1987 MAZDA 626 key

1C ASSEMBLY (TIMING BELT)
Rear Camshaft Pulley
1. Install the rear camshaft pulley.
2. Hold the camshaft with a wrench (29 mm, 1.14 in)
and tighten to the specification.
Tightening torque:
55—65 Nm (5.6—6.6 m-kg, 41—48 ft-lb)
76G01C-189
Camshaft Pulley
1. Connect the camshaft pulley onto the camshaft with
the semicircular (woodruff) key.
4BG01B-200
2. Hold the camshaft with a wrench (29 mm, 1.14 in),
tighten the camshaft pulley lock bolt.
Tightening torque:
55—65 Nm (5.6—6.6 m-kg, 41—48 ft-lb)
3. Align the mark on the camshaft pulley with the mark
on the seal plate.
76G01C-190
Injection Pump Pulley
1. Install the injection pump pulley with the semicir-
cular (woodruff) key to the injection pump shaft.
2. Rotate the injection pump pulley until the timing
marks are aligned.
3. Affix the injection pump pulley to the bracket us-
ing two bolts (35—40 mm, 1.4—1.6 in).
4. Tighten the lock nut.
Tightening torque:
59—69 N-m (6.0—7.0 m-kg, 43—51 ft-lb)
1C-82

TROUBLESHOOTING GUIDE 7A
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Change lever won't Seized change lever ball Replace 7A-58 shift smoothly, or is Seized change control rod joint Replace 7A-58
hard to shift Bent change control rod Replace 7A-58
Too much play in Worn change control rod bushing Replace 7A-58 change lever Weak spring of ball or change lever Replace 7A-58 Worn bushing of ball or change lever Replace 7A—58
Difficult to shift Bent change rod Replace 7A—58
No grease in transmission control Lubricate with grease 7A-58
Insufficient oil Add oil 7A-6
Deterioration of oil quality Replace with oil of 7A-6 specified quality
Wear or play of shift fork or shift rod Replace 7 A—18
Wear of synchronizer ring Replace 7A-27
Wear of synchronizer cone of gear Replace 7A-27
Bed contact of synchronizer ring and cone of Replace 7A-27 gear
Excessive longitudinal play of gears Replace 7A-22
Wear of bearing Adjust or replace 7A—22
Wear of synchronizer key spring Replace 7A-27
Excessive shaft gear bearing preload Adjust 7A-37
Improperly adjusted change guide plate Adjust 7A-20
Won't stay in gear Bent change control rod Replace 7A-58
Worn change control rod bushing Replace 7A-58
Weak change lever ball spring Replace 7A-58
Improperly installed extension bar Tighten 7A-58
Wear of shift fork Replace 7A—22
Wear of clutch hub Replace 7A-27
Worn clutch hub sleeve Replace 7A-27
Worn gear sliding part of both shaft gears Replace 7A-26
Worn gear sliding part of each gear Replace 7A-26
Worn steel sliding groove of control end Replace 7 A—18
Weak spring pressing against steel ball Replace 7A-18
Excessive thrust clearance Replace 7A—33,35
Worn bearing Replace 7A—22
Improperly installed engine mount Tighten 7A—49
Abnormal noise Insufficient oil Add oil 7A-6
Deterioration of oil quality Replace 7A-6
Worn bearing Adjust or replace 7A-22
Worn gear sliding surface of both shaft gears Replace 7A—26
Wear of sliding surfaces of gears Replace 7A-26
Excessive thrust clearance Replace 7A—33,35
Damaged gear teeth Replace with oil of 7A-26
specified quality Foreign material in gears Replace 7A-22
Damaged differential gear, or excessive backlash Adjust or replace 7A—30
76G07A-005
7A-5

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

INSPECTION 7A
86U07A-057
Synchronizer Ring
1. Engagement with gear
2. Worn or damaged teeth
3. Worn or damaged tapered surface
4. Clearance from side of gear
Clearance: 1.5 mm (0.059 in)
Minimum: 0.8 mm (0.031 in)
Note
a) Press the synchronizer ring uniformly
against the gear and measure around the
circumference.
b) If the clearance is less than specified, re-
place the synchronizer ring or gear.
Clutch Hub
1. Worn or damaged splines.
2. Worn or damaged synchronizer key groove.
3. Worn end surface.
4. Operation of the hub sleeve when it is installed.
63U07A-070
Clutch Hub Sleeve
1. Worn or damaged hub splines.
2. Worn or damaged sleeve fork groove.
3. Clearance between sleeve and shift fork.
Standard: 0.2—0.458 mm (0.008—0.018 in)
Limit: 0.5 mm (0.020 in)
63U07A-071
Synchronizer Key and Spring
1. Worn key.
2. Bent spring.
63U07A-072
Ik—21

ASSEMBLY 7 A
STEP 2
Note
During assembly, check the thrust clearance of each gear. (Refer to page 7A—33, 35)
76G07A-029
Assembly
Install the synchronizer key spring in the clutch hub
with the hook in the groove. This holds the three syn-
chronizer keys in place.
Note
a) The sizes of the synchronizer keys are
different.
86U07A-067
Specification: mm (in)
© © ©

1st/2nd 19 (0.7480) 4.25 (0.1673) 4.25 (0.1673)
3rd/4th
5th/Rev. 17 (0.6693) 4.25 (0.1673) 4.25 (0.1673)

86U07A-068
7 A—31

7A ASSEMBLY
49 F401 331
•
49 F401 331
•
86U07A-069
"Oil groove
(four places)
76G07A-030
ZJJ
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
Secondary Shaft
1. Assemble the 1st gear, synchronizer ring, and
clutch hub assembly (reverse gear), as shown in
the figure.
Note
Align the synchronizer ring, groove and clutch
housing hub key when installing.
86U07A-077
-IP Press on the clutch hub assembly (reverse gear)
with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
Install the retaining ring.
86U07A-078
4. Install the synchronizer ring and 2nd gear.
5. Install the secondary 3rd gear with the SST.
Note
Press to 19,620 N (2,000 kg, 4,400 lb).
86U07A-079
6. Install the retaining ring.
7. Install the secondary 4th gear and new bearing in-
ner race.
86U07A-080
7A-34

1 1 POWER BRAKE UNIT
Removal Note
Steering Shaft
To remove the mounting nuts of the power brake unit,
the steering shaft must be removed. (Refer to page
10—22 for removal and installation procedures.)
76G11X-102
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure, referring to disassembly note for specially marked
parts.
2. Inspect each part, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to assembly note for specially marked parts.
8.8—13 N-m (90-130 cm-kg, 78—112 in-lb)
1. Dust boot
2. Rear shell assembly
3. Retainer
4. Bearing
5. Dust seal
6. Retainer
7. Air filters
8. Air silencer
9. Diaphragm and plate
10. Power piston assembly
11. Retainer key
12. Valve rod and plunger as-
sembly
13. Reaction disc
76G11X-070
14. Spring
15. Push rod
16. Front shell assembly
17. Retainer
18. Seal
19. Vacuum switch (RF, RF-CX)
11-30