Install the steering lock assembly on the jacket. Install new
steering lock mounting bolts, and tighten them until the heads
break off.
I 13UONX-034
N-12

MANUAL STEERING N
STEERING GEAR AND LINKAGE
Removal / Installation
1. Loosen the wheel lug nuts.
2. Jack up the front of the vehicle and support it with safety stands.
3. Remove the wheels.
4. Remove in the order shown in the figure, referring to
Removal Note.
5. install in the reverse order of removal, referring to Installation Note.
6. Adjust the toe-in (Refer to Section R).
/
37-52 (3.8-5.3, 27-38)
REPLACE 31-42)
N-m (m-kg, ft-lb)
23UONX-01,
1. Cotter pin 6. Nut
2. Nut Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
3. Steering knuckle 7. Steering gear and linkage
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7 Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
4. Set plate
5. Fixing bolt (Intermediate shaft/Pinion shaft)
installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page
N-14
N-13

N MANUAL STEERING
r
13UONX-035
I 23UONX-015
Removal note
Steering gear and linkage
Remove the steering gear from the right side of the vehicle.
Installation note
Nut
install the steering gear mounting nuts in the order shown in
the figure.
Tightening torque:
37-52 N,m (3.8-5.3 m-kg, 27-38 ft-lb)
Fixing bolt (Intermediate shaft, Pinion shaft)
1. Remove the intermediate shaft and pinion shaft bolts, and
move the intermediate shaft upward.
2. Connect the intermediate shaft and the pinion shaft. Tight-
en the bolts, to the specified torques.
Tightening torque:
18-28 N-m (1.8-2.7 m-kg, 13-20 ft-lb)
23UONX-016
N-14

MANUAL STEERING N
Disassembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
23UONX-017
1. Tie rod end 12. Pinion protector
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 6 Disassembly note ,.,..,.............,... page N-16
2. Boot wire
3. Boot clip
4. Boot
5. Tie rod
Disassembly Note . . . . . . . . . . . . . . . . . . . . . .
6. Washer
7. Locknut
8. Adjusting cover
9. Spring
10. Pressure pad plate
11. Pressure pad 13. Oil seal
14. Snap ring cap
15. Snap ring
16. Pinion
page N-16 Disassembly Note ,....,,.............,. page N-l 7
17. Rack
Disassembly
Note . . . . . . . . . . . . . . . . . . . . . . page N-l 7
18. Bushing
19. Mounting bracket and rubber
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-17
20. Gear housing .
N-15

N MANUAL STEERIN
93GONX-007
23UONX-01 I
c-7
23UONX-01
63U 1 OX-089
Disassembly note
Steering gear and linkage
1, Secure the mounting part of the removed gear and linkage
in a vise.
Caution
l Be sure to insert a soft, protective material between
the part and the jaws of the vise.
Tie rod end
1. Make a matching mark on the tie rod threads for proper
reassembly.
Tie rod
1. Uncrimp the locking washer.
2. After wrapping the rack in a rag and securing it in a vise,
remove the tie rod from the rack.
Pinion protector
1. Hit the rim of pinion protector with a plastic hammer gently
from under to remove it.
I m-
I
93GONX-067
N-16