1992 MAZDA PROTEGE boot

TRANSAXLE J2
Clutch Housing and Transaxle Case Components
Caution
l Do not remove an oil seal if not necessary.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
ACE
1. Bearing outer race (Primary shaft) 19. Oil seal (differential)
2. Oil seal Replacement (On-vehicle) . . . . . . . . . page J2-16
3. Bearing outer race (Secondary shaft) 20. Bearing outer race (differential)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16 Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16
4. Funnel 21. Reverse lever shaft
5. Guide plate 22. Reverse lever
6. Change arm 23. Drain plug and washer
7. Roll pin 24. Neutral switch and gasket
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16 25. Bearing outer race (transaxle case)
8. Change rod assembly Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16
9. Boot 26. Diaphragm spring
10. Spring 27. Adjust shim
11. Reverse gate 28. Bearing outer race (differential)
12. Selector Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-16
13. Oil seal 29. Adjust shim(s)
14. Bleeder cover 30. Oil seal (differential)
15. Bleeder Replacement (On-vehicle) . . . . . . . . . page J2-16
16. Speedometer driven gear assembly 31. Back-up light switch
Inspection ..,.,,.,......,................... page J2-24 32. Oil passage
17. Driven gear 33. Joint
18. Gear case 34. Change rod
52-l 5

TRANSAXLE
03UOJ2-02
03UOJ2-0:
I IO
03UOJ2-031
1
03UOJ2-121
Caution
l Do not damage the dust boots.
4. Remove the clinch bolt and pull the lower arm downward.
Separate the knuckle from the lower arm ball joint.
5. Loosen the nut and disconnect the tie-rod end with the
SST.
Caution
l Do not subject the tripod joint to shock when remov-
ing the driveshaft.
6. Disconnect the driveshaft from the transaxle by prying with
a bar between the outer ring and the transaxle.
7. Suspend the driveshaft with a rope.
8. Remove the oil seal with a screwdriver.
Note
l Tap in until the oil seal installer contacts the case.
l Coat the oil seal lip with transaxle oil.
9. Tap the new oil seal into the transaxle case with the SST.
10. Replace the driveshaft end clip with a new one. Insert the
driveshaft with the end-gap of the clip facing upward.
I I
I 03UOJ2-032
J2-17

TRANSAXLE J2
Clutch Housing and Transaxle Case Components
1. Select the adjust shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the figure, referring to Assembly Note.
3. Verify that the bearing preload is satisfied after assembly, referring to Bearing Preload.
-s
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS EXCEPT SWITCHES
&II N.m (SO-110 cm-kg, SO-95 In-lb)
20-29
P-3,
@NEW=
O-RING, I
14-22) 11
R N.m (120-160 cm-kg,
104-l 39 in-lb)
A
=SELECTlVE ROLL PIN NE
(120-140 cm-kg,
SELECTIVE 20-29 (2-3, 14-22)
N.m (m-kg,
??I 1
1. Change rod 16. Oil seal
2. Joint
3. Oil passage
4. Back-up light switch
5. Oil seal
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
6. Adjust shim(s)
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
7. Bearing outer race
8. Adjust shims
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
9. Diaphragm springs
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
17. Gear case
18. Driven gear
19. Speedometer driven gear assembly
20. Bleeder
21. Bleeder cover assembly
22. Oil seal
23. Selector
24. Reverse gate
25. Spring
26. Boot
Assembly Note ,.,....................... page J2-35
27. Change rod assembly
28. Roll pin
10. Bearing outer races
11. Neutral switch and gasket
12. Drain plug and washer
13. Reverse lever
14. Reverse lever shaft
15. Bearing outer race 29. Change arm
30. Guide plate
31, Funnel
32. Bearing outer race
33. Oil seal
34. Bearing outer race
J2-31

TRANSAXLE
i
03UOJ2-078
-
Thickness
0.10 (0.004)
0.20 (0.008)
0.25 (0.010)
0.30 (0.012)
0.35 (0.014)
0.40 (0.016)
0.45 (0.018)
050 (0020)
0.55 (0.022)
0 60 (0.024)
0.65 (0.026)
03UOJZO7 mm (in)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
1.00 (0.039)
1.05 (0.041)
1.10 (0.043)
1.15 (0.045)
1.20 (0.047)
03UOJ2-081
, T/RAkiXiE /CA/SE/////,///
BEARING OUTER RACE
,ADJUSTMENT SHIM
__________
po3u0J2-08i
Caution
l Measure the gap around the entire circumference
of the selector
13. Use a feeler gauge to measure the gap in the selector for
the differential.
14. Add 0.15mm (0.0059 in) to the measured clearance and
select the combination of shims closest in value to that meas-
urement.
Note
l Use a maximum of two shims.
See the table below for available shim sizes.
Example: 0.32mm (0.013 in)
0.32mm (0.013 in) + 0.15mm (0.006 in) = 0.47mm
(0.019 in).
So the nearest shim (on the thick side) to 0.47mm
(0.019 in) is 0.50mm (0.020 in).
15. Remove the SST and the transaxle case.
16. Remove the selectors, the primary shaft assembly and the
-differential.
17. Remove the bearing outer races.
Assembly note
Oil seals
1. Apply transaxle oil to outer periphery.
2. Install the new oil seals with the SST.
Diaphragm spring
1. Install the diaphragm spring as shown in the figure.
Boot
1. Install the boot with the drain hole facing downward.
03UOJ2-082
J2-35

SHIFT MECHANISM
1. Change lever knob
2. Rear console
3. Front console
4. Boot
5. Nut
6. Washer
7. Bolt
8. Cover
9. Nut
10. Washer
11. Bushing
12. Spring
Inspect for damage and weaked
Assembly note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-47
13. Change lever
14. Ball seat (Upper)
15. Boot
Inspect for wear or damage 16. Holder
17. Ball seat (lower)
18. Nut
19. Washer
20. Pipe
21. Bushing
Inspect for wear or damage
22. Washer
23. Extension bar
Assembly note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-47
24. Insulator
Inspect for damage and cracks
25. Nut
26. Bolt
27. Bushing
Inspect for wear and damage
28. Change control rod
Inspect for bending
03UOJ2-109
CHAGE CONT
03UOJ2-111
Assembly Note
Extension bar
1. Connect the extension bar to the transaxle, and 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.
J2-47

OUTLINE, TROUBLESHOOTING GUIDE M
OUTLINE
SPECIFICATIONS
Engine/Transaxle
86 SOHC
I BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX
Front axle
Bearing play axial direction Rear axle
Bearina olav axial direction I
mm (in) 0.05 (0.002)
mm (in) I 0.05 (0.002) Drive shaft
j Inside Tripod ioint
I Joint type I -
Outside I Ball ioint 1
Right side 919.3 (36.19)
918.7 (36.17) 630.7 (24.83)
Length of shaft
mm (in)
Left side 637.8 (25.11)
640.2 (25.20) 621.2 637.1
(24.46) (25.08)
Shaft diameter mm (in) Right side 21.5 (0.85) 23.0 (0.91)
Left side
21.5 (0.85)
23.0 (0.91)
23UOMX-003
TROUBLESHOOTING GUIDE
FRONT AXLE Problem
Steering wheel
vibration
Steering wheel pulls
or one-sided braking
Excessive steering
wheel play
Abnormal noise
Grease leakage from
boot Possible Cause Action
Worn or damaged wheel bearing
Excessive wheel bearing play
Worn or damaged wheel bearing
Excessive wheel bearing play
Excessive wheel bearing play Replace
Tighten or replace
Replace
Tighten or replace
Tighten or replace
Bent drive shaft or joint shaft
Worn or damaged wheel bearing
Worn drive shaft or joint shaft splines
Insufficient grease in joint or on splines of drive shaft
insufficient grease in joint or splines of joint shaft
Nom drive shaft tripod joint Replace
Replace
Replace
Replenish or replace
Add or replace
Replace
Damaged or broken boot
Faulty boot band
Excessive grease Replace
Replace
Reoair Page M- 7
M- 5,7
M- 7
M- 5,7
M- 57
M-18, 22
M- 7
M-18, 22
M-22, 25
M-18
M-25
M-25
M-25
M-25
23UOMX-004
REAR AXLE Problem Possible Cause Action Page
Steering wheel
Worn or damaged wheel bearing
Replace M-11, 14 vibration
Excessive wheel bearing play Tighten or replace M-11, 14 Steering wheel pulls
Worn or damaged wheel bearing Replace M-11, 14 or one-sided braking Excessive wheel bearing play Tighten or replace M-11, 14 Excessive steering
Excessive wheel bearing play Tighten or replace M-11, 14 wheel olav
Abnormal noise
Worn or damaged wheel bearing Replace M-11, 14
23UOMX-005
M-3

M FRONT AXLE
23UOMX-0:
Removal note
Tie rod end
Caution
l Do not damage the dust boot.
1. Loosen the nut and disconnect the tie-rod end with the SST.
Installation note
Tie rod end
Caution
l Do not damage the dust boot.
1. Install the nut and secure it with the new cotter pin.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
Locknut
1, Install a new locknut and stake it, as shown.
Tightening torque:
235-319 Nnrn (24.0-32.5 m-kg, 174-235 ft-lb)
03UOMX-010
M-6

DRIVE SHAFT M
r
I
23UOMX-039
03UOMX-030
I
03UOMX-03
ii I I
23UOMX-04
03UOMX-03
Removal note
Tie rod end
Caution
l Do not damage the dust boot.
1. Loosen the nut and disconnect the tie rod end with the SST.
Joint shaft
Caution
l Do not damage the oil seal.
1. Remove the joint shaft.
Installation note
Joint shaft
Caution
l Do not damage the oil seal.
1. Install the joint shaft.
2. Tighten the bolts in the order shown.
Tightening torque:
42-62 N*m (4.3-6.3 m-kg, 31-46 ft-lb)
Tie rod end
Caution
l Do not damage the dust boot.
1. Install the nut and secure it with the new cotter pin.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
Stabilizer
1. Install the stabilizer bolt.
Dimension A: 17-19mm (0.67-0.75 in)
M-19