1992 MAZDA PROTEGE engine

Jl TRANSAXLE
L
r
r
23UOJl-002
03lJOJl-016
Tie-rod end
Caution
l Do not damage the dust boot.
1. Remove the cotter pin and loosen the nut.
2. Disconnect the tie-rod end with the
SST.
Driveshaft
1. Remove the clinch bolt.
Caution
l Wrap a rag around the ball Joint dust boot to pro-
tect it from damage.
2. Disconnect the lower arm from the knuckle with a pry bar.
.-’
Caution
l Do not sub]ect the tripod joint to shock when remov-
ing the driveshaft.
3. Separate the driveshaft from the transaxle by prying with
a bar inserted between the outer ring and the transaxle.
4. Suspend the driveshaft with a rope.
Transaxle
1. Loosen the SST (engine support) and lean the engine to-
ward the transaxle.
2. Support the transaxle with a jack.
Jl-12

/ cm-kg, -26-52 In-lb)
(3.8-5.3, 27-M)
Jl TRANSAXLE
INSTALLATION
1. Raise the vehicle and support it with safety stands.
2 Install in the order shown in the figure, referring to Installation Note.
3’ Add the specified amount of the specified transaxle oil. (Refer to page Jl-7.)
4: Warm up the engine and transaxle, and inspect for oil leakage and transaxle operation.
2.4-5.S N.m (30-60
9
1 8-11 N-m
o-110 cm-kg,
* h-95 In-lb)
.O,
cc.
ft-I
03UOJl-119
b)
51-48

TRANSAXLE Jl
1. Transaxle
Installation Note ..,......,.............. page Jl-49
2. Engine mount No.4
3. Driveshaft
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
4. Stabilizer (BP SOHC)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
5. Tie-rod end
Installation Note ,........,..,........... page Jl-50
6. Clutch release cylinder
7. Engine mount No.2
8. Exhaust pipe
9. Engine mounting member
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-50
10. Control rod
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51 11. Extension bar
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51
1 12. Starter
13. Ground
Installation Note .,..,...,......,........ page Jl-5
14. Neutral switch connector
15. Back-up light switch connector
16. Speedometer cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-5
17. Battery carrier
18. Battery
19. Air hose and resonance chamber
20. Splash shield
21. Wheel and tire 1
Installation Note
Transaxle
1. Set the transaxle on a jack and lift it into place.
Install tne transaxle oorts.
Tightening torque:
64-69 N*rn (6.5-9.1 m-kg, 47-66 ft-lb)
Loosely tighten engine mount No.4 bolts.
Jl-49

03UOJi-12 3
03UOJl-124
L 03UOJl.126 I-
03UOJl-12
Jl TRANSAXLE
Driveshaft
Caution
l Verify that the oil seal is not damaged.
l Do not damage the oil seal
1. Insert the clip with the end-gap at the top of the groove.
2. Apply transaxle oil around the oil seal lip. Install the
driveshaft.
3. Verify that the driveshaft is correctly seated by pulling on
the shaft.
4. Connect the lower arm to the knuckle and tighten the clinch
bolt.
Tightening torque:
43-59 N-m (4.4-6.0 m-kg, 32-43 ft-lb)
Stabilizer (BP SOHC)
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension A: 17-l 9mm (0.67-0.75 in)
Tie-rod end
1. Install the locknut.
Tightening torque:
42-57 N-m (4.3-5.6 m-kg, 31-42 ft-lb)
2. Secure the locknut with a new cotter pin.
Engine mounting member
1. Install the bolts and nuts as shown.
Tightening torque
@ : 37-52 N,m (3.6-5.3 m-kg, 27-36 ft-lb)
@I: 64-89 N-m (6.5-9.1 m-kg, 47-66 ft-lb)
51-50

TRANSAXLE Jl
03UOJl-12!
03UOJi-13
2. Tighten engine mount No.4 nuts.
Tightening torque:
67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)
3. Remove the SST (Engine support).
Control rod and extension bar
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 Nern (3.2-4.7 m-kg, 23-34 ft-lb)
2. Install the change control rod to the transaxle.
Tightening torque:
16-23 N*m (1.6-2.3 m-kg, 12-17 ft-lb)
Ground
1. Connect the ground to the clutch pipe bracket.
Tightening torque:
16-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Speedometer cable
1. Add the specified oil through the speedometer gear case
mounting. (Refer to page Jl-7.)
2. Install the speedometer driven gear.
Tightening torque:
7.6-l 2 N*m (60-120 cm-kg, 69-104 in-lb)
3. Connect the speedometer cable to the speedometer driv-
en gear.
J141

OUTLINE J2
OUTLINE
SPECIFICATIONS
Item
Transaxle control
Synchromesh system EnginelTransaxle
BP DOHC
GSM-R Floor shift
Forward: Synchromesh
Reverse: Selective sliding and synchromesh
T- I-
Gear ratio
I
1 st 3.307
2nd 1.833
3rd 1.310
4th 1.030
5th 0.795
Reverse 3.166
Final gear ratio 4.105
q
Oil Viscosity All-season
Above -18OC (OOF) ATF DexronYI, M2C33F or SAE75W-80
API service GL-4 SAE80W-90
Capacity liters (US qt, Imp qt) 3.35 (3.55, 2.96)
23UOJ2-001
52-3

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. Wheel and tire 14. Exhaust pipe
2. Splash shield 15. Engine mount No.2
3. Air hose and resonance chamber 16. Clutch release cylinder
4. Battery Removal Note .,...........,....,.,...... page J2-11
5. Battery carrier 17. Tie-rod end
6. Speedometer cable Removal Note . . . . . . . . . . . . . . . . ..*........ page J2-11
7. Back-up light switch connector 18. Stabilizer
8. Neutral switch connector 19. Driveshaft
9. Ground Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-12
10. Starter 20. Joint shaft
11. Extension bar 21. Engine mount No.4
12. Control rod 22. Transaxle
13. Engine mount member Removal Note ..,..,....*................ page J2-12
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-1 1
03UOJ2-014
-
03UOJ2-01
Removal Note
Engine mount member
1. Suspend the engine with the SST and remove the engine
mount member.
Clutch release cylinder
Caution
l Do not damage the clutch pipe.
1. Remove the bolts shown.
2. Lay aside the clutch release cylinder and the clutch pipe.
I ,
03UOJ2-016
Tie-rod end
1. Remove the cotter pin.
Caution
l Do not damage the dust boot.
2. Loosen the nut and disconnect the tie-rod end with the SST.
I I
03UOJ2-017
52-l 1