1992 MAZDA PROTEGE differential

DIFFERENTIAL Jl
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove the inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
3. Inspect all parts and repair or replace as necessary.
4. Assemble in the reverse order of disassembly, referring to
Assembly Note.
5. Measure the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin 7. Side bearing inner race
13UOJl-00:
Assembly Note .......................... page Jl -55 Disassembly Note.. ..................
2. Pinion shaft Inspection .................................
3. Thrust washer Assembly Note .........................
4. Pinion gear 8. Speedometer drive gear
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 9. Side bearing inner race
Inspection of backlash.. ............ page Jl-55 Disassembly Note.. ..................
5. Side gear Inspection .................................
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 10. Ring gear and ring case
Inspection of backlash.. ............ page Jl-55 Inspection .................................
6. Thrust washer
03UOJl-13 4
page Jl-54
page Jl -54
page Jl-55
page Jl -55
page Jl-54
page Jl-54
page Jl-55
page Jl-54
Preinspection
Backlash of side gear and pinion gear
Measure the backlash by the following procedure.
1. Install the left and right driveshafts in the differential as-
sem bly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O. 1 mm (O-0.004 in)
51-53

Jl DIFFERENTIAL
4. If the backlash exceeds specification, adjust by selecting
and installing thrust washers between the case and the side
gears.
Caution
l Use thrust washers with the same thickness on each
side.
-.
Thrust washer thickness: mm (in)
1 2.0 (0.079) 2.1 (0.083) 2.2 (0.087) 23UOJl-012
03UOJ2-10
1 03UOJ2-104
03UOJl-13
Jl-54
03UOJl-1: 6
Disassembly Note
Side bearing inner race (Side opposite ring gear)
Caution
l Hold the gear case with one hand so that it does
not fall.
1. Remove the bearing inner race with the SST.
Side bearing inner race (Ring gear side)
Note
l Use pads in the vise.
1. Remove the bearing inner race with the SST.
Inspection
Inspect all parts and repair or replace as necessary.
Ring gear and ring case
Note
l If the gear case is replaced, adjust the bearing
preload.
1. Inspect the ring gear for wear and cracks.
Bearing inner race
Note
l When replacing the bearing inner race, replace the
bearing outer race and inner race as a set.
l If the bearing is replaced, adjust the bearing
preload.
1. Inspect for wear and rough rotation. --

DIFFERENTIAL Jl
03UOJl-138
Assembly Note
Speedometer drive gear
1. Install the speedometer drive gear as shown in the figure.
1
03UOJl-13!
I
03UOJ2-10
I
03UOJl-14
I 03UOJl-14 .l
Side bearing inner race (Side opposite ring gear)
1. Install the speedometer drive gear.
2. Install the new side bearing inner race with the
SST.
Side bearing inner race (Ring gear side)
1. Install the new bearing inner race with the SST.
Roll pin
1, Install the new roll pin as shown in the figure to hold the
pinion shaft.
Backlash of Side Gear and Pinion Gear
Measure the backlash by the following procedure.
1. Install the driveshafts in the differential assembly.
2. Support the driveshafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: O-O.1 mm (O-0.004 in)
4. If not as specified, select the proper thrust washers.
(Refer to preinspection, page Jl-53.)
Jl-55

J2
MANUAL TRANSAXLE
(G5M-R)
INDEX .....................................................
J2- 2
OUTLINE
................................................
J2- 3
SPECIFICATIONS
................................... J2- 3
STRUCTURAL VIEW ...............................
J2- 4
POWER FLOW
......................................
J2- 5
TROUBLESHOOTING
GUIDE.. ................... J2- 6
TRANSAXLE OIL .....................................
J2- 7
INSPECTION
.........................................
J2- 7
REPLACEMENT .....................................
J2- 7
TRANSAXLE
...........................................
J2- 6
PREPARATION ......................................
J2- 6
REMOVAL
............................................
J2-10
DISASSEMBLY
......................................
52-l 2
INSPECTION .........................................
J2-22
ASSEMBLY
...........................................
J2-26
INSTALLATION
......................................
J2-41
DIFFERENTIAL
........................................
J2-43
PREPARATION
......................................
52-43
DISASSEMBLY / INSPECTION I ASSEMBLY J2-44
SHIFT MECHANISM
.................................
52-46
OVERHAUL
..........................................
52-46
03UOJ2-001

J2 INDEX
IN
new IYLA
BACK-lx LIU, 1, w.., 1 vm q
SERVICE, SECTION
F
k’c’ 1T6AL SWITCH 8.L”
SERI /ICE, SECTION T VISCOSITY: ALL-SEASON ATF DEXRON-II,
M2C33F OR SAE75W-80
ABOVE -18% (OOF) API SERVICE
GL-4 SAE80W-90
CAPACITY: 3.35 liters (3.55 US at. 2.98 ho 41)
1. Transaxle
Removal ..,.....,.,..,....,..,.........,.... page J2-10
Disassembly ,., ,..,., . ,,...., ,.. .., .., page J2-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
Assembly . . . . . . . . . ,.,...................... page J2-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-41
52-2
2. Differential
Disassembly / Inspection I
Assembly ,..,.,.,, ,_, ,. .,. ,_. ,_. . . . page J2-44
3. Shift mechanism
Overhaul ,....,.......,..... ,........, . . . . . . page J2-46
4. Transaxle oil
inspection . . . . . . . . ..,........I....I.,..... page J2- 7
Replacement .,.,.., ,.,...,...,.. . . . . . . . . . page J2- 7 .___I’

J2 OUTLINE
03UOJ2-OC
1, Primary 1 st gear
2. Primary 2nd gear
3. Primary 3rd gear
4. Primary 4th gear
5. Primary 5th gear
J2-4
6. Primary reverse gear
7. Secondary 1st gear
8. Secondary
2nd gear 9. Secondary 3rd gear
10. Secondary 4th gear Il. Secondary 5th gear
12. Secondary reverse gear
13. Reverse idler gear
14. Differential

J2 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Shift lever won’t shift
Seized shift lever ball Replace J2-46
smoothly or is hard Seized change control rod joint Replace JZ-46
to shift Bent change control rod Replace J2-46
Too much play in Worn change control rod bushing Replace J2-46
shift lever Weak shift lever ball spring Replace J2-46
Worn shift lever ball bushing Replace J2-46
Difficult to shift Bent change control rod Replace J2-46
No grease in transaxle control Lubricate with grease J2-46
Insufficient oil Add oil J2- 7
Deterioration of oil quality Replace with oil of J2- 7
specified quality
Wear or play of shift fork or shift rod Replace J2-13
Worn synchronizer ring Replace J2-18
Worn synchronizer cone of gear Replace J2-18
Bad contact of synchronizer ring and cone of gear Replace J2-18
Excessive longitudinal play of gears Replace J2-18
Worn bearing Replace J2-18
Worn synchronizer key spring
Replace J2-18
Excessive primary shaft gear bearing preload Adjust J2-32
Improperly adjusted change guide plate
Adjust J2-15
Won’t stay in gear Bent change control rod Replace J2-46
Worn change control rod bushing Replace J2-46
Weak shift lever ball spring Replace J2-46
Improperly installed extension bar Tighten J2-46
Worn shift fork Replace J2-18
Worn clutch hub Replace J2-18
Worn clutch hub sleeve Replace J2-18
Worn gear sliding part of both shaft gears Replace J2-18
Worn gear sliding part of each gear Replace J2-18
Worn steel sliding groove of control end Replace J2-13
Weak spring pressing against steel ball Replace J2-13
Excessive thrust clearance Replace J2-18
Worn bearing Replace J2-18
Improperly installed engine mount
Tighten J2-41
Abnormal noise Insufficient oil Add oil J2- 7
Deterioration of oil quality
Replace J2- 7
Worn bearing Adjust or replace J2-18
Worn sliding surfaces of gears or shafts Replace J2-18
Excessive gear backlash Replace J2-18
Damaged gear teeth Replace with oil of J2-18
specified quality
Foreign material in gears Replace J2-18
Damaged differential gear or excessive backlash Adjust or replace J2-44
J2-6

TRANSAXLE J2
Sth/Reverse Gear and Housing Parts
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
1. Rear cover
2. Locknut (Primary shaft)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-14
3. Locknut (Secondary shaft)
Disassembly Note . . . . . . . . . . . . . . . . . . . . .
page J2-14
4. Primary reverse synchronizer gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
5. Synchronizer ring (Reverse)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
6. Secondary reverse synchronizer gear
Inspection ,,.*.....,.,..............I.,..,.. page J2-22
7. Roll pin
8. 5th/Reverse shift fork
9. Clutch hub assembly (5thIReverse) 14. Lock bolt
15. Guide bolt
16. Lock bolt, ball, and spring
17. Transaxle case assembly
18. Magnet
19. Reverse idler shaft
20. Reverse idler gear
21. Lock bolt
22. 5thlReverse shift rod and clip
23. 5th/Reverse shift rod end
24. Pin
25. Crank lever shaft
26. Crank lever assembly
27. Shift fork and shift rod assembly
.- . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-22 Disassembly Note . . . . . . . . . . . . . . . . . . . . . page
JZ-14
10. Synchronizer ring (5th) 28. Steel ball
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22 29. Spring
11. 5th gear 30. Primary shaft gear assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22 31. Secondary shaft gear assembly
12. Gear sleeve 32. Differential assembly
13. Secondary 5th gear 33. Clutch housing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
52-l 3