1987 MAZDA 626 Workshop Manual

DISASSEMBLY 7 A
Disassembly Note
Transaxle
Mount the transaxle on the SST.
86U07A-037
Lock nut
1. Lock the primary shaft with the SST.
2. Shift to 1st or 2nd gear.
3. Remove the lock nut.
86U07A-038
Shift rod
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Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the
control lever, then turn the shift rod counter-
clockwise.
2. While holding the 1st-2nd shift fork with one hand
and the 3rd-4th shift fork with the other, raise them
both at the same time and shift each of the clutch
hub sleeves.
86U07A-039
3. Lift the control end and remove the steel ball, and,
at the same time, remove the shift rod from the
clutch housing.
4. Separate the shift rod and shift fork assembly from
each of the clutch hub sleeves.
76U07A-227
7A-19

7A DISASSEMBLY
STEP 2
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
76G07A-018
76G07A-019
1. Bearing outer race 15. Selector 28. Roll pin
2. Oil seal 16. Oil seal 29. Reverse lever shaft
3. Bearing outer race 17. Bolt 30. Reverse lever
4. Funnel 18. Bleeder cover 31. Drain plug and washer
5. Bolts 19. Bleeder 32. Neutral switch and gasket
6. Guide plate 20. Bolt 33. Bearing outer race
7. Pipe 21. Speedometer driven gear 34. Diaphragm spring
8. Bolt assembly 35. Adjust shim
9. Change arm 22. O-ring 36. Bearing outer race
10. Roll pin 23. Roll pin 37. Adjust shim
11. Change rod 24. Driven gear 38. Oil seal
12. Boot 25. Gear case 39. Back-up light switch
13. Spring 26. Oil seal 40. Oil passage
14. Reverse gate 27. Bearing outer race
7A-20

DISASSEMBLY 7 A
Disassembly Note
Bearing outer race (primary shaft)
Remove the bearing outer race with the SST.
86U07A-041
Bearing outer race (secondary shaft)
Remove the bearing outer race by lifting out the fun-
nel and race together.
86U07A-042
Roll pin
Align the groove for removal of the clutch housing
pin with the position of the roll pin, then tap the pin
out using a pin punch.
76G07A-020
Bearing outer race (differential)
Remove the bearing outer race with the SST.
86U07A-044
7A-21

7 A DISASSEMBLY
STEP 3
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
Note
a) Replace the bearings with new ones whenever they are disassembled.
b) Before disassembly, check the thrust clearance of all gears. (Refer to page 7A—33, 35.)
76G07A-021
1. Shift fork (3rd and 4th 13. 2nd gear 26. 4th gear
gears) 14. Synchronizer ring 27. Synchronizer ring
2. Interlock sleeve 15. Retaining ring 28. Retaining ring
3. Roll pin 16. Clutch hub assembly 29. Clutch hub assembly (3rd
4. Control end 17. Synchronizer spring and 4th gears)
5. Shift fork (1st and 2nd 18. Synchronizer key 30. Synchronizer spring
gears) 19. Clutch hub 31. Synchronizer key
6. Roll pin 20. Clutch hub sleeve (reverse 32. Clutch hub
7. Control lever gear) 33. Clutch hub sleeve
8. Control rod 21. Synchronizer ring 34. Synchronizer ring
9. Bearing outer race 22.
1
st gear 35. 3rd gear
10. Secondary 4th gear 23. Bearing inner race 36. Bearing inner race
11. Retaining ring 24. Secondary shaft 37. Primary shaft
12. Secondary 3rd gear 25. Bearing inner race
IK—22

DISASSEMBLY 7A
Disassembly Note
Secondary Shaft
Bearing inner race (secondary 4th gear end)
Remove the bearing inner race and secondary 2nd
gear with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-022
Secondary 3rd gear and 2nd gear
1. Remove the retaining ring.
2. Shift the gears to 1st gear.
3. Remove the secondary 3rd gear and 2nd gear with
the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
86U07A-047
1st gear
1. Remove the retaining ring.
2. Remove the clutch hub assembly (reverse gear)
and 1st gear as shown in the figure.
Caution
Hold the shaft with one hand so that it does
not fall.
86U07A-048
Bearing inner race
Remove the bearing inner race with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-023
7 A—23

7A DISASSEMBLY
Primary Shaft
Bearing inner race (4th gear end)
1. Remove the retaining ring.
2. Remove the bearing inner race with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-024
Clutch hub assembly (3rd/4th)
1. Remove the retaining ring.
2. Remove the clutch hub assembly with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
86U07A-051
Bearing inner race
Remove the bearing inner race with the SST.
Caution
Hold the shaft with one hand so that it does
not fall.
76G07A-025
7A-24

DISASSEMBLY 7A
STEP 4 (DIFFERENTIAL)
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
Note
a) If the bearing inner races are removed replace them with new ones.
b) Before disassembly, check the backlash of the side gears and pinion gears.
(Refer to page 7A—30)
1. Knock pin
2. Pinion shaft
3. Pinion gear
4. Thrust washer
5. Side gear
6. Thrust washer
7. Side bearing in-
ner race
8. Speedometer
drive gear
9. Side bearing in-
ner race
10. Gear case
76G07A-026
Disassemble Note
Side bearing inner race (side opposite ring gear)
Remove the race from the gear case with the SST.
Caution
Hold the gear case with one hand so that it
does not fall.
76G07A-027
Side bearing inner race (ring gear side)
Remove the race with a combination of parts from
the SST.
86U07A-055
7A-25

7A INSPECTION
INSPECTION
Check the following parts, and replace if necessary.
1st, 2nd, 3rd, 4th, and 5th gears
1. Worn or damaged synchronizer cone.
2. Worn or damaged hub sleeve coupling.
3. Worn or damaged teeth.
4. Worn or damaged inner surface or end surface of
gears.
63U07A-064
Primary Shaft Gear and Primary Gear
1. Worn teeth
2. Primary shaft gear run-out
Run-out: 0.05 mm (0.002 in) max.
Note
If the shaft gear is replaced, adjust the bear-
ing preload. (Refer to page 7A—37)
76G07A-028
Secondary Shaft Gear
1. Worn or damaged gear contact surface.
2. Worn or damaged splines.
3. Worn teeth.
4. Clogged oil passage.
5. Secondary shaft gear run-out.
Standard run-out: 0.015 mm (0.0006 in)
63U07A-068
6. Oil clearance between secondary gear shaft and
gears.
Standard: 0.03—0.08 mm (0.001—0.003 in)
Caution
If the shaft gear is replaced, adjust the bear-
ing preload.
63U07A-069
7A-26