1990 MAZDA 232 lock

J3
MANUAL TRANSAXLE AND
TRANSFER UNIT (GSMX-R)
INDEX .........................................
J3- 2
/FEATURES] I
OUTLINE .....................................
J3- 4
OUTLINE OF CONSTRUCTION ..... J3- 4
SPECIFlCATtUNS ....................... J3- 5
TRANSAXLE AND TRANSFER UNIT J3- 5
STRUCTURAL VIEW.. ................. J3- 6
TRANSAXLE ................................ J3- 8
DOUBLE CONE SYNCHRU
MECHANlSM ........................... J3- 8
SHIFT FORKS AND SHIFT RODS . . J3- 10
iNTERLUCK MECHANISM ......... ., J3- 11
TRANSFER UNtT
.......................... J3- 12
CENTER DIFFERENTIAL ............. J3- 14
VISCOUS COUPLING
(BP DOHC TURBO). .................. J3- 20
CENTER DlFFERENTIAL LUCK
SYSTEM (MANUAL) .................. J3- 23
CENTER DIFFERENTIAL LOCK
SYSTEM (ELECTRICAL) ............. J3- 24
CENTER DIFFERENTIAL LOCK
CONTROL SWITCH ................... J3- 28
CENTER DIFFERENTIAL LUCK
ASSEMBLY
.............................. J3- 29
CENTER DIFFERENTIAL LOCK
SENSOR SWlTCH.. ................... J3- 31
IDLER GEAR SHAFI- ................... J3- 33
POWERFLOW .............................. J3- 34
TROUBLESHOOTING GUIDE ......... J3- 35 TRANSAXLE OIL .......................... J3- 36
INSPECTlON ............................. 33- 36
REPLACEMENT.. ....................... J3- 36
TRANSFER CARRIER CM .............
339 36
INSPECTION ............................. J3- 36
REPLACEMENT. ........................ J3- 36
TRANSAXLE AND
TRANSFER UNIT ........................ J3- 38
PREPARATION .......................... J3- 38
REMOVAL ................................. J3- 42
DISASSEMBLY
........................... J3- 48
INSPECTION ............................. J3- 72
ASSEMBLY ............................... J3- 75
INSTALLATION
.......................... J3-I I2
SHIFT MECHANISM.. .................... J3-119
OVERHAUL ............................... J3-119
CENTER DIFFERENTIAL
LOCK SYSTEM ........................... J3-121
SYSTEM DIAGRAM ..................... J3-121
INSPECTION ............................. J3-122
CENTER DIFFERENTIAL
LOCK MOTOR ............................ J3-123
INSPECTDN ............................. J3-123
REPLACEMENT ......................... J3-123
4x4 CONTROL UNIT.. ................... J3-126
INSPECTION ............................. 53-l 26
REPLACEMENT.. ....................... 53-l 26
CENTER DIFFERENTIAL
LOCK SWITCH ........................... J3-126
INSPECTION ............................. J3-126
REPLACEMENT ......................... J3-127
CENTER DIFFERENTIAL
LUCK SENSOR SWITCH ............. J3-127
INSPECTION ............................. J3-127
REPLACEMENT ......................... J3-127
93GOJ3-701

J3 INDEX
JNDEX
LHD
// /
vIscOsIn:
ALL SEASON DEXRON-II, \_\;/ M-III
ABOVE -18OC @OF): ?5W-90
CAPACITY: 2.6 liters
(2.7 us qt, 2.2 Imp qt) ABOVE -18OC (UOF): 90
BELOW --t8OC (UOF): 8UW
CAPACITY: 0.5 liter
IO.53 US qt, 0.44 Imp qt 1. Transaxle oil
Inspection.. ._._.. . . . . . . . . . . . . . . . . . . . . . . . . page J3- 36
Replacement -.._.......-............... page J3- 36
2. Transfer carrier oi!
Inspection
. . . ..-*..-.*a. . . . . * . . . . . . . . . . . . . page J3- 36
Replacement . . ..-...Ir.....*....~......
page J3- 36 3. Transaxle and transfer unit
Removal . . . . . . . ..-.-........-._._._....... page J3- 42
Disassembly, .._. . . .-. ._. .-. . . . . . . . . . . . . page J3- 48
Inspection.. . . . . . . ._. .-. .-. .-. . ._. . . . ._. . . page J3- 72
Assembly _.._..._.__._......._._..._...._ page J3- 75
Installation _.._.._.._._..._. . . . . . . . . .._.._ page J3-1 I 2
4. Shift mechanism
Overhaul ,._.._... . . . . . . . . . . . ._..._......_ page
J3-1 19 J3-2 Inspection . . . . . . . . . . . . . .._......._._...... 5. Center differential lock motor
page J3-I 23 Replacement .,-.....,..._..............
page J3-123 6.4x4 Control unit
Inspection ,.......... ~ ....._._._........I- page J3-I 26
Replacement ..*...** . . . . *.*...- . . . . . . . - page J3-126 7. Center differential lock switch
1 nspection ..,....*.....*.. *.*.* . . . . -.- . . . . page J3-126
Replacement ..~ ..,....._.........._,... page 33-l 26
8.
Center differential lock sensor switch
Inspection.. . . . . . . _ _ _ . . . _. . . _. _ _ _. __. . . . _ _ page J 3- 128
Replacement ..,.. . . . . . . . . . . . . . .._...... page J3-128

t
1
lNDEX J3
GRADE: API SERVICE GL-5
ABOVE -18OC (OOF): 90
BELOW -18°C (OOf): 80W
CAPACITY: 0.5 liter
(0.53 us qt, 0.44 Imp qt)
SERVICE, SECTiON T
GRADE: API SERVICE Gt4
ALL SEASON DEXRON-II, M-D
ABOVE -18OC (OOF): 75W-90
CAPACITY: 2.6 liters
(2.7 US qt, 2.2 Imp qt)
I. Transaxle oil
Inspection . . . . .._........_................ page J3-
36
Reptacement . . . . . . . . . _,. . . . ._. . . . . . . . . .
page J3-
36
2. Transfer carrier oil
Inspection.. . .._. . . .._ ._. ._.. . . . . . . . . . . . . .
page
J3- 36
Replacement . . . . . . . . . . ..l._............ page J3-
36
3. TransaxIe and transfer unit
Removal .I...............~.......~......__
page J3- 42
Disassembly .**.,.--......-.**.....,.._.
page J3- 48
t nspection . . .._........*...*I.-..-........
page J3- 72
Assembly . .._....._.....--......-........ page J3- 75
lnstaliation . . . . ._. . . _ .-. . . . . . ..-. . . .._., . _ page J3-I 12
4. Shift mechanism
Overhaul . . . ..*..-.*._.........-..........
pageJ3-119 5. Center differential lock motor
Inspection . . . . . . . . . . . . . . . . . . .._..._....... page J3-123
Replacement . . . _ , . . . . . . *. . . . . _ . _. . . . _ . .
page J3- 123
6. 4x4 Control unit
Inspection . . . . . . . . . . . . .._...._......._....
page J3-126
Replacement . . . .._......_........ . . . . . .
page J3-126
7. Center differential lock switch
Inspection.. . _ . _ . _. _. . _. . . . . _ . . . _ . . . . . . . . .
page J3-f 27
Replacement . . . . . .._...._........_..... page 33-l 27
8. Center differential lock sensor switch
Inspection . . . . . . . . . . . . . . ** .-... 1*..**-.I..
pageJ3-128
Replacement
. . ..=......-.... -* . . . . -..-. page J3-I 28
J3-3

J3 OUTLtNE
OUTLINE OF CONSTRUCTION
l Full-time 4-wheel drive, incorporating a viscous coupling is used on the BP DUHC Turbo model. BP SUHC
engine equipped models are fitted with an electronically controlled, lockable center differential.
With this system all driving conditions are easily contended with; from good roads to bad roads and
ad-
verse weather conditions.
l The transaxle and transfer unit were developed based on the GSM-R type transaxle.
The transaxle, center differential, viscous coupling, and front differentia! are a single, compact unit.
l The center differential employs a planetary carrier. system and a viscous coupling, and functions to distrib-
ute the driving force to the front and rear differentials as needed.
Through the use of this center differential, tire scuffing common to 4-wheel drive vehicles during tight cor-
nering, is eliminated.
l The speedometer driven gear (for detection of vehicle speed) is installed in the transfer carrier and detects
the speed of the rear wheels.
l Lubrication oil of the transaxle and transfer unit and of the carrier is contained separately.
93GOJ3-704
J3-4