1990 MAZDA 232 differential

A SCHEDULED MAINTENANCE SERVICES (Australia)
lumber of months or km, whichever cumes first
P
_ 48 54 60 1 66 72
5
60 67.5 75 90 .--- .-- -
.-m-w --v-w _ _ -_-- - - _ _ - -
_ -- - - --- __-
_-
-- -- (82.5
Exhaust manifold bolts and nuts (except turbo) T 1
I i T 1
1 T
Engine timlrtg belt”’ Replace every 105,000 km
Drwe belts * a
A I 1 I 1 1 I 1
! ’ I I 1 1
Engine oil * ’ Except turbo models 1 RIR\R/RIRIRIR R R,R R R/R
For turbo models R
Replace every 5,000 km or 6 months
r-k:1 c:t+*-* 1 Except turbo models
R 1 R 1 1 R ( ) R ( 1 R ( 1
R 1 f R
-
1 VII IIIIc;I 1 For turbo models I R 1 ReDlace everv IO.000 km or E
Engine coolant (Wrth Reservoir)
Fuel
system
Replace e&y 24 months
For F-i. system
Idle speed (if equipped Idle 1 1 1 I
I speed controf)
Air cleaner element 1
R , I R I R
Fuet filter
I I? R R
~ Fuel lines and hoses
1 I 1 I I 1 I I 1 1
Ignition system
t Initial ignition timing
Spark plugs i I I I -1 I I
I I I I I
f
Evaporative emission control system
Evaporative system
Throttle sensor
Exhaust emission contra! system
[ Dashpot
(Except for ATX) I 1 I
1 1 I 1 1 t 1 1 1 1 1 ! 1 1 I 1
Electrical system
Battery electrolyte level and specific gravity ]
I 1 1 I 1 t I ’ 1 1 I 1 f I ( 1
I 1
Chassis and body
Brake lines, hoses and connections
Brake fluid * a
Parking brake
Disc brakes
1 Power steering fluid and line Ilf &uiDDedl
I 1 1 I I I
I 1 1 III II
I ’
I I
Steering operations and gear housing
I
1 1 I --r--j- 1 I
I
Steerino linkanes. rack auide and tie rod pnds .-- --
----.“.a ..‘-~--, J- -.-- _.- .-- -..-- I I I t I 1 1 I I I I I I I 1
Manual transaxle oil I \\!‘I rl\jl I 1 I R III
1 Transfer Automatic carrier oil or 09 automatic transaxle fluid level
1 1 I 1 111 I 1 I l 1 I 1 I 1[11i t I 1 I 1 I I 1 I
R 1 Iii 1 I
1 Rear axle oil (Differential) 1 t I I I I I I I I
t ’ I r . ’ 1 . I I I I I R I 1
I
I I
i T
1 T T T 1 T [ T I 1 T
Front suspension ball joints
Bolts and nuts on chassis and body
I I I . I ! ,
I 1 I . I 1 ’ I I ’
Drive shaft dust boots
I
I 1 I 1
I 1 1 I
~~
- - ’ C1utcl-1 pedat
Clutch fluid
1
A-4

REMOVAL Bl
/
/
93G05? -72t
Removal note
P/S oil pump
Caution
l Do not damage the hoses.
I _ Remove the P/S oil pump with the hoses still connected.
2. Position the pump away from the engine and secure it with
wire.
A/C compressor
Caution
l Do not damage the hoses.
1. Remove the AC compressor with the hoses still connected.
2. Position the compressor away from the engine and secure
it with wire.
Step 2
1. Disconnect the harness connectors shown in the figure.
DIFFERENTIAL
DIFFERENTIAL
LUCK SENSOR
OIL PRESSURE SWITCH --- -
GROUND
r, IDLE SPEED CONTROL
NEUTRAL SWITCH
’ SOLENOID VALVE w MTX!
(ECE WITHOUT _--------I
CATALYST) BACK-UP LIGHT SWITCH
\‘C
Y ~55 ATX’
d ---a-- ,-,---1
INHIBITOR SWITCH

REMOVAL Bl
Step 6
Separate the engine and transaxle in the order shown in the figure,
MTX
ATX
43GX3i-71
1 _ Intake manifold bracket 5. Air hose [ECE without catalyst only)
2. Center differential lock motor 6. Torque converter nuts @TX)
Removal Note . . _. _. . . ._. . . . . . . . . . . . . _. page 33-l 23 7. Transaxle mounting bolts
3. Starter and bracket 8. Tramaxle
4. Throttle cable (ATX)
Bl-73

91 1NSTALLATION
Step 4
1. Connect the hoses shown in the figure.
Caution
l Position the hose clamp in the original location on the hose, and squeeze it lightly with large
pliers to ensure a good fit.
Step 5
1. Connect the harness connectors shown in the figure.
OIL PRESSURE SWITCH
Df STRlBUTdR
OXYGEN SENSOR
(EXCEPT ECE
WITHOUT CATALYST) lVFFFRFh!TIAI
-.I I -4 m-m. I -r-h LOCK SENSOR DIFFERENTIAL
THRO77LE
/--+I / LOCK MOTOR
AC. .A--
r IDLE SPEED CONTROL
r
dz k
/NEUTRAL SWITCH
“Rou2ydy __
HEAT GAUGE UNIT ’
IDLE-UP
SOLENOID VALVE
IECE WlTl-tOUT
‘CATALYST-)
BACK-UP LIGHT SWITCH INHlBlTdR SWITCH
G3UOBX-837
E3i -20

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