1992 MAZDA PROTEGE key

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
1. 3rd/4th shift fork
2. Interlock sleeve
3. Roll pin
4. Control end
5. lst/2nd shift fork
6. Roll pin
7. Control lever
8. Control rod
9. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-23
10. Secondary 4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
11. Retaining ring
12. Secondary 3rd gear
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-20
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
13 2nd gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection .,,.,~,,.,,..........,,..........,
page J2-22
14. Synchronizer ring (2nd)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
15. Retaining ring
16. Clutch hub assembly (lst/2nd)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
17. Synchronizer ring (1 st)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
18. 1st gear
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-19
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22 19. Bearing inner race
Disassem.bly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
20. Secondary shaft
Inspection ,................................. page J2-23
21. Bearing inner race
Pre-inspection ,..,.,..................... page J2-20
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
22. 4th gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
23. Synchronizer ring (4th)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
24. Retaining ring
25. Clutch hub assembly (3rd/4th)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
Inspection ..,............................... page J2-22
26. Synchronizer ring (3rd)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
27.3rd gear
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-20
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
28. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-21
29. Primary shaft
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-23
30. Synchronizer spring
31. Synchronizer key
32. Clutch hub
33. Clutch hub sleeve (reverse gear)
34. Synchronizer spring
35. Synchronizer key
36. Clutch hub
37. Clutch hub sleeve
03UOJ2.03! 03UOJ2-034
Pre-inspection
Thrust clearance
1. Measure the clearance between the 2nd gear and secon-
dary 3rd gear.
Clearance: 0.175-0.455mm (0.0069-0.0179 in)
Maximum : OS05mm (0.0199 in)
2. Measure the clearance between the 1 st gear and differen-
tial drive gear.
Clearance: 0.05-0.26mm (0.002-0.011 in)
Maximum : 0.33mm (0.0130 in)
03UOJ2-036
52-l 9

52 TRANSAXLE
INSPECTION
Inspect all parts and repair or replace as necessary.
05UOJX-023
-’
03UOJ2-04
I
-
03UOJ2-11
13UOJ2-00
9MUOJX-05
52-22
Gears
1. Inspect synchronizer cones for wear.
2. Inspect individual gear teeth for damage, wear, and cracks.
3. Inspect synchronizer ring matching teeth for damage and
wear.
Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear,
and cracks.
2. Inspect taper surface for wear and cracks.
Note
l Set the synchronizer ring squarely in the gear; then
measure around the circumference.
3. Measure the clearance between the synchronizer ring and
flank surface of the gear.
Standard clearance: 1.5mm (0.059 in)
Minimum: 0.8mm (0.032 in)
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.

TRANSAXLE J2
1. Clutch hub
Assembly Note ,......................... page J2-27
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Clutch hub
Assembly Note ,......................... page J2-27
6. Synchronizer key
7. Clutch hub sleeve (reverse gear)
8. Synchronizer spring
9. Primary shaft
10. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
11. 3rd gear
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
12. Synchronizer ring (3rd)
Assembly Note.. . . . . . . . . . . . . . . . . . . page J2-28
13. Clutch hub assembly (3rd14th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
14. Retaining ring
15. Synchronizer ring (4th)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
16. 4th gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-28
17. Bearing inner race
Assembly Note.. . . . . . . . . . . . . . . . . . page J2-28
18. Secondary shaft
19. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . page J2-29 20. 1st gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
21. Synchronizer ring (1 st)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
22. Clutch hub assembly (IstMnd)
Assembly Note ,,..........,............. page J2-29
23. Retaining ring
24. Synchronizer ring (2nd)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
25.2nd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
26. Secondary 3rd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
27. Retaining ring
28. Secondary 4th gear
Assembly Note ,.,............,....,..... page J2-30
29. Bearing inner race
Assembly Note. . . . . . . . . . . . . . . . . . page J2-30
30. Control rod
31. Control lever
32. Roll pin
33. lst/2nd shift fork
34. Control end
35. Roll pin
36. Interlock sleeve
Assembly Note.. . . . . . . . . . . . . . . . page J2-30
37. 3rd/4th shift fork
03UOJ2 051
___-__ 03UOJ2-11
Assembly note
Clutch hub
Note
l Synchronizer key dimensions are as follows.
mm (in)
(l-1
12) 1\3>
_--
1stMnd 19 (0.7480) 4.25 (0.1673) -5.00 (0.1969)
3rdl4th
SthlRev. 17 (0.6693) 4.25 (0.1673) 5.00 (0.1969)
1. Install the synchronizer key springs in the clutch hub with
the hooks in the grooves to hold the three synchronizer keys
in place.
03UOJ2-052
J2-27

J2 TRANSAXLE
I
23UOJ2-OC
W-W i
W-U
(REVERSE)
I 03UOJ2-054
(FOUR PLACES)!
23UOJ2-00
r
1
03UOJ2-O!
52-m
7
1 57
Bearing inner race (primary shaft end)
1. install the new bearing inner race with the SST.
3rd gear, synchronizer ring (3rd) and clutch hub
assembly (3rd/4th)
Note
l The size of the lst, 2nd, 3rd, and 4th synchronizer
rings are the same. Be careful when installing them.
The 2nd ring has the larger cut-out as shown in the
illustration.
l Align the synchronizer ring groove and clutch hous-
ing hub key when installing.
1, Install the 3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th) with the
SST.
Synchronizer ring (4th), 4th gear and bearing inner race
1. Install the synchronizer ring (4th), 4th gear, and bearing in-
ner race with the
SST.
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05-0.20mm (0.002-0.008 in)
Maximum : 0.25mm (0.010 in)

TRANSAXLE J2
13UOJ2-006
I 03UOJ2-06f
23UOJ2.011
3. Measure the clearance between the 4th gear and bearing
inner race.
Clearance: 0.165-0.365mm (0.0065-0.0144 in)
Maximum : 0.415mm (0.0163 in)
4. If not as specified, reassemble the primary shaft assembly.
Bearing inner race (secondary shaft end)
1. Install the new bearing inner race with the SST.
1st gear, synchronizer ring (1st) and clutch hub
assembly (1 st/2nd)
Note
l Align the synchronizer ring, groove and clutch hous-
ing hub key when installing.
1. Assemble the 1 st gear, synchronizer ring (1 St), and clutch
hub assembly (lst/2nd), as shown in the figure.
2. Press the clutch hub assembly (1 st/2nd) on with the
SST.
Synchronizer ring (2nd), 2nd gear and secondary 3rd
gear
1. Install the synchronizer ring (2nd) and 2nd gear.
2. Install the secondary 3rd gear with the
SST.
23UOJ2-011
J2-29

N MANUAL STEERING
1 I
13UONX-033
Steering lock assembly (ATX)
Verify that the cable connector does not move when the key
is in the LOCK position and that it moves freely with the key
in other positions.
Assembly note
Steering lock assembly
Install the steering lock assembly on the jacket. Install new
steering lock mounting bolts, and tighten them until the heads
break off.
I 13UONX-034
N-12

DASHBOARD S
1, Rear ashtray (Without passive IO. Combination switch 18. Glove box lid
shoulder belt) Removal / Installation 19. Lower panel (R.H.)
2. Rear console ,..,,.,......,,.,.,....... Section T 20. Front ashtray
3. Front console 11. Center upper hole cover 21. Lower panel (Center)
4. Control box center cover 12. Upper garnish
22. Glove box cover
(With small front console) 13. Side panel 23. Dash board
5. Side walls 14. Hood release knob Removal Note . . page S-95
6. Undercover 15. Lower panel (L.H.) Installation Note page S-96
7. Steering column 16. Meter hood 24. Pipe frame (Lower)
Removal / Installation 17. Instrument cluster 25. Pipe frame (Upper)
. . . . . . . . ...*. . . . . ..n..... Section N Removal I Installation
1 suosx-017
8. Key cylinder set ring
9. Column cover
JOINT BOX
. . . . . . . . . . . . . . . . . . . . . . . . . . Section T
Removal Note
Dashboard
1, Remove the control wires of the heater unit and blower unit.
2. Disconnect the necessary harness connectors.
s-95