1987 MAZDA 626 transaxle

INSTALLATION 1C
Heater Hose
Connect the heater hoses.
Note
Position the hose clamp in the original loca-
tion on the hose and squeeze the clamp lightly
with large pliers to ensure a good fit.
86U01X-221
Connector Location
Install each harness as shown in the figure.
1. Alternator
2. Boost air temperature sensor (RF-CX)
3. Heat gauge unit
4. Water thermo switch
5. Pick up coil
6. Glow cord
7. Front harness connector and ground
76G01C-222
8. Fuel cut valve
9. Oil pressure switch
10. Starter
11. Water temperature switch
12. Transaxle harness
13. Grounds
1C—95

1C INSTALLATION
76G01C-223
76G01C-224
76G01C-225
A/C Compressor
1. Install the A/C compressor.
Tightening torque:
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
2. Install the drive belt and adjust the belt deflection.
(Refer to page 1C—7)
Speedometer Cable
Install the speedometer cable.
Transaxle harness
Install the transaxle harness.
Clutch Release Cylinder
1. Set the pipe bracket in position.
Tightening torque:
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
2. Install the clutch release cylinder.
Tightening torque
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
No.4 Engine Mount
Install the No.4 engine mount.
Tightening torque:
(A): 55—80 N-m
(5.6—8.2 m-kg, 41—59 ft-lb)
(|): 36—54 N-m
(3.7—5.5 m-kg, 27—40 ft-lb)
©: 64—89
N
m
(6.5—9.1 m-kg, 47—66 ft-lb)
67—93 N-m
(6.8—9.5 m-kg, 49—69 ft-lb)
76G01C-226
1C-96

4D SUPERCHARGING SYSTEM (RF-CX)
ON-VEHICLE INSPECTION
Boost Pressure
1. Connect a pressure gauge to the hose from the
intake manifold.
2. (On chassis dynomometer, full load)
(1) Set the vehicle on a chassis dynomometer.
(2) Run the vehicle in gear at 3,000 rpm with the
acceleration pedal fully depressed.
(3) Measure the boost pressure.
Boost pressure:
82 kPa (0.87 kg/cm2, 8.1 psi)
Note
The above inspection should be done on a
chassis dynomometer. If a dynomometer is
not available follow the below procedure.
3. (Off chassis dynomometer, no load)
(1) Shift the transaxle out off gear.
(2) Run the engine in neutral at 3,000 rpm of the
engine no load.
Measure the boost pressure.
Boost pressure:
5 kPa (0.05 kg/cm2, 0.7 psi)
Note
The boost pressure is varied by engine speed
and engine load.
(3) Remove the starting valve bypass hose.
(4) Check that the bypass valve is closed at 3,000
rpm.
4.
If
the pressure is below specification, check the fol-
lowing. Replace the Comprex supercharger if
necessary.
(1) Intake air and exhaust passages leakage
(2) Intake air and exhaust passages clogged
(3) Wastegate (Refer to 4D—12.)
(4) Starting valve (Refer to 4D—15.)
(5) Fuel system (Injection nozzle... refer to page
4D—31, injection pump...refer to page 4D—24,
etc.)
5. If the pressure exceeds specification, check the
wastegate operation. (Refer to page 4D—12.)
4D—11

CLUTCH AND FLYWHEEL 6
CLUTCH AND FLYWHEEL
REMOVAL
Components
Gasoline: 96—103 N-m (9.8—10.5 m-kg, 71—76 ft-lb)
Diesel: 177—186 N-m (18—19 m-kg, 130—137 ft-lb)
18-26 N-m (1.8—2.7 m-kg, 13—20 ft-lb)
1. Clutch release bearing
2. Clutch release fork
3. Clutch cover
76G06X-024
4. Clutch disc
5. Pilot bearing
6. Flywheel
7. Ring gear
1. Remove the transaxle. (Refer to Section 7).
2. Attach the SST to the engine, and remove the
clutch cover and clutch disc.
B6U06X-030
6-15

6 CLUTCH AND FLYWHEEL
86U06X-042
86U06X-043
5. Clean the clutch disc splines and primary shaft
splines, then apply clutch grease (Mori White TA
No. 2 or equivalent organic molybdenum
grease).
6. Install the clutch disc with the SST.
Note
Install the clutch so that it faces in the direc-
tion shown in the figure.
7. Install the SST, and tighten the clutch, cover di-
agonally and evenly.
Tightening torque: 18—26 N-m
(1.8—2.7 m-kg, 13—20 ft-lb)
8. Install the transaxle. (Refer to Section 7A.)
76G06X-027
6-20

MANUAL TRANSAXLE
OUTLINE 7 A— 2
STRUCTURAL VIEW 7A— 2
CROSS-SECTIONAL VIEW 7A— 3
SPECIFICATIONS 7A— 4
TROUBLESHOOTING GUIDE 7A— 5
ON-VEHICLE MAINTENANCE 7A— 6
TRANSAXLE OIL 7A— 6
DRIVESHAFT OIL SEALS 7A— 7
REMOVAL 7A—10
DISASSEMBLY 7A—18
STEP 1 7A—18
STEP 2 7A—20
STEP 3 7A—22
STEP 4 7A—25
INSPECTION 7A—26
ASSEMBLY 7A—29
STEP 1 7A—29
STEP 2 7A—31
STEP 3 7A—36
STEP 4 7A—44
INSTALLATION 7A—49
TRANSAXLE CONTROL 7A—58
76G07A-001

7A OUTLINE
OUTLINE
STRUCTURAL VIEW
76G07A-002
1. Primary shaft gear assembly
2. Secondary shaft gear assembly
3. Differential assembly
4. Clutch housing
5. Primary reverse synchronizer gear
6. Secondary reverse synchronizer gear
7. Reverse idle gear
8. Transaxle case
7A—2

7A OUTLINE
SPECIFICATIONS
•Engine model
Item ——
FE DOHC F6 FE 12-valve
FE 8-valve F8 RF-N RF-CX •Engine model
Item —— Leaded Unleaded F6 FE 12-valve Carb. Fl F8 RF-N RF-CX
Transaxle control Floor shift
Synchromesh system Forward synchromesh, Reverse selective sliding and synchromesh
Gear ratio
1st 3.307
Gear ratio
2nd 1.833
Gear ratio 3rd 1.310 1.233 1.161 Gear ratio
4th 1.030 0.970 0.914 0.861
Gear ratio
5th 0.837 0.795 0.755 0.680
Gear ratio
Reverse 3.166
Final gear ratio 4.105 3.850 4.105 3.850 4.105
Oil Type
ATF: DEXRON-II Above -18°C (0°F): API: GL-4 or GL-5 SAE 80W-90 or SAE 90 Oil
Capacity 3.35 liters (3.6 US qt, 3.9 Imp qt)
76G07A-004
7A—4