1992 MAZDA PROTEGE Workshop Manual

TRANSAXLE Jl
- 23UOJl-01
03UOJl-11
03UOJl-14
I 03UOJl-11
Transaxle case assembly
1, Apply a thin coat of sealant to the contact surfaces of the
clutch housing and transaxle case, tighten the transaxle case
installation bolts to the specified torque.
Tightening torque:
19-26 Nom (1.9-2.6 m-kg, 14-19 ft-lb)
Clutch hub assembly (6th) and 6th shlft fork
1. Install the clutch hub assembly (5th) and the 5th shift fork
together.
Locknut
1. Shift to 1 st gear.
2. Lock the primary shaft with the
SST.
3. Tighten new locknuts on the primary and secondary shafts.
Tightening torque:
126-206 N*m (13.0-21 m-kg, 94-152 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06-0.26mm (0.0024-0.0102 in)
Maximum : 0.31 mm (0.0122 in)
6. If not as specified, reassemble the transaxle.
Jl-47

/ 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

Jl DIFFERENTIAL
DIFFERENTIAL
PREPARATION
SST
49 B017 1AO
Remover set,
bearing
49 8092 371
Attachment E
(Part of
49 8017 1AO)
49 F401 3308
Installer set,
bearing
49 F401 337A
Attachment C
(Part of
49 F401 3308) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
For
installation of
bearing 49 F401 366A
Plate
(Part of
49 8017 1AO)
49 0839 42%
Puller set,
bearing
49 F401 331
Body
(Part of
49 F401 3309) For
removal of
bearing
For
removal of
bearing
For
installation of
bearing
03UOJl-13 .-,
5142

DIFFERENTIAL Jl
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove the inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Preinspection.
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. Measure the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin 7. Side bearing inner race
13UOJl-00:
Assembly Note .......................... page Jl -55 Disassembly Note.. ..................
2. Pinion shaft Inspection .................................
3. Thrust washer Assembly Note .........................
4. Pinion gear 8. Speedometer drive gear
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 9. Side bearing inner race
Inspection of backlash.. ............ page Jl-55 Disassembly Note.. ..................
5. Side gear Inspection .................................
Inspect for wear and cracks Assembly Note.. .......................
Preinspection ............................ page J l-53 10. Ring gear and ring case
Inspection of backlash.. ............ page Jl-55 Inspection .................................
6. Thrust washer
03UOJl-13 4
page Jl-54
page Jl -54
page Jl-55
page Jl -55
page Jl-54
page Jl-54
page Jl-55
page Jl-54
Preinspection
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-
sem bly.
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)
51-53

Jl DIFFERENTIAL
4. If the backlash exceeds specification, adjust by selecting
and installing thrust washers between the case and the side
gears.
Caution
l Use thrust washers with the same thickness on each
side.
-.
Thrust washer thickness: mm (in)
1 2.0 (0.079) 2.1 (0.083) 2.2 (0.087) 23UOJl-012
03UOJ2-10
1 03UOJ2-104
03UOJl-13
Jl-54
03UOJl-1: 6
Disassembly Note
Side bearing inner race (Side opposite ring gear)
Caution
l Hold the gear case with one hand so that it does
not fall.
1. Remove the bearing inner race with the SST.
Side bearing inner race (Ring gear side)
Note
l Use pads in the vise.
1. Remove the bearing inner race with the SST.
Inspection
Inspect all parts and repair or replace as necessary.
Ring gear and ring case
Note
l If the gear case is replaced, adjust the bearing
preload.
1. Inspect the ring gear for wear and cracks.
Bearing inner race
Note
l When replacing the bearing inner race, replace the
bearing outer race and inner race as a set.
l If the bearing is replaced, adjust the bearing
preload.
1. Inspect for wear and rough rotation. --