1992 MAZDA PROTEGE differential

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

J2 TRANSAXLE
J2-16
BEARING OUTE
23UOJ2-00
86U07A-04
03UOJ2-02
23UOJ2-OC
Disassembly note
Bearing outer race (transaxle case)
Note
l Since removing the bearing outer race is difficult,
use the SST.
1. Remove the bearing outer race.
Bearing outer race (secondary shaft)
1. Remove the bearing outer race by lifting out the funnel and
race together.
Roll pin
1. Align the groove for removal of the clutch housing pin with
the position of the roll pin, then tap the pin out using a pin
punch.
Bearing outer race (differential)
Caution
l Hold the SST with one hand so that it does not fall.
1. Remove the bearing outer race with a press.
Oil seal (differential)
Replacement (On-vehicle)
Jack up the vehicle and support it with safety stands. Drain
the transaxle oil. Next, use the following procedure to replace
the driveshaft oil seal:
1. Remove the front wheel.
2. Remove the splash shield.
3. Separate the front stabilizer from the lower arm.

TRANSAXLE J2
OUTER RACE
SELECTOR
03UOJ2-069
03UOJ2-07(
86U07A-25:
-sllzd-L-
03UOJZ071
03UOJ2-Oi 1. Install the primary and secondary shaft bearing outer races
into the transaxle case (diaphragm springs and shims
removed).
2. Mount the clutch housing onto the transaxle hanger, and
set the differential bearing outer race into the clutch housing.
Position a piece of pipe against the outer race and tap in
with a hammer until it contacts the clutch housing.
3. Set the outer races into the
SST (selector) as shown in the
figure.
Note
l Turn the selector to eliminate the gap indicated by
the arrow in the figure.
4. Set the differential assembly into the clutch housing; then
set the bearing outer race and the
SST (selector) on the
differential. Set the assembled selectors for the primary and
secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the figure.
5. Set the
SST (collars) in the positions shown in the figure.
6. Install the transaxle case and tighten the
SST (bolts) to the
specified torque.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
7. To seat the bearings, mount the SST (bars) on parts @and
@of the selector, and turn the selector so the gaps are
widened.
Then turn the
SST in the reverse direction until the gaps
are eliminated.
J2-33

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

J2 TRANSAXLE
03UOJ2-OE i3
03UOJ2-120
03UOJ2-08 4
03UOJF085
Bearing preload
Verify the shaft gears and the differential bearing preload.
Note Note
l Verify that the correct adjust shims were selected. l Verify that the correct adjust shims were selected.
l If the bearing preload is not within specification, ad- l If the bearing preload is not within specification, ad-
just again. just again.
1. Set the primary shaft gear and the differential into the clutch
housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 f&lb)
3. Connect the SST and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the
preload.
Preload:
1.4-2.0 N.m (14-20 cm-kg, 12-17 in-lb)
5. Remove the SST.
6. With the transaxle facing in the direction shown in the fig-
ure, install the
SST to the primary shaft gear.
7. Measure the preload.
Preload:
0.1-0.25 N-m (1.0-2.5 cm-kg, 0.87-2.18 in-lb)
8. Remove the SST, transaxle case, primary shaft gear and
differential.
9. Install the secondary shaft gear and transaxle case then
tighten to the specified torque.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
IO. Measure the secondary shaft preload with the SST
Preload:
0.2-0.4 N.m (2.0-4.0 cm-kg, 1.7-3.5 in-lb)
J2-36

TRANSAXLE J2
ShIReverse Gear and Housing Parts
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
37-52 (3.8-8.3, 27-38)
, .-- 104-122 in-lb)
H50-210 cm-ka NEW
O/NEW 8 iN m ’ --13OL-i82 in-@
@mI - *
(80-l 15 Cm-kg,
NEW 89-l 00 In-lb)
128-198
(13-20, 94-145)
1. Differential assembly
2. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
3. Primary shaft gear assembly
6. Shift fork and shift rod assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Assembly
J2-38
7. Crank lever assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly page
Note . . . . . . . . . . . . . . . . . . . . . J2-38
page 4. Spring
J2-38
8. Crank lever shaft 5. Steel ball
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
9. Pin
10. 5thlReverse shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-39
Il. 5th/Reverse shift rod and clip
Assembly Note . . . . . . . . . . . . . . . . . . . . . . page J2-39
12. Lock bolt
13. Reverse idler gear
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . page J2-39
14. Reverse idler shaft
Assembly Note.. . . . . . . . . . . . . . . page J2-39
15. Magnet
“J”“JL-“O)O
21. Secondary 5th gear 16. Clutch housing
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly
page J2-39
22. Gear sleeve Note . . . . . . . . . . . . . . . . . . . . . . . . . .
23. 5th gear page
24. Synchronizer ring (5th) J2-39
25. Clutch hub assembly (5thIReverse)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . page J2-39
26. 5thlReverse shift fork 17. Transaxle case assembly
Assembly Note .,........................ page J2-39
27. Roll pin Assembly
28. Secondary reverse synchronizer gear Note . . . . . . . . . . . . . . . . . . . . . . . . . .
29. Synchronizer ring (Reverse) page
30. Primary reverse synchronizer gear J2-39
31. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-40
32. Locknut 18. Lock bolt, ball and spring
Assembly
19. Guide bolt
Note.. . . . . . . . . . . . . . . . . page J2-40
33. Rear cover 20. Lock bolt
52-37

DIFFERENTIAL J2
DIFFERENTIAL
PREPARATION
SST
49 GO17 1AO
Bearing remover
set
49 8092 375
Attachment J
(Part of
49
GO17 1AO)
49 GO30 338
Attachment E For
removal of
bearing
For
removal of side
bearing inner
race
For
installation of side
bearing inner
race 49 F401 366A
Plate
(Part of
49 GO17 1AO) For
removal of side
bearing inner
race
49 0839 425C
Puller set,
bearing For
removal of side
bearing inner
race I
23UOJ2-01
J2-43

J2 DIFFERENTIAL
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Pre-inspection.
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 Mwn~lre the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin
2. Pinion shaft
3. Pinion gear
Inspection for wear and cracks
Pre-inspection .,...,........,............ page J2-44
Inspection of backlash. . . . ,.,.,..,,. page J2-45
4. Thrust washer
5. Side gear
Inspect for wear and cracks
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-44
Inspection of backlash . . . . . . . . . . . . . . page J2-45
6. Thrust washer
1
J ______ Ji
7. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-45
Assembly Note, .., ,.,..,,,,....,...,..,. page J2-45
8. Speedometer drive gear
9. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note .., ..,...., . ,. . . . . . . . page J2-45
Assembly
Note.. . . . . . . ,.. . . . ..,.. . . . . . . . page J2-45
10. Ring gear and gear case assembly
Inspect ring gear for wear or damage
Pre-inspection
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-
sembly.
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)
J2-44