1992 MAZDA PROTEGE torque

TRANSAXLE Jl
- 23UOJl-01
03UOJl-11
03UOJl-14
I 03UOJl-11
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.
Tightening torque:
19-26 Nom (1.9-2.6 m-kg, 14-19 ft-lb)
Clutch hub assembly (6th) and 6th shlft fork
1. Install the clutch hub assembly (5th) and the 5th shift fork
together.
Locknut
1. Shift to 1 st gear.
2. Lock the primary shaft with the
SST.
3. Tighten new locknuts on the primary and secondary shafts.
Tightening torque:
126-206 N*m (13.0-21 m-kg, 94-152 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06-0.26mm (0.0024-0.0102 in)
Maximum : 0.31 mm (0.0122 in)
6. If not as specified, reassemble the transaxle.
Jl-47

TRANSAXLE Jl
1. Transaxle
Installation Note ..,......,.............. page Jl-49
2. Engine mount No.4
3. Driveshaft
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
4. Stabilizer (BP SOHC)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
5. Tie-rod end
Installation Note ,........,..,........... page Jl-50
6. Clutch release cylinder
7. Engine mount No.2
8. Exhaust pipe
9. Engine mounting member
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-50
10. Control rod
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51 11. Extension bar
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51
1 12. Starter
13. Ground
Installation Note .,..,...,......,........ page Jl-5
14. Neutral switch connector
15. Back-up light switch connector
16. Speedometer cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-5
17. Battery carrier
18. Battery
19. Air hose and resonance chamber
20. Splash shield
21. Wheel and tire 1
Installation Note
Transaxle
1. Set the transaxle on a jack and lift it into place.
Install tne transaxle oorts.
Tightening torque:
64-69 N*rn (6.5-9.1 m-kg, 47-66 ft-lb)
Loosely tighten engine mount No.4 bolts.
Jl-49

03UOJi-12 3
03UOJl-124
L 03UOJl.126 I-
03UOJl-12
Jl TRANSAXLE
Driveshaft
Caution
l Verify that the oil seal is not damaged.
l Do not damage the oil seal
1. Insert the clip with the end-gap at the top of the groove.
2. Apply transaxle oil around the oil seal lip. Install the
driveshaft.
3. Verify that the driveshaft is correctly seated by pulling on
the shaft.
4. Connect the lower arm to the knuckle and tighten the clinch
bolt.
Tightening torque:
43-59 N-m (4.4-6.0 m-kg, 32-43 ft-lb)
Stabilizer (BP SOHC)
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension A: 17-l 9mm (0.67-0.75 in)
Tie-rod end
1. Install the locknut.
Tightening torque:
42-57 N-m (4.3-5.6 m-kg, 31-42 ft-lb)
2. Secure the locknut with a new cotter pin.
Engine mounting member
1. Install the bolts and nuts as shown.
Tightening torque
@ : 37-52 N,m (3.6-5.3 m-kg, 27-36 ft-lb)
@I: 64-89 N-m (6.5-9.1 m-kg, 47-66 ft-lb)
51-50

TRANSAXLE Jl
03UOJl-12!
03UOJi-13
2. Tighten engine mount No.4 nuts.
Tightening torque:
67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)
3. Remove the SST (Engine support).
Control rod and extension bar
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 Nern (3.2-4.7 m-kg, 23-34 ft-lb)
2. Install the change control rod to the transaxle.
Tightening torque:
16-23 N*m (1.6-2.3 m-kg, 12-17 ft-lb)
Ground
1. Connect the ground to the clutch pipe bracket.
Tightening torque:
16-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Speedometer cable
1. Add the specified oil through the speedometer gear case
mounting. (Refer to page Jl-7.)
2. Install the speedometer driven gear.
Tightening torque:
7.6-l 2 N*m (60-120 cm-kg, 69-104 in-lb)
3. Connect the speedometer cable to the speedometer driv-
en gear.
J141

SHIFT MECHANISM Jl
03UOJl-14
03UOJi-144
Assembly Note
Extension bar
1, Connect the extension bar onto the transaxle, then mount
it to the floor.
Tightening torque:
16-23 N#m (1.6-2.3 m-kg, 12-17 ft-lb)
Spring
1. Verify that the hooked part of the spring is properly seated
in the bracket groove.
51-57

TRANSAXLE OIL 52
03UOJ2-00’
03UOJ2-008
03UOJ2-00
1 9
23UOJ2-002
TRANSAXLE OIL
INSPECTION
Note
l Park the vehicle on level ground.
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Verify that the oil level is between F and L.
3. Install the speedometer driven gear.
Tightening torque:
7.8-12 Nmrn (80-120 cm-kg, 89-104 in-lb)
4. Connect the speedometer cable.
REPLACEMENT
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Remove the drain plug and washer. Drain the oil into a suit-
able container.
3. Install a new washer and the drain plug.
Tightening torque:
39-59 N*m (4.0-8.0 m-kg, 29-43 ft-lb)
4. Add the necessary amount of the specified oil through the
speedometer gear case hole.
Specified oil
Viscosity: All-season ATF Dexron@lI, M2C33F or
SAE75W-80
Above -18*C (O*F) API service GL-4
SAE 8OW-90
Capacity: 3.35 liters (3.55 US qt, 2.96 Imp qt)
5. Verify the oil level.
6. Install the speedometer driven gear and connect the
speedometer cable.
03UOJ2-011
J2-7

TRANSAXLE J2
OUTER RACE
SELECTOR
03UOJ2-069
03UOJ2-07(
86U07A-25:
-sllzd-L-
03UOJZ071
03UOJ2-Oi 1. Install the primary and secondary shaft bearing outer races
into the transaxle case (diaphragm springs and shims
removed).
2. Mount the clutch housing onto the transaxle hanger, and
set the differential bearing outer race into the clutch housing.
Position a piece of pipe against the outer race and tap in
with a hammer until it contacts the clutch housing.
3. Set the outer races into the
SST (selector) as shown in the
figure.
Note
l Turn the selector to eliminate the gap indicated by
the arrow in the figure.
4. Set the differential assembly into the clutch housing; then
set the bearing outer race and the
SST (selector) on the
differential. Set the assembled selectors for the primary and
secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the figure.
5. Set the
SST (collars) in the positions shown in the figure.
6. Install the transaxle case and tighten the
SST (bolts) to the
specified torque.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
7. To seat the bearings, mount the SST (bars) on parts @and
@of the selector, and turn the selector so the gaps are
widened.
Then turn the
SST in the reverse direction until the gaps
are eliminated.
J2-33

J2 TRANSAXLE
03UOJ2-OE i3
03UOJ2-120
03UOJ2-08 4
03UOJF085
Bearing preload
Verify the shaft gears and the differential bearing preload.
Note Note
l Verify that the correct adjust shims were selected. l Verify that the correct adjust shims were selected.
l If the bearing preload is not within specification, ad- l If the bearing preload is not within specification, ad-
just again. just again.
1. Set the primary shaft gear and the differential into the clutch
housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 f&lb)
3. Connect the SST and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the
preload.
Preload:
1.4-2.0 N.m (14-20 cm-kg, 12-17 in-lb)
5. Remove the SST.
6. With the transaxle facing in the direction shown in the fig-
ure, install the
SST to the primary shaft gear.
7. Measure the preload.
Preload:
0.1-0.25 N-m (1.0-2.5 cm-kg, 0.87-2.18 in-lb)
8. Remove the SST, transaxle case, primary shaft gear and
differential.
9. Install the secondary shaft gear and transaxle case then
tighten to the specified torque.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
IO. Measure the secondary shaft preload with the SST
Preload:
0.2-0.4 N.m (2.0-4.0 cm-kg, 1.7-3.5 in-lb)
J2-36