1992 MAZDA PROTEGE Workshop Manual

TRANSAXLE J2
03UOJ2-04
P==7 II
03UOJ2-04
03UOJ2-04d
03UOJ2-04:
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.
Bearing inner race (4th gear end)
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race with the SST.
Clutch hub assembly (3rd/4th), synchronizer ring (3rd)
and 3rd gear
1. Remove the retaining ring.
Caution
l Hold the shaft with one hand so that it does not fall.
2. Remove the clutch hub assembly (3rd/4th) synchronizer ring
(3rd) and 3rd gear with the
SST.
Bearing inner race (primary shaft end)
1. Remove the bearing inner race with the SST.
J2-21

52 TRANSAXLE
INSPECTION
Inspect all parts and repair or replace as necessary.
05UOJX-023
-’
03UOJ2-04
I
-
03UOJ2-11
13UOJ2-00
9MUOJX-05
52-22
Gears
1. Inspect synchronizer cones for wear.
2. Inspect individual gear teeth for damage, wear, and cracks.
3. Inspect synchronizer ring matching teeth for damage and
wear.
Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear,
and cracks.
2. Inspect taper surface for wear and 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: 1.5mm (0.059 in)
Minimum: 0.8mm (0.032 in)
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.

TRANSAXLE 52
I I
13UOJ2.006
03UOJ2-114
, 03UOJ2-115
BE Tt
03UOJ2-047
03UOJ2-04 6
4. Measure the clearance between hub sleeve and shift fork.
Clearance mm (in)
I I Standard
I Maximum
I
I l&end I 0.08-0.228 (0.003-0.009~ I 0.728 (0.029) I
3rd14th 0.1 O-0.500 (0.004-0.020) 1.000 (0.039)
5thlRev. 0.15-0.458 (0.059-0.018) 0.958 (0.038)
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:
0.1 O-0.32mm (0.004-0.013 In)
Maximum: 0.5mm (0.020 in)
Bearing
1. Inspect for damage and rough rotation.
Primary Shaft and Secondary Shaft
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for clogging.
5. Inspect the shaft gears’ runout.
Primary shaft gear runout: 0.05mm (0.002 in)
Secondary shaft gear runout: 0.015mm (0.0006 in)
Note
l If the shaft gear is replaced, adjust the bearing
preload. (Refer to page J2-32.)
J2-23

J2 TRANSAXLE
4TH
3RD
23UOJ2-015
2ND 1ST
03UOJ2-049
6. Oil clearance between shaft gears and gears.
Oil Clearance
Shaft Gear Sleeve
(Outer dia.) (inner dia.) (Outer dia.) Oil 'learanCe
1st 39.445-39.470 39.500-39.525 _
(1.553-1.554) (1.555-1.556)
2nd 34.945-34.970 35.000-35.025 _
(1.376-1.377) (1.378-1.379)
3rd 35.945-35.970 36.000-36.025 0.03-0.08
_
(1.415-1.416) (1.417-1.418) (0.001-0.003)
4th 30.945-30.970 31.000-31.025 _
(1.218-1.219) (1.220-1.221)
34.000-34.025
33.945-33.970
1 5th
-
(1.339-1.340) (1.336-1.337)
/
Speedometer Driven Gear Assembly
1. Inspect the teeth for damage and wear.
2. inspect the O-ring for damage and wear. mm (in)
_......
52-24

TRANSAXLE J2
MEMO
52-25

J2 TRANSAXLE
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. The bearing outer race and bearing inner race must be replaced as a unit.
3. Before assembly, make sure all parts are completely clean.
4. Assemble the 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.
Primary Shaft Assembly and Secondary Shaft Assembly
1. Assemble in the order shown in the figure, referring to Assembly Note.
1
1
OIL GROOVE
(FOUR PLACESj==z
L
J2-26

TRANSAXLE J2
1. Clutch hub
Assembly Note ,......................... page J2-27
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Clutch hub
Assembly Note ,......................... page J2-27
6. Synchronizer key
7. Clutch hub sleeve (reverse gear)
8. Synchronizer spring
9. Primary shaft
10. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
11. 3rd gear
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
12. Synchronizer ring (3rd)
Assembly Note.. . . . . . . . . . . . . . . . . . . page J2-28
13. Clutch hub assembly (3rd14th)
Assembly Note.. . . . . . . . . . . . . . . . . . . . page J2-28
14. Retaining ring
15. Synchronizer ring (4th)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-28
16. 4th gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-28
17. Bearing inner race
Assembly Note.. . . . . . . . . . . . . . . . . . page J2-28
18. Secondary shaft
19. Bearing inner race
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . page J2-29 20. 1st gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
21. Synchronizer ring (1 st)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
22. Clutch hub assembly (IstMnd)
Assembly Note ,,..........,............. page J2-29
23. Retaining ring
24. Synchronizer ring (2nd)
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
25.2nd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-29
26. Secondary 3rd gear
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page J2-29
27. Retaining ring
28. Secondary 4th gear
Assembly Note ,.,............,....,..... page J2-30
29. Bearing inner race
Assembly Note. . . . . . . . . . . . . . . . . . page J2-30
30. Control rod
31. Control lever
32. Roll pin
33. lst/2nd shift fork
34. Control end
35. Roll pin
36. Interlock sleeve
Assembly Note.. . . . . . . . . . . . . . . . page J2-30
37. 3rd/4th shift fork
03UOJ2 051
___-__ 03UOJ2-11
Assembly note
Clutch hub
Note
l Synchronizer key dimensions are as follows.
mm (in)
(l-1
12) 1\3>
_--
1stMnd 19 (0.7480) 4.25 (0.1673) -5.00 (0.1969)
3rdl4th
SthlRev. 17 (0.6693) 4.25 (0.1673) 5.00 (0.1969)
1. Install the synchronizer key springs in the clutch hub with
the hooks in the grooves to hold the three synchronizer keys
in place.
03UOJ2-052
J2-27

J2 TRANSAXLE
I
23UOJ2-OC
W-W i
W-U
(REVERSE)
I 03UOJ2-054
(FOUR PLACES)!
23UOJ2-00
r
1
03UOJ2-O!
52-m
7
1 57
Bearing inner race (primary shaft end)
1. install the new bearing inner race with the SST.
3rd gear, synchronizer ring (3rd) and clutch hub
assembly (3rd/4th)
Note
l The size of the lst, 2nd, 3rd, and 4th synchronizer
rings are the same. Be careful when installing them.
The 2nd ring has the larger cut-out as shown in the
illustration.
l Align the synchronizer ring groove and clutch hous-
ing hub key when installing.
1, Install the 3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th) with the
SST.
Synchronizer ring (4th), 4th gear and bearing inner race
1. Install the synchronizer ring (4th), 4th gear, and bearing in-
ner race with the
SST.
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05-0.20mm (0.002-0.008 in)
Maximum : 0.25mm (0.010 in)