1992 MAZDA PROTEGE Workshop Manual

.
TRANSAXLE Jl
03UOJl-03: 3
03UOJl-040
03UOJ l-04
I 03UOJl-04
2
03UOJl-043
Preinspection
3rd gear thrust clearance
1. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.06-0.21 mm (0.002-0.008 in)
Maximum : 0.26mm (0.010 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 3rd gear, 2nd gear and clutch hub (3rd/4th).
Replace worn or damaged parts.
4th gear thrust clearance
1. Measure the clearance between 4th gear and the ball
bearing.
Clearance: 0.21-0.61 mm (0.008-0.024 in)
Maximum: 0.66mm (0.026 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 4th gear, ball bearing, and clutch hub
(3rd/4th). Replace worn or damaged parts.
Disassembly note
Bearing and 4th gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the ball bearing and 4th gear with the SST.
Clutch hub assembly (3rd/4th), synchronizer ring (3rd)
and 3rd gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the clutch hub assembly (3rd/4th), synchronizer
ring (3rd) and 3rd gear with the
SST.
Bearing
1. Remove the bearing with the SST.
Jl-23

Jl TRANSAXLE
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
0 REPLACE-
/
1. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
2. Secondary 4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
3. Retaining ring
4. Secondary 3rd gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
5.2nd gear
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (2nd)
Inspection.. . . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . . page J l-27
7. Retaining ring
8. Clutch hub assembly (lst/2nd)
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-29 9. Synchronizer ring (1 st)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. ,,..... . . . . . . . . . . . . . . . . . . . . . . . . . page J l-27
10. 1st gear
Disassembly Note ..,..,,.,,,....,..,.. page Jl-25
Inspection ..,................,.............. page J l-29
11. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . , . . . . page Jl -26
12. Secondary shaft
Inspection., , , . , . , . . , , . . . . . . . . , . , . . . . . , . . . . . page J l-28
13. Synchronizer spring
14. Clutch hub sleeve
15. Synchronizer key
16. Clutch hub
Jl-24

TRANSAXLE Jl
03UOJ 1.04!
03UOJ 1.041
03UOJl-047
, , .” ,,,,,..
03UOJl-04t
03UOJ l-04!
Preinspection
1st gear thrust clearance
1, Measure the clearance between 1 st gear and the differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 in)
Maximum: 0.33mm (0.013 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 1 st gear, differential drive gear of the secon-
dary shaft gear, and clutch hub assembly (1 st/2nd). Replace
worn or damaged parts.
2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary
3rd gear.
Clearance: 0.18-0.51 mm (0.007-0.020 in)
Maximum: 0.58mm (0.022 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 2nd gear, secondary 3rd gear, and clutch
hub assembly (1 stMnd). Replace worn or damaged parts.
Disassembly note
Bearing inner race and secondary 4th gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race and secondary 4th gear with
the
SST.
Secondary 3rd gear and 2nd gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the secondary 3rd gear and 2nd gear with the
SST.
Clutch hub assembly (lst/2nd), synchronizer ring (1st)
and 1st gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the clutch hub assembly (1 st/2nd), synchronizer
ring (1st) and 1st gear with the
SST.
Jl-25

Jl TRANSAXLE
. . ..f.... y:;::::. :::: ’
. . . .
‘.I
F j r
03UOJl-051
Bearing inner race (Secondary shaft end)
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race with the SST.
51-26

TRANSAXLE Jl
INSPECTION
Inspect all parts and repair or replace as necessary.
03UOJl.051
03UOJl-05
03UOJl-05:
13UOJl.001
Synchronizer Ring
1. Inspect individual synchronizer ring teeth for damage, wear,
cracks.
2. Inspect taper surface for wear or 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: 1.12-l .88mm (0.044-0.074 in)
Minimum: 0.8mm (0.032 in)
Reverse Idler Gear and Reverse Lever
1. Inspect gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bush-
ing and the reverse lever.
Standard clearance: O.lO-0.32mm (0.004-0.013 in)
Maximum: 0.37mm (0.015 in)
Primary Shaft
Note
l If the shaft gear is replaced, adjust the bearing
preload. (Refer to page Jl-37.)
1. Inspect the shaft gear runout.
Maximum runout: 0.05mm (0.002 in)
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
51-27

Jl TRANSAXLE
3rd Gear, 4th Gear, 5th Gear, and Gear Sleeve (5th gear)
1. Measure the clearance between the shaft gears and gears.
4TH 3RD
03UOJl-05
03UOJl-05
9MUOJX-063
51-28
03UOJl-06 i0
Oil Clearance mm (in)
1 Shaft (A 1 G Sleeve (C)
(outer biakter) (inneFikr!?ter) (outer diameter) Oil (D)
Clearance
35.15-35.17 35.20-35.22 _ P) = W-(A)
3rd Gear
(1.384-l ,385) (1.386-l ,387) 0.03-0.07
(0.001-0.003)
31.95-31.97 32.00-32.02 _ 0 = W-(A)
4th Gear
(1.258--1.259) (1.260-l ,261) 0.03-0.07
~0.001-0.003~
5th Gear -
‘(D) = (B)-(C)’ 34.00-34.02 33.94-33.97 o,03-o,08
(1,338-l .339) (1.336-l .337) (o,oo,-o,oo3)
I I I I I
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
Bearing
1. Inspect for damage or rough rotation.
Secondary Shaft
Note
l If the shaft gear is replaced, adjust the bearing
preload. (Refer to page Jl-37.)
1. Inspect the shaft gear runout.
Maximum runout: 0.015mm (0.001 in)
2. Inspect the gear teeth for damage, wear, and cracks.

TRANSAXLE
1ST 2ND
03UOJl-06 03UOJl-06
9MUOJX-05
03UOJl-05
1st Gear and 2nd Gear
1. Measure the clearance between the shaft gears and the
gears.
Oil Clearance mm (in)
Shaft (A) Gear (B) Sleeve (C) Oil (D)
(outer diameter) (inner diameter) (outer diameter)
Clearance
39.45-39.47 39.50-39.52 03 =(B)-(A)
’ st Gear (1.553-l 554) (1,555-l ,556) - 0.03-0.07
(0.001-0.003)
35.15-35.17 35.20-35.22 PI = (B)-(A)
2nd Gear (1.384-I ,385) (1,386-l ,387) - 0.03-0.07
(0.001-0.003)
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
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.
4. Measure the clearance between the hub sleeve and the shift
fork.
mm (in)
1 stMnd Standard clearance
0.1 O-O.36
(0.004-0.014) Maximum
0.86 (0.034)
I 3rd14th
I 0.20-0.50
(0.008-0.020)
I 1 .oo (0.039)
I
5th 0.40-0.75
(0.016-0.030) 1.25 (0.049)
51-29

Jl TRANSAXLE
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. Verify that all parts are completely clean before assembly.
3. Assemble parts within 10 minutes after applying sealant.
Allow all sealant to cure at least 30 minutes after assembly before filling the transaxle with transaxle oil.
4. The bearing outer race and bearing inner race must be replaced as a unit.
03UOJl-063
OBUOJl-06
-.--___
l-----o1
r-o-i
q----j H
I4
OBUOJI-065
03UOJl-06
SYNCHRONIZER RING
CLUTCH HUB SLEEVE

SYNCHRONIZER KEY 6
I
03UOJ l-067
51-30
Clutch hub assembly
Note
l Synchronizer ring diameters are as follows.
1st and 2nd
3rd and 4th
5th mm (in)
61.7 (2.429)
61.7 (2.429)
49.7 (1.957)
l Synchronizer key dimensions are as follows.
mm (in)
0 0
0
1 stl2nd 19.00 (0.748)
4.25 (0.167) 5.00 (0.197)
3rdl4th 17.00 (0.669)
4.25 (0.167) 5.00 (0.197)
5th
17.00 (0.669) 5.55 (0.219)
5.00 (0.197)
1. Install the synchronizer key springs in the clutch hub with
the hooks in the grooves to hold the three synchronizer keys
in place.
2. Align the synchronizer ring grooves with the synchronizer
key during assembly.