1992 MAZDA PROTEGE key

TRANSAXLE Jl
1, Rear cover
2. Locknut (Primary shaft)
Disassembly Note .,......,,.,......... page Jl-15
3. Stop plate
4. Locknut (Secondary shaft)
Disassembly Note ,..,....,,.,......... page Jl-15
5. 5th shift fork
6. Clutch hub assembly (5th)
Inspection . . . . . . . . . . . . . . . . ..*............... page J l-29
7. Synchronizer ring (5th)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-27
8. 5th gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-28
9. Gear sleeve
Inspection . . . . . . . . . . . . . . . . ..*...*........... page Jl-28
10. Secondary 5th gear
11. Lock bolt and washer
12. Back-up light switch
13. Neutral switch
14. Transaxle case assembly
15. Magnet
16. Reverse idler shaft
17. Reverse idler gear
Inspection.. . . , . . . . . . . . . . . . . . . , , . , . . . . . . . . . . page J l-27
L ,
03UOJl-022
I
I I
03UOJl-023
18. 5th shift rod
19. 5th shift rod end
20. Pin
21. Crank lever shaft
22. Crank lever assembly
23. Shift fork and shift rod assembly
Disassembly Note ,.................... page Jl-16
24. Steel ball
25. Spring
26. Primary shaft gear assembly
27. Secondary shaft gear assembly
28. Differential assembly
29. Clutch housing
30. Synchronizer spring
31. Clutch hub sleeve
32. Synchronizer key
33. Clutch hub
34. 3rd/4th shift fork
35. Interlock sleeve
36. Control lever
37. lstl2nd shift fork
38. Control rod
39. Control end
03UOJl-021
Preinspection
5th gear thrust clearance
1. 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)
2. If the clearance exceeds the the maximum, check the con-
tact surfaces of 5th gear and the clutch hub. Replace worn
or damaged parts.
Disassembly note
Locknut
1, Mount the transaxle on the SST.
Jl-15

Jl TRANSAXLE
Primary Shaft Assembly
1. Measure the thrust clearances of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
REPLACE
1. Bearing
Disassembly Note.. . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . .., . . . . . . . . . . . . . . . . . . . . . page J l-28
2.4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . . . . . . . . . . . . . . . . . . . . . page J l-28
3. Synchronizer ring (4th)
Inspection.. . . . . . . . . . . . . . . . . . . . . . page J l-27
4. Retaining ring
5. Clutch hub assembly (3rd/4th)
Disassembly Note . . . . . . . . . . . . . . . . page Jl-23
inspection.. . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (3rd)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . . .., . . . . . . ,.. . . . . . . . . page J l-27 7. 3rd gear
Disassembly Note.. . . . . . . . . . . . page J l-23
Inspection.. . . . . . . . . . . page J 1-28
8. Bearing
Disassembly Note.. . ., . . . page J l-23
9. Primary shaft
Inspection., . . . . . . . . . . . page J 1-27
10. Synchronizer spring
11. Clutch hub sleeve
12. Synchronizer key
13. Clutch hub
. . /’
Jl-22

Jl TRANSAXLE
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
0 REPLACE-
/
1. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
2. Secondary 4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
3. Retaining ring
4. Secondary 3rd gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
5.2nd gear
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (2nd)
Inspection.. . . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . . page J l-27
7. Retaining ring
8. Clutch hub assembly (lst/2nd)
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-29 9. Synchronizer ring (1 st)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. ,,..... . . . . . . . . . . . . . . . . . . . . . . . . . page J l-27
10. 1st gear
Disassembly Note ..,..,,.,,,....,..,.. page Jl-25
Inspection ..,................,.............. page J l-29
11. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . , . . . . page Jl -26
12. Secondary shaft
Inspection., , , . , . , . . , , . . . . . . . . , . , . . . . . , . . . . . page J l-28
13. Synchronizer spring
14. Clutch hub sleeve
15. Synchronizer key
16. Clutch hub
Jl-24

TRANSAXLE
1ST 2ND
03UOJl-06 03UOJl-06
9MUOJX-05
03UOJl-05
1st Gear and 2nd Gear
1. Measure the clearance between the shaft gears and the
gears.
Oil Clearance mm (in)
Shaft (A) Gear (B) Sleeve (C) Oil (D)
(outer diameter) (inner diameter) (outer diameter)
Clearance
39.45-39.47 39.50-39.52 03 =(B)-(A)
’ st Gear (1.553-l 554) (1,555-l ,556) - 0.03-0.07
(0.001-0.003)
35.15-35.17 35.20-35.22 PI = (B)-(A)
2nd Gear (1.384-I ,385) (1,386-l ,387) - 0.03-0.07
(0.001-0.003)
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
Clutch hub assembly
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the individual gear teeth for damage, wear, and
cracks.
3. Inspect the synchronizer key for damage, wear, and cracks.
4. Measure the clearance between the hub sleeve and the shift
fork.
mm (in)
1 stMnd Standard clearance
0.1 O-O.36
(0.004-0.014) Maximum
0.86 (0.034)
I 3rd14th
I 0.20-0.50
(0.008-0.020)
I 1 .oo (0.039)
I
5th 0.40-0.75
(0.016-0.030) 1.25 (0.049)
51-29

Jl TRANSAXLE
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. Verify that all parts are completely clean before assembly.
3. Assemble parts within 10 minutes after applying sealant.
Allow all sealant to cure at least 30 minutes after assembly before filling the transaxle with transaxle oil.
4. The bearing outer race and bearing inner race must be replaced as a unit.
03UOJl-063
OBUOJl-06
-.--___
l-----o1
r-o-i
q----j H
I4
OBUOJI-065
03UOJl-06
SYNCHRONIZER RING
CLUTCH HUB SLEEVE

SYNCHRONIZER KEY 6
I
03UOJ l-067
51-30
Clutch hub assembly
Note
l Synchronizer ring diameters are as follows.
1st and 2nd
3rd and 4th
5th mm (in)
61.7 (2.429)
61.7 (2.429)
49.7 (1.957)
l Synchronizer key dimensions are as follows.
mm (in)
0 0
0
1 stl2nd 19.00 (0.748)
4.25 (0.167) 5.00 (0.197)
3rdl4th 17.00 (0.669)
4.25 (0.167) 5.00 (0.197)
5th
17.00 (0.669) 5.55 (0.219)
5.00 (0.197)
1. Install the synchronizer key springs in the clutch hub with
the hooks in the grooves to hold the three synchronizer keys
in place.
2. Align the synchronizer ring grooves with the synchronizer
key during assembly.

TRANSAXLE Jl
Secondary Shaft Assembly
1. Assemble in the order shown in the figure, referring to Assembly Note.
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
6 REPLACE=
P
10. Retaining ring
11. Synchronizer ring (2nd) 1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Secondary shaft
6, Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
7. 1st gear
Assembly Note.., . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
8. Synchronizer ring (1st)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . page J l-32
9. Clutch hub assembly (lst/2nd)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
23UOJl-00
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
12.2nd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
13. Secondary 3rd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-32
14. Retaining ring
15. Secondary 4th gear
Assembly Note ,......................... page Jl-32
16. Bearing inner race
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . page Jl -32
Jl-31

Jl TRANSAXLE
Primary Shaft Assembly
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
23UOJl.00
1. Clutch hub
9. Clutch hub assembly (3rd/4th)
2. Synchronizer key
Assembly
Note . . . . :..I . . . . . . . . . . . . . . . . . .
page Jl-35
3. Clutch hub sleeve
10. Retaining ring
4. Synchronizer spring
11. Synchronizer ring (4th)
5. Primary shaft
Assembly
Note . . . . . . . . . ,...... . . . . . . . . . .
page Jl-35
6. Searing
12. 4th gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-35 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-35
7.3rd gear
13. Bearing
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . .
page Jl -35 Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-35
8. Synchronizer ring (3rd)
Assembly Note.. . . . . . . . . . . . . III.. . . . . . . .
page J l-35
51-34

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