clutch MAZDA PROTEGE 1992 Manual Online

Jl TRANSAXLE
,
,,
03UOJi-09
03UOJl-10
Jl-40
OSUOJl-1C
15. Remove the bearing outer race from the SST (selector).
16. install the selected shim(s) and bearing outer race to the
transaxle case.
-’
Bearing preload (Differential)
Measure the preload as follows.
1. Set the differential assembly into the clutch housing.
2. Install the transaxle case onto the clutch housing.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
3. Install the SST to the differential side gear through the trans-
axle case.
4. Measure the bearing preload.
Preload:
0.03-0.74 N,m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
5. If not as specified, readjust the bearing preload.
6. Remove the SST.
7. Remove the transaxle case and differential assembly.

Jl TRANSAXLE
03UOJl-10
-
23UOJl.01
Adjust shim (Primary shaft gear)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
1. Apply transaxle oil to the adjust shim(s) and install it.
Funnel and bearing outer race
Caution
l Apply transaxle oil to the bearing outer race.
1. Install the funnel and the bearing outer race.
Oil seal (Primary shaft gear)
Caution
* Apply transaxle oil to outer circumference of the oil
seal.
1. install the new oil seal with a suitable pipe.
Oil seal (Change rod)
Caution
l Apply transaxle oil to the oil seal lip.
1. Install the oil seal.
Boot and change rod assembly
Caution
l Install the boot with the air bleed downward as
shown in the figure.
1. Slide the boot onto the change rod assembly.
2. Install the change rod assembly into the clutch housing.
-,
Jl-42

TRANSAXLE Jl
1. Control rod
2. Control end
3. lstl2nd shift fork
4. Control lever
5. Interlock sleeve
6.3rd/4th shift fork
7. Clutch hub
8. Synchronizer key
9. Clutch hub sleeve
10. Synchronizer spring
11. Clutch housing
12. Differential assembly
13. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-45
14. Primary shaft gear assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . , . page J 1-45
15. Spring
16. Steel ball
17. Shift fork and shift rod assembly
Assembly Note.. . . . . . . . . . . , . . . . . . . . . , . . , page J 1-45
18. Crank lever assembly
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
19. Crank lever shaft
Assembly Note.. . . . . . . . . . . , , . . . . . . . . . . . . page Jl -46
20. Pin
21. 5th shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page 31-46
22. 5th shift rod
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-46
23. Reverse idler gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
24. Reverse idler shaft
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . page Jl -46
25 Magnet
26. Transaxle case assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl -47
27. Neutral switch
28. Back-up light switch
29. Lock bolt and washer
30. Secondary 5th gear
31. Gear sleeve
32. 5th gear
33. Synchronizer ring (5th)
34. Clutch hub assembly (5th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
35. 5th shift fork
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
36. Stop plate
37. Locknut (Secondary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
38. Locknut (Primary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-47
39. Rear cover
13UOJl-005
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.
03UOJl-115 Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
03UOJ2-088
51-45

Jl TRANSAXLE
I I 03UOJ2-089
03UOJ2-091 3
03UOJ2-09
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, the rod will
at the same time 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. -’
5th shift rod end and 5th shift rod
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 (1) and the shift rod (2), 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.
Jl-46

TRANSAXLE Jl
- 23UOJl-01
03UOJl-11
03UOJl-14
I 03UOJl-11
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.
Tightening torque:
19-26 Nom (1.9-2.6 m-kg, 14-19 ft-lb)
Clutch hub assembly (6th) and 6th shlft fork
1. Install the clutch hub assembly (5th) and the 5th shift fork
together.
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:
126-206 N*m (13.0-21 m-kg, 94-152 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06-0.26mm (0.0024-0.0102 in)
Maximum : 0.31 mm (0.0122 in)
6. If not as specified, reassemble the transaxle.
Jl-47

TRANSAXLE Jl
1. Transaxle
Installation Note ..,......,.............. page Jl-49
2. Engine mount No.4
3. Driveshaft
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
4. Stabilizer (BP SOHC)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
5. Tie-rod end
Installation Note ,........,..,........... page Jl-50
6. Clutch release cylinder
7. Engine mount No.2
8. Exhaust pipe
9. Engine mounting member
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-50
10. Control rod
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51 11. Extension bar
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51
1 12. Starter
13. Ground
Installation Note .,..,...,......,........ page Jl-5
14. Neutral switch connector
15. Back-up light switch connector
16. Speedometer cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-5
17. Battery carrier
18. Battery
19. Air hose and resonance chamber
20. Splash shield
21. Wheel and tire 1
Installation Note
Transaxle
1. Set the transaxle on a jack and lift it into place.
Install tne transaxle oorts.
Tightening torque:
64-69 N*rn (6.5-9.1 m-kg, 47-66 ft-lb)
Loosely tighten engine mount No.4 bolts.
Jl-49

TRANSAXLE Jl
03UOJl-12!
03UOJi-13
2. Tighten engine mount No.4 nuts.
Tightening torque:
67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)
3. Remove the SST (Engine support).
Control rod and extension bar
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 Nern (3.2-4.7 m-kg, 23-34 ft-lb)
2. Install the change control rod to the transaxle.
Tightening torque:
16-23 N*m (1.6-2.3 m-kg, 12-17 ft-lb)
Ground
1. Connect the ground to the clutch pipe bracket.
Tightening torque:
16-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Speedometer cable
1. Add the specified oil through the speedometer gear case
mounting. (Refer to page Jl-7.)
2. Install the speedometer driven gear.
Tightening torque:
7.6-l 2 N*m (60-120 cm-kg, 69-104 in-lb)
3. Connect the speedometer cable to the speedometer driv-
en gear.
J141

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 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

TRANSAXLE J2
Sth/Reverse Gear and Housing Parts
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
1. Rear cover
2. Locknut (Primary shaft)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-14
3. Locknut (Secondary shaft)
Disassembly Note . . . . . . . . . . . . . . . . . . . . .
page J2-14
4. Primary reverse synchronizer gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
5. Synchronizer ring (Reverse)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
6. Secondary reverse synchronizer gear
Inspection ,,.*.....,.,..............I.,..,.. page J2-22
7. Roll pin
8. 5th/Reverse shift fork
9. Clutch hub assembly (5thIReverse) 14. Lock bolt
15. Guide bolt
16. Lock bolt, ball, and spring
17. Transaxle case assembly
18. Magnet
19. Reverse idler shaft
20. Reverse idler gear
21. Lock bolt
22. 5thlReverse shift rod and clip
23. 5th/Reverse shift rod end
24. Pin
25. Crank lever shaft
26. Crank lever assembly
27. Shift fork and shift rod assembly
.- . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-22 Disassembly Note . . . . . . . . . . . . . . . . . . . . . page
JZ-14
10. Synchronizer ring (5th) 28. Steel ball
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22 29. Spring
11. 5th gear 30. Primary shaft gear assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22 31. Secondary shaft gear assembly
12. Gear sleeve 32. Differential assembly
13. Secondary 5th gear 33. Clutch housing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
52-l 3