1987 MAZDA 626 lock

7A DISASSEMBLY
DISASSEMBLY
STEP 1
Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked
parts.
76G07A-016
76G07A-017
24. Crank lever shaft
25. O-ring
26. Crank lever assembly
27. Shift fork and shift rod as-
sembly
28. Steel ball
29. Spring
30. Primary shaft gear as-
sembly
31. Secondary shaft gear as-
sembly
32. Differential assembly
33. Clutch housing
1. Rear cover
2. Lock nut
3. Lock nut
4. Primary reverse synchroniz-
er gear
5. Secondary reverse syn-
chronizer gear
6. Roll pin
7. Shift fork
8. Clutch hub assembly
9. Synchronizer ring
10. 5th gear
11. Gear sleeve
12. Secondary 5th gear
13. Lock bolt
14. Guide bolt
15. Lock bolt, ball and spring
16. Transaxle case
17. Magnet
18. Reverse idle shaft
19. Reverse idle gear
20. Lock bolt
21. Shift rod (5th and reverse)
and clip
22. Gate
23. Pin
7 A—18

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

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

7A ASSEMBLY
86U07A-062
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86U07A-063
86U07A-064

Identification mark Thickness
0 2.0
mm
(0.079
in)

1 2.1
mm
(0.083
in)

2 2.2
mm
(0.087
in)
3. Install the thrust washers and pinion gears.
4. Install the pinion shaft.
5. Install the knock pin, then crimp it so that it cannot
come out of the gear case.
6. Install the thrust washers and the side gears.
Check and adjust using the following procedure.
7. Install the left and right driveshafts in the differen-
tial assembly.
8. Support the driveshafts on V-blocks as shown in
the figure.
9. Measure the backlash of both pinion gears.
Backlash: 0—0.1 mm (0—0.004 in)
86U07A-065
10. If the backlash is more than specified, adjust by
selecting thrust washers from the table and install
them between the case and side gears.
Note
Use the same thickness thrust washer on each
side.
7A-30

7A ASSEMBLY
49 F401 331
•
49 F401 331
•
86U07A-069
"Oil groove
(four places)
76G07A-030
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49 F40I 336 B
49 0636 145
86U07A-071
Primary Shaft
1. Install the new bearing inner race with the SST.
Note Press to 19,620 N (2,000 kg, 4,400 lb).
2. Install the 3rd gear, synchronizer ring, and clutch
hub assembly with the SST. (Refer to page
7A—33)
Note
a) Press to 19,620 N (2,000 kg, 4,400 lb).
b) Align the synchronizer ring groove and
clutch housing hub key when installing.
3. Install the retaining ring.
4. Install the synchronizer ring, 4nd gear, and bear-
ing inner race with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
5. Install both shift forks and the interlock sleeve, as
in the figure.
86U07A-072
7A-32

7A ASSEMBLY
8. Fit the crank lever in between the change arm and
the control end, and connect the crank lever shaft
to the crank lever.
9. Align the pin holes of the crank lever shaft and the
clutch housing, and insert the pin.
Note
Use a new O-ring for the crank lever shaft.
86U07A-113
10. Install the gate © and the shift rod ©, and tight-
en the gate mounting bolt.
Note
The mark (indicated by the arrow in the fig-
ure) and the gate mounting bolt hole must be
in the same direction.
76U07A-121
11. Install the reverse idle gear and the reverse idle
shaft.
12. Connect the magnet to the clutch housing.
13. Align the end of the interlock sleeve with the con-
trol lever indicated by the arrow, and, at the same
time, face the reverse idle shaft screw hole in the
direction shown in the figure.
76U07A-122
14. Apply a thin coat of sealant to the contact surfaces
of the clutch housing and transmission case, tight-
en the transaxle case installation bolts to the speci-
fied torque.
Tightening torque:
18—26 N m (1.8—2.7 m-kg, 13—18.8 ft-lb)
15. Insert the SST to driveshaft coupling hole.
7A-46

ASSEMBLY 7A
76G07A-048
86U07A-116
86U07A-117
16. Install the lock bolt 0, the guide bolt ©.
17. Install the ball, spring and lock bolt (5).
Tightening torque:
(1) 18—26
N
m
(1.8—2.7 m-kg, 13—19 ft-lb)
(2) 9—14 N-m
(90—140 cm-kg, 78—121 in-lb)
(3) 15—21 N-m
(150—210 cm-kg, 129—181 in-lb)
Note
Check that gear change operation is smooth.
18. Install the secondary 5th gear as shown.
19. Install the gear sleeve, the 5th gear and synchroniz-
er ring to primary shaft.
20. Tap in the roll pin.
21. Install the synchronizer ring and the reverse syn-
chronizer gears.
86U07A-118
7A—47

7A ASSEMBLY
22. Shift to 1st gear.
23. Lock the primary shaft with the SST.
24. Tighten new lock nuts.
Tightening torque: 128—196 N-m
(13.0—20.0 m-kg, 94—145 ft-lb)
25. Stake the lock nuts.
86U07A-119
26. Clean and coat the both surfaces and install the
rear cover.
Tightening torque: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
76G07A-049
7A-48