1992 MAZDA PROTEGE steering

MANUAL STEERING N
13UONX-01
23UONX-05
POSITION
1 SGONX-Oi
23UONX.01 I1
Disassembly note
Steering lock assembly
Use a chisel to make a groove in the head of the steering lock
mounting bolts. Remove the bolts with a screwdriver; then re-
move the steering lock assembly.
Caution
l Secure the shaft in a vise protected with brass pads
or cloth.
Inspection
Check for the following and replace the assembly if necessary.
Steering shaft assembly
1. Column bushing wear.
2. Steering shaft length.
Specified length: 558.3~560.3mm (21.98-22.06 in)
3. Tilt operation.
(1) Verify that the adjusting lever moves smoothly from un-
lock position to lock position.
(2) Verify that the steering shaft is fixed firmly when the ad-
justing lever is locked.
Intermediate shaft, Universal joint
Universal joint looseness, abnormal noise, or sticking.
N-l 1

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

MANUAL STEERING N
STEERING GEAR AND LINKAGE
Removal / Installation
1. Loosen the wheel lug nuts.
2. Jack up the front of the vehicle and support it with safety stands.
3. Remove the wheels.
4. Remove in the order shown in the figure, referring to
Removal Note.
5. install in the reverse order of removal, referring to Installation Note.
6. Adjust the toe-in (Refer to Section R).
/
37-52 (3.8-5.3, 27-38)
REPLACE 31-42)
N-m (m-kg, ft-lb)
23UONX-01,
1. Cotter pin 6. Nut
2. Nut Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
3. Steering knuckle 7. Steering gear and linkage
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7 Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
4. Set plate
5. Fixing bolt (Intermediate shaft/Pinion shaft)
installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page
N-14
N-13

N MANUAL STEERING
r
13UONX-035
I 23UONX-015
Removal note
Steering gear and linkage
Remove the steering gear from the right side of the vehicle.
Installation note
Nut
install the steering gear mounting nuts in the order shown in
the figure.
Tightening torque:
37-52 N,m (3.8-5.3 m-kg, 27-38 ft-lb)
Fixing bolt (Intermediate shaft, Pinion shaft)
1. Remove the intermediate shaft and pinion shaft bolts, and
move the intermediate shaft upward.
2. Connect the intermediate shaft and the pinion shaft. Tight-
en the bolts, to the specified torques.
Tightening torque:
18-28 N-m (1.8-2.7 m-kg, 13-20 ft-lb)
23UONX-016
N-14

MANUAL STEERING N
Disassembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
23UONX-017
1. Tie rod end 12. Pinion protector
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 6 Disassembly note ,.,..,.............,... page N-16
2. Boot wire
3. Boot clip
4. Boot
5. Tie rod
Disassembly Note . . . . . . . . . . . . . . . . . . . . . .
6. Washer
7. Locknut
8. Adjusting cover
9. Spring
10. Pressure pad plate
11. Pressure pad 13. Oil seal
14. Snap ring cap
15. Snap ring
16. Pinion
page N-16 Disassembly Note ,....,,.............,. page N-l 7
17. Rack
Disassembly
Note . . . . . . . . . . . . . . . . . . . . . . page N-l 7
18. Bushing
19. Mounting bracket and rubber
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-17
20. Gear housing .
N-15

N MANUAL STEERIN
93GONX-007
23UONX-01 I
c-7
23UONX-01
63U 1 OX-089
Disassembly note
Steering gear and linkage
1, Secure the mounting part of the removed gear and linkage
in a vise.
Caution
l Be sure to insert a soft, protective material between
the part and the jaws of the vise.
Tie rod end
1. Make a matching mark on the tie rod threads for proper
reassembly.
Tie rod
1. Uncrimp the locking washer.
2. After wrapping the rack in a rag and securing it in a vise,
remove the tie rod from the rack.
Pinion protector
1. Hit the rim of pinion protector with a plastic hammer gently
from under to remove it.
I m-
I
93GONX-067
N-16

MANUAL STEERING N
93GONX-OO! 3
63U 10X-09,
3
23UONX-052
13UOKX-01:
93GONX-01
Pinion
1. Gently grasp the serrated part of the pinion, and pull it out.
Rack
1. Remove the rack by taking it out in the direction indicated
by the arrow.
Caution
l If the rack is taken out in the opposite direction, the
inside surface of the rack bushing might be
damaged by the edge of the rack gear.
Mounting bracket and rubber
1. Remove the mounting bracket and rubber from the housing.
Inspection
Check the following points, replace the part if a problem is
found.
1. Cracking, damage, or deterioration of boots
2. Cracking, worn teeth, or damage to rack and pinion
3. Looseness, abnormal noise, or poor bearing operation in-
side the gear housing
4. Worn rack bushing inside the gear housing. Wear, normal
noise, or rough movement of the bearing on the pinon shaft.
Caution
l If replacement is necessary, replace the entire gear
housing assembly.
l Abnormal noise or rough movement of the bearing.
l If replacement is necessary, replace the entire pin-
ion and bearing assembly.
N-17

N MANUAL STEERING
5. Wear of sliding surface of pressure pad which contacts rack
6. Cracking or deformation of gear housing
7. Looseness or lack of smoothness in tie rod ball-joint
operation
8. Bent tie rod or tie rod ends
9. Damage to tie rod or tie rod end
23UONX-020
N-18