1992 MAZDA PROTEGE differential

TRANSAXLE Jl
03UOJ 1.04!
03UOJ 1.041
03UOJl-047
, , .” ,,,,,..
03UOJl-04t
03UOJ l-04!
Preinspection
1st gear thrust clearance
1, Measure the clearance between 1 st gear and the differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 in)
Maximum: 0.33mm (0.013 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 1 st gear, differential drive gear of the secon-
dary shaft gear, and clutch hub assembly (1 st/2nd). Replace
worn or damaged parts.
2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary
3rd gear.
Clearance: 0.18-0.51 mm (0.007-0.020 in)
Maximum: 0.58mm (0.022 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 2nd gear, secondary 3rd gear, and clutch
hub assembly (1 stMnd). Replace worn or damaged parts.
Disassembly note
Bearing inner race and secondary 4th gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race and secondary 4th gear with
the
SST.
Secondary 3rd gear and 2nd gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the secondary 3rd gear and 2nd gear with the
SST.
Clutch hub assembly (lst/2nd), synchronizer ring (1st)
and 1st gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the clutch hub assembly (1 st/2nd), synchronizer
ring (1st) and 1st gear with the
SST.
Jl-25

TRANSAXLE

I
\m/ 7.8-11 N-m
1. Change
rod
2. Joint
3. Bearing outer race
4. Funnel
Assembly Note 11. Oil passage
29. Guide plate assembly
12. Oil
seal (Differential) 30.
Gear case
Assembly Note 31, Oil seal
,.................... page Jl -41 (Speedometer gear cace)
13. Transaxle case Assembly Note
. . . . . . . . . . . . . . . . . . . . .
page Jl-42
5. Bearing outer race
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-42
6. Bearing outer race
(Differential)
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-41
7. Adjust shim (Differential)
Assembly Note
. . . . . . . . . . . . . . . ...*.. page Jl-41
8. Bearing outer race
(Secondary shaft gear)
Assembly Note
,..*.,...............
page Jl -41
9. Adjust shim
(Secondary shaft gear)
Assembly Note
. . . . . . ...*. . . . . . . . . . . page Jl-41
IO. Adjust shim
(Primary shaft gear)
Assembly Note
14. Reverse lever . . . . . . . . . . . . . . . . . . . . . page Jl-41
15. Lever set spring 32. Packing
16. Reverse lever shaft 33. O-ring
17. Roll pin 34. Drive gear
18. Blind plug 35. Roll pin
19. Oil seal (Primary shaft gear) (Speedometer driven gear
Assembly Note assembly)
. . . . . . . . . . . . . . . . . . . . . page Jl-42 Assembly Note
20. Gasket ..,......*. ..,,...... page Jl-41
21. Bleeder cover 36. Speedometer driven gear
22. Bushing assembly
23. Oil seal (Change rod) 37. Bleeder
Assembly Note 38. Pivot
..,..,...,........... page Jl-42 39. Oil seal (Differential)
24. Boot Assembly Note
Assembly Note . . . . . . . . . . . . . . . . . ...* page Jl-41
.,.,.,............... page Jl-42 40. Clutch housing
25. Change rod
Assembly Note
. ..*.................
page J l-42 .,................... page Jl-42
26. Change arm
27. Selector
28. Roll pin
Jl-36

Jl TRANSAXLE
51-38
03UOJ l-08!
RACE
OWOJ i-09
ONJOJl-09 , _.
03UOJ I-09
Example: 0.22mm (0.009 in)
0.22mm (0.009 in) + 0.03mm (0.001 in)
= 0.25mm (0.010 in)
0.22mm (0.009 in) + 0.08mm (0.003 in)
= 0.30mm (0.012 in)
Range: 0.25mm (0.010 in)-0.30mm (0.012 in)
Select the 0.30mm (0.012 in).
Adjustment shim thickness:
mm (in)
0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.012)
0.35 (0.014) 0.40 (0.016) 0.45 (0.018) 0.50 (0.020)
93GOJ I-524
Differential
1. Install the bearing outer race into the clutch housing.
2. Set the differential assembly into the clutch housing.
Note
l Turn A and B until the gap shown in the figure is
eliminated.
3. Install the transaxle case side bearing outer race to the SST
(selector).
4. Set the
SST (collars) in the positions shown in the figure.
5. Tighten the
SST (bolts) to the specified torque.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)

TRANSAXLE Jl
03UOJl-09:
03UOJi-09
03UOJl-09
03UOJl-09
03UOJl-0:
Note
l Turn the bars until the SST (selector) can no longer
be moved.
6. To seat the bearings, mount the bars on parts @ and @I
of the selector, and turn the selector so the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.
8. Install the
SST to the differential pinion gear through the
transaxle case.
9. Turn the
SST with a torque wrench. Adjust the SST (selec-
tor) with the bars until the specified preload is obtained.
Preload:
0.03-0.74 N#m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
10. Remove the SST.
11. Measure the clearance around the entire circumference of
the
SST (selector).
12. Select the proper adjust shim(s) to be used for the differen-
tial by referring to the table and selecting the shim which
is nearest (on the thick side) to the largest measured clear-
ance in the selector.
Adjust shim thickness:
0.20 (0.008)
0.25 (0.010)
0.40 (0.016)
0.45 (0.018) mm (in)
0.30 (0.012) 0.35 (0.014)
0.50 (0.020) 0.55 (0.022)
13. Remove the SST (bolts).
14. Remove the transaxle case and the
SST (collars).
Jl-39

Jl TRANSAXLE
,
,,
03UOJi-09
03UOJl-10
Jl-40
OSUOJl-1C
15. Remove the bearing outer race from the SST (selector).
16. install the selected shim(s) and bearing outer race to the
transaxle case.
-’
Bearing preload (Differential)
Measure the preload as follows.
1. Set the differential assembly into the clutch housing.
2. Install the transaxle case onto the clutch housing.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
3. Install the SST to the differential side gear through the trans-
axle case.
4. Measure the bearing preload.
Preload:
0.03-0.74 N,m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
5. If not as specified, readjust the bearing preload.
6. Remove the SST.
7. Remove the transaxle case and differential assembly.

TRANSAXLE Jl
Assembly note
Oil seal (Speedometer gear cace)
1. Install the new oil seal with a suitable pipe.
Pipe diameter: 15mm (0.591 in)
23UOJ I-00
03UOJl-IO
03UOJl-IO!
03UOJ1.10
Roll pin (Speedometer driven gear assembly)
1. Install the new roll pin as shown in the figure.
Oil seal (Differential)
Caution
l Apply transaxle oil to the outer circumference of the
oil seal.
1. Install the new oil seal with the SST.
Adjust shim and bearing outer race (Secondary shaft
gear)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
l Apply transaxle oil to the bearing outer race.
1. Install the adjust shim(s) and the bearing outer race with
a suitable pipe.
Adjust shim and bearing outer race (Differential)
Caution
l Use adjust shim(s) selected during bearing preload
adjustment.
l Apply transaxle oil to the bearing outer race.
1, Install the adjust shim(s) and the bearing outer race with
a suitable pipe.
Jl-41

TRANSAXLE Jl
1. Control rod
2. Control end
3. lstl2nd shift fork
4. Control lever
5. Interlock sleeve
6.3rd/4th shift fork
7. Clutch hub
8. Synchronizer key
9. Clutch hub sleeve
10. Synchronizer spring
11. Clutch housing
12. Differential assembly
13. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-45
14. Primary shaft gear assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . , . page J 1-45
15. Spring
16. Steel ball
17. Shift fork and shift rod assembly
Assembly Note.. . . . . . . . . . . , . . . . . . . . . , . . , page J 1-45
18. Crank lever assembly
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
19. Crank lever shaft
Assembly Note.. . . . . . . . . . . , , . . . . . . . . . . . . page Jl -46
20. Pin
21. 5th shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page 31-46
22. 5th shift rod
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-46
23. Reverse idler gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-46
24. Reverse idler shaft
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . page Jl -46
25 Magnet
26. Transaxle case assembly
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl -47
27. Neutral switch
28. Back-up light switch
29. Lock bolt and washer
30. Secondary 5th gear
31. Gear sleeve
32. 5th gear
33. Synchronizer ring (5th)
34. Clutch hub assembly (5th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
35. 5th shift fork
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
36. Stop plate
37. Locknut (Secondary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page Jl-47
38. Locknut (Primary shaft)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J 1-47
39. Rear cover
13UOJl-005
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.
03UOJl-115 Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
03UOJ2-088
51-45

Jl DIFFERENTIAL
DIFFERENTIAL
PREPARATION
SST
49 B017 1AO
Remover set,
bearing
49 8092 371
Attachment E
(Part of
49 8017 1AO)
49 F401 3308
Installer set,
bearing
49 F401 337A
Attachment C
(Part of
49 F401 3308) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
For
installation of
bearing 49 F401 366A
Plate
(Part of
49 8017 1AO)
49 0839 42%
Puller set,
bearing
49 F401 331
Body
(Part of
49 F401 3309) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
03UOJl-13 .-,
5142