1992 MAZDA PROTEGE oil

Jl TRANSAXLE
3rd Gear, 4th Gear, 5th Gear, and Gear Sleeve (5th gear)
1. Measure the clearance between the shaft gears and gears.
4TH 3RD
03UOJl-05
03UOJl-05
9MUOJX-063
51-28
03UOJl-06 i0
Oil Clearance mm (in)
1 Shaft (A 1 G Sleeve (C)
(outer biakter) (inneFikr!?ter) (outer diameter) Oil (D)
Clearance
35.15-35.17 35.20-35.22 _ P) = W-(A)
3rd Gear
(1.384-l ,385) (1.386-l ,387) 0.03-0.07
(0.001-0.003)
31.95-31.97 32.00-32.02 _ 0 = W-(A)
4th Gear
(1.258--1.259) (1.260-l ,261) 0.03-0.07
~0.001-0.003~
5th Gear -
‘(D) = (B)-(C)’ 34.00-34.02 33.94-33.97 o,03-o,08
(1,338-l .339) (1.336-l .337) (o,oo,-o,oo3)
I I I I I
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
Bearing
1. Inspect for damage or rough rotation.
Secondary Shaft
Note
l If the shaft gear is replaced, adjust the bearing
preload. (Refer to page Jl-37.)
1. Inspect the shaft gear runout.
Maximum runout: 0.015mm (0.001 in)
2. Inspect the gear teeth for damage, wear, and cracks.

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
03UOJl-07 r
I
03UOJl-07
I
W
-==f =--
03UOJl-07
03UOJl-08
03UOJ l-08
Assembly note
Bearing
1, Install the bearing with a press.
3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th)
Caution
l Apply transaxle oil to the bore of 3rd gear.
1. Turn the primary shaft over and install the 3rd gear, syn-
chronizer ring (3rd) and clutch hub assembly (3rd/4th) with
a press.
Synchronizer ring (4th), 4th gear, and bearing
1. Install the retaining ring.
2. Install the synchronizer ring (4th), 4th gear, and ball bear-
ing with a press.
3. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.06-0.21 mm (0.002-0.006 in)
Maximum : 0.26mm (0.010 in)
4. Measure the clearance between 4th gear and the ball
bearing.
Clearance: 0.21-0.61 mm (0.006-0.024 in)
Maximum: 0.66mm (0.026 in)
5. If not as specified, reassemble the primary shaft assembly.
51-35

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

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