1992 MAZDA PROTEGE clutch

TRANSAXLE J2
ShIReverse Gear and Housing Parts
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
37-52 (3.8-8.3, 27-38)
, .-- 104-122 in-lb)
H50-210 cm-ka NEW
O/NEW 8 iN m ’ --13OL-i82 in-@
@mI - *
(80-l 15 Cm-kg,
NEW 89-l 00 In-lb)
128-198
(13-20, 94-145)
1. Differential assembly
2. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
3. Primary shaft gear assembly
6. Shift fork and shift rod assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Assembly
J2-38
7. Crank lever assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly page
Note . . . . . . . . . . . . . . . . . . . . . J2-38
page 4. Spring
J2-38
8. Crank lever shaft 5. Steel ball
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
9. Pin
10. 5thlReverse shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-39
Il. 5th/Reverse shift rod and clip
Assembly Note . . . . . . . . . . . . . . . . . . . . . . page J2-39
12. Lock bolt
13. Reverse idler gear
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . page J2-39
14. Reverse idler shaft
Assembly Note.. . . . . . . . . . . . . . . page J2-39
15. Magnet
“J”“JL-“O)O
21. Secondary 5th gear 16. Clutch housing
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly
page J2-39
22. Gear sleeve Note . . . . . . . . . . . . . . . . . . . . . . . . . .
23. 5th gear page
24. Synchronizer ring (5th) J2-39
25. Clutch hub assembly (5thIReverse)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . page J2-39
26. 5thlReverse shift fork 17. Transaxle case assembly
Assembly Note .,........................ page J2-39
27. Roll pin Assembly
28. Secondary reverse synchronizer gear Note . . . . . . . . . . . . . . . . . . . . . . . . . .
29. Synchronizer ring (Reverse) page
30. Primary reverse synchronizer gear J2-39
31. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-40
32. Locknut 18. Lock bolt, ball and spring
Assembly
19. Guide bolt
Note.. . . . . . . . . . . . . . . . . page J2-40
33. Rear cover 20. Lock bolt
52-37

J2 TRANSAXLE
03UOJ2-08
03UOJ2-09(
03UOJ2-09’
J2-38
Assembly note
Primary shaft gear assembly and secondary shaft gear
assembly
1. Install the primary shaft gear assembly and the secondary
shaft gear assembly together.
Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
2. Insert the spring seat and spring into the reverse lever shaft,
install the steel ball, and place a scraper so that it contacts
the steel ball.
3. With the edge of the control end against the scraper, when
the control end is pushed in the direction of the arrow in
the figure so that the ball goes into the shaft, at the same
time the rod will line up with the shift rod coupling hole in
the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap
the shift rod from above so that the steel ball goes into the
center groove (of the 3 grooves in the control end).
5. Pull the ball part of the control end forward so that the steel
ball goes into the detent in the groove.
Crank lever assembly and crank lever shaft
Note
l Use a new O-ring for the crank lever shaft.
1. Fit the crank lever between the change arm and the con-
trol end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch
housing, and insert the new pin.

TRANSAXLE 52
r
03UOJ2-09:
03UOJ2-09
03UOJ2-094
03UOJ2-09!
03UOJ2-09t
fith/Reverse shift rod end, Sth/Reverse shift rod and clip
Note
l The mark (indicated by the arrow in the figure) and
the shift rod end mounting bolt hole must be in the
same direction.
1. Install the shift rod end @ and the shift rod 0, and tighten
the gate mounting bolt.
Reverse idler gear and reverse idler shaft
1. install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever
(indicated by the arrow), and, at the same time, face the
reverse idler shaft screw hole in the direction shown in the
figure.
Clutch housing and transaxle case assembly
1. Apply a thin coat of sealant to the contact surfaces of the
clutch housing and transaxle case, tighten the transaxle case
installation bolts to the specified torque.
Tlghtenlng torque:
37-52 Nsrn (3.8-5.3 m-kg, 27-38 ft-lb)
2. Insert the SST through driveshaft hole.
Secondary 5th gear
1. Install the secondary 5th gear as shown.
Clutch hub assembly (Sth/Reverse) and !%h/Reverse shift
fork
1. Install the clutch hub assembly (5thReverse) and the 5th/Re-
verse shift fork together.
52-39

TRANSAXLE J2
INSTALLATION
1. Raise the vehicle and support it with safety stands.
2. Install in the order shown in the figure, referring to
Installation Note,
3. Fill the transaxle with the specified amount of the specified transaxle oil after installation.
4. Warm up the engine and transaxle, and inspect for oil leakaae and transaxle ooeration.
37-52 (3.8-5.3, 27-38) 37-52 (3.8-5.3, 27-38)
9.8-12 (1.0-1.2, 7.2-8.7)
7.8-l 2 (0.8-l .2, 5.8-8.7)
1. Transaxle
6. Tie-rod end
2. Engine mount No.4 7. Clutch release cylinder
3. Joint shaft
8. Engine mount No.2
4. Driveshaft
9. Exhaust pipe
Installation Note
10. Engine mount member
. . . . . . . . . . . . . . . . . . . . .
page J2-42 11. Control rod
5. Stabilizer
12. Extension bar
Installation Note 13. Starter
. . . . . . . . . . . . ..______. page J2-42 14. Ground
31-48 (3.2-4. ‘8
88-l 18 (g-12,65-87)
(6.5-9.1, 47-88)
37-52 (3.8-5.3, 27-38)
N.m (m-kg, Mb)
15. Neutral switch connector
16. Back-up light switch
connector
17. Speedometer
cable
18. Battery carrier
19. Battery
20. Air hose and resonance
chamber
21. Splash shield
22. Wheel and tire
52-41

T INDEX
CRUISE CONTROL SYSTEM
23UOTX-004
1. Cruise control switch
Removal / Installation . . . . . . . . . . . . . . . . . . page T-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-21
2. Speed sensor (in the meter)
Inspection ,,,,..~..,,,..,,,.,........,.,..,.. page T-72
3. Actuator
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-87
4. Cruise control unit
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . page T-83
Removal / Installation . . . . . . . . . . . . . . . . . . page T-85
Self-diagnostic inspection . . . . . . . . . . . page T-80
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-86 5. Stoplight switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . pages T-47, 87
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . page T-87
6. Clutch switch (For MTX)
Adjustment ..,,....,...,..,..,,....., page T-87
7. Cruise control main switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-21
T-6

T CRUISE CONTROL SYSTEM
CRUISE CONTROL SYSTEM
STRUCTURAL VIEW
r
1. Cruise control switch
Removal / Installation . . . . . . . . . . . . . . . . . . page T-20
Inspection . . . . . . . . . . . . ...*..*...*.........*.. page T-21
2. Speed sensor (in the meter)
Inspection . . . . . . . . . . . . . . . . . . . . . . ,. . . . . . . . . . . . page T-72
3. Actuator
Inspection .,........**.,....*,......,..,..... page T-87
4. Cruise control unit
Troubleshooting . . ,. . . . . . . . . . . . . . . . . ,. . . . , page T-83
Removal I Installation . . . . . . . . . . . . . . . . . . page T-85
Self-diagnostic inspection , . . . . . . . . . , page T-80
Inspection . . . . . . . .._... . . . . . . . . . . . . . . . . . . . page T-86 5. Stoplight switch
Inspection , . , . , . . . . . . . . . . . . . . . . . . . . . . pages T-47, 87
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . page T-87
6. Clutch switch (For MTX)
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . page T-87
7. Cruise control main switch
Inspection ,..,.,.,..,....,........... page T-21
T-78

CRUISE CONTROL SYSTEM
I
23UOTX-056
1 23UOTX-057
Inspection Procedure
Quick inspection of cruise control system
1. Locate the cruise control connector.
2. Connect a 1.4W test light between terminals f and d, with
connector attached to control unit. -1
Note
l There is no wire in terminal d of the connector. Push
the test light through the connector and touch the
corresponding pin on the control unit.
3. Turn the ignition switch to ON.
4. Verify that the MAIN switch is OFF. (The MAIN indicator lamp
is OFF.)
5. Press the RESUMElACCEL switch and the MAIN switch
simultaneously to activate the system inspection. (The MAIN
indicator lamp will come ON.)
6. Operate each switch as described below and verify the oper-
ation codes.
7. Press the MAIN switch to deactivate the system inspection.
(The MAIN indicator lamp will go OFF.)
Note
l The cruise control system will not operate when in
the self-diagnosis mode.
Operation Code Numbers
Inspection of cruise control system
The test light will flash if the system is operating correctly. If the light fails to flash, inspect the system.
Note
l Shift the selector lever to D or R range before operating the inspection. (For ATX)
l Shift to the gear except the neutral position. (For MTX)
Procedure
Press SET/COAST switch Pattern of output signal Code
(Test light) No. Actlon to inspect ON
n II 21 Inspect cruise control switch
(Refer to page T-21)
OFF
Press RESUMElACCEL switch
ON
n 22 inspect cruise control switch
(Refer to page T-21)
OFF
Depress brake pedal
ON
n ml 31 Inspect stoplight switches
(Refer to pages T-47 and
OFF T-88)
Turn ignition switch to ON and shift the ON 35 Inspect inhibitor switch
selector lever to P or N range (For ATX) (Refer to Section K) or clutch
Depress clutch pedal (For MTX) switch (Refer to Section F)
OFF
Drive vehicle above 40 km/h (25 mph) ON 37 Inspect speed sensor or wire
harness
OFF
I
1
. . . _
T-82

I
CRUISE CONTROL SYSTEM
s q 0 m
9 e c a
t rpn i j
h
f d b
*
Inspection
Cruise control unit
1. Connect a voltmeter between cruise control unit and ground.
2. Turn the ignition switch ON and check the terminal voltages
as described below.
03UOTX-146
VB: Batterv voltage
c (Output) Actuator
I ov
Approx. 9V
e (Input)
I Cruise control main
I
VB switch (NC)
f (Input)
9 Wv-4 Cruise control main
switch (N.0)
EC-AT control unit
VB
V0
h (Output) (only ATX)
Stoplight switch 2 (N.C) Approx. 9V
i (hW Note I
Inhibitor switch (ATX)
I ov
Approx. 5V Disconnect t
EGI control
Clutch switch (MTX)
ov unit connector Approx. 5V
Cruise control switch
(Set/coast switch) V0
Approx. 5V unit connector
a
S I Battery
I VI3 t
1 Ground I ov Procedure
Ignition switch ON
Main switch ON
Ignition switch ON
Main switch ON
ignition switch ON
Main switch ON
Ignition switch ON
Main switch ON
Ignition switch ON
Main switch ON
“N” or “P” range and main switch ON
Other range and main switch ON
Clutch pedal depressed and main switch ON
Main switch ON
Horn switch OFF
Ignition switch ON
Brake pedal depressed
Main switch ON
While pushing the resumelaccel switch after main switch
ON
Main switch ON
While pushing the set/coast switch after main switch ON
Main switch ON
Brake pedal depressed
While rotating the rear tire
Constant
Constant
23UOTX-OE $0
‘,.__,
_ _-_,’
T-86