1992 MAZDA PROTEGE Workshop Manual

DIFFERENTIAL Jl
03UOJl-138
Assembly Note
Speedometer drive gear
1. Install the speedometer drive gear as shown in the figure.
1
03UOJl-13!
I
03UOJ2-10
I
03UOJl-14
I 03UOJl-14 .l
Side bearing inner race (Side opposite ring gear)
1. Install the speedometer drive gear.
2. Install the new side bearing inner race with the
SST.
Side bearing inner race (Ring gear side)
1. Install the new bearing inner race with the SST.
Roll pin
1, Install the new roll pin as shown in the figure to hold the
pinion shaft.
Backlash of Side Gear and Pinion Gear
Measure the backlash by the following procedure.
1. Install the driveshafts in the differential assembly.
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)
4. If not as specified, select the proper thrust washers.
(Refer to preinspection, page Jl-53.)
Jl-55

Jl SHIFT MECHANISM
SHIFT MECHANISM
OVERHAUL
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to
Assembly Note.
t
w 16-G (1.6-2.3, 12-17)
“..d
n /~~16--23 (1.6-2.3, 12-17)
1. Shift lever knob
2. Rear ashtray
3. Rear console
4. Front console
5. Boot
6. Nut
7. Washer
8. Bolt
9. Nut
10. Washer
Il. Bushing
12. Spring
Inspect for damage and weakness
Assembly Note.. . . . , . . . . . . . . . . . . . . . . . . . . page Jl -57
13. Shift lever
;45. “,Mlseat (upper)
Inspect for wear and damage
Jl-56
16. Holder
17. Ball seat (lower)
18. Nut
19. Washer
20. Pipe
21. Bushing
Inspect for wear and damage
22. Washer
23. Extension bar
Assembly Note,.. . . ., . . . . . . . . . . . . . . . . . . .
24. Insulator
Inspect for damage and cracks
25.
Nut
26. Bolt
27. Bushing
Inspect for wear and damage
28. Change control rod
Inspect for bending
142
page Jl -57

SHIFT MECHANISM Jl
03UOJl-14
03UOJi-144
Assembly Note
Extension bar
1, Connect the extension bar onto the transaxle, then mount
it to the floor.
Tightening torque:
16-23 N#m (1.6-2.3 m-kg, 12-17 ft-lb)
Spring
1. Verify that the hooked part of the spring is properly seated
in the bracket groove.
51-57

J2
MANUAL TRANSAXLE
(G5M-R)
INDEX .....................................................
J2- 2
OUTLINE
................................................
J2- 3
SPECIFICATIONS
................................... J2- 3
STRUCTURAL VIEW ...............................
J2- 4
POWER FLOW
......................................
J2- 5
TROUBLESHOOTING
GUIDE.. ................... J2- 6
TRANSAXLE OIL .....................................
J2- 7
INSPECTION
.........................................
J2- 7
REPLACEMENT .....................................
J2- 7
TRANSAXLE
...........................................
J2- 6
PREPARATION ......................................
J2- 6
REMOVAL
............................................
J2-10
DISASSEMBLY
......................................
52-l 2
INSPECTION .........................................
J2-22
ASSEMBLY
...........................................
J2-26
INSTALLATION
......................................
J2-41
DIFFERENTIAL
........................................
J2-43
PREPARATION
......................................
52-43
DISASSEMBLY / INSPECTION I ASSEMBLY J2-44
SHIFT MECHANISM
.................................
52-46
OVERHAUL
..........................................
52-46
03UOJ2-001

J2 INDEX
IN
new IYLA
BACK-lx LIU, 1, w.., 1 vm q
SERVICE, SECTION
F
k’c’ 1T6AL SWITCH 8.L”
SERI /ICE, SECTION T VISCOSITY: ALL-SEASON ATF DEXRON-II,
M2C33F OR SAE75W-80
ABOVE -18% (OOF) API SERVICE
GL-4 SAE80W-90
CAPACITY: 3.35 liters (3.55 US at. 2.98 ho 41)
1. Transaxle
Removal ..,.....,.,..,....,..,.........,.... page J2-10
Disassembly ,., ,..,., . ,,...., ,.. .., .., page J2-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
Assembly . . . . . . . . . ,.,...................... page J2-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-41
52-2
2. Differential
Disassembly / Inspection I
Assembly ,..,.,.,, ,_, ,. .,. ,_. ,_. . . . page J2-44
3. Shift mechanism
Overhaul ,....,.......,..... ,........, . . . . . . page J2-46
4. Transaxle oil
inspection . . . . . . . . ..,........I....I.,..... page J2- 7
Replacement .,.,.., ,.,...,...,.. . . . . . . . . . page J2- 7 .___I’

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 OUTLINE
03UOJ2-OC
1, Primary 1 st gear
2. Primary 2nd gear
3. Primary 3rd gear
4. Primary 4th gear
5. Primary 5th gear
J2-4
6. Primary reverse gear
7. Secondary 1st gear
8. Secondary
2nd gear 9. Secondary 3rd gear
10. Secondary 4th gear Il. Secondary 5th gear
12. Secondary reverse gear
13. Reverse idler gear
14. Differential