1992 MAZDA PROTEGE Workshop Manual

TRANSAXLE J2
13UOJ2-006
I 03UOJ2-06f
23UOJ2.011
3. Measure the clearance between the 4th gear and bearing
inner race.
Clearance: 0.165-0.365mm (0.0065-0.0144 in)
Maximum : 0.415mm (0.0163 in)
4. If not as specified, reassemble the primary shaft assembly.
Bearing inner race (secondary shaft end)
1. Install the new bearing inner race with the SST.
1st gear, synchronizer ring (1st) and clutch hub
assembly (1 st/2nd)
Note
l Align the synchronizer ring, groove and clutch hous-
ing hub key when installing.
1. Assemble the 1 st gear, synchronizer ring (1 St), and clutch
hub assembly (lst/2nd), as shown in the figure.
2. Press the clutch hub assembly (1 st/2nd) on with the
SST.
Synchronizer ring (2nd), 2nd gear and secondary 3rd
gear
1. Install the synchronizer ring (2nd) and 2nd gear.
2. Install the secondary 3rd gear with the
SST.
23UOJ2-011
J2-29

J2 TRANSAXLE
03UOJ2-06 3
r
03UOJ2-068 ‘4
03UOJ2-06
03UOJ2-Of
Secondary 4th gear and bearing Inner race
1. Install the secondary 4th gear and new bearing inner race.
2. Measure the clearance between the 1 st gear and differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 In)
Maximum: 0.33mm (0.0130 in)
3. Measure the clearance between the 2nd gear and secon-
dary 3rd gear.
Clearance: 0.175-0.455mm (0.0089-0.0179 in)
Maximum: 0.505mm (0.0199 in)
4. If not as specified, reassemble the secondary shaft at
sembly. -’
Interlock sleeve
1. Install both shift forks and the interlock sleeve, as in the
figure.
J2-30

TRANSAXLE J2
Clutch Housing and Transaxle Case Components
1. Select the adjust shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the figure, referring to Assembly Note.
3. Verify that the bearing preload is satisfied after assembly, referring to Bearing Preload.
-s
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS EXCEPT SWITCHES
&II N.m (SO-110 cm-kg, SO-95 In-lb)
20-29
P-3,
@NEW=
O-RING, I
14-22) 11
R N.m (120-160 cm-kg,
104-l 39 in-lb)
A
=SELECTlVE ROLL PIN NE
(120-140 cm-kg,
SELECTIVE 20-29 (2-3, 14-22)
N.m (m-kg,
??I 1
1. Change rod 16. Oil seal
2. Joint
3. Oil passage
4. Back-up light switch
5. Oil seal
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
6. Adjust shim(s)
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
7. Bearing outer race
8. Adjust shims
Bearing preload adjustment . . . . . page J2-32
Bearing preload . . . . . . . . . . . . . . . . . . . . . . . . page J2-36
9. Diaphragm springs
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-35
17. Gear case
18. Driven gear
19. Speedometer driven gear assembly
20. Bleeder
21. Bleeder cover assembly
22. Oil seal
23. Selector
24. Reverse gate
25. Spring
26. Boot
Assembly Note ,.,....................... page J2-35
27. Change rod assembly
28. Roll pin
10. Bearing outer races
11. Neutral switch and gasket
12. Drain plug and washer
13. Reverse lever
14. Reverse lever shaft
15. Bearing outer race 29. Change arm
30. Guide plate
31, Funnel
32. Bearing outer race
33. Oil seal
34. Bearing outer race
J2-31

TRANSAXLE
Bearing preload adjustment
Adjust the bearing preload by selecting adjust shim(s).
SST
TRANSAXLE CASE
CUTER RACES
PRIMARY SHAFT ASSEMBLY
iECONDARY SHAFT
rSSEMBLY
CLUTCH HOUSIN
SST USAGE
83U07A-03

TRANSAXLE J2
OUTER RACE
SELECTOR
03UOJ2-069
03UOJ2-07(
86U07A-25:
-sllzd-L-
03UOJZ071
03UOJ2-Oi 1. Install the primary and secondary shaft bearing outer races
into the transaxle case (diaphragm springs and shims
removed).
2. Mount the clutch housing onto the transaxle hanger, and
set the differential bearing outer race into the clutch housing.
Position a piece of pipe against the outer race and tap in
with a hammer until it contacts the clutch housing.
3. Set the outer races into the
SST (selector) as shown in the
figure.
Note
l Turn the selector to eliminate the gap indicated by
the arrow in the figure.
4. Set the differential assembly into the clutch housing; then
set the bearing outer race and the
SST (selector) on the
differential. Set the assembled selectors for the primary and
secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the figure.
5. Set the
SST (collars) in the positions shown in the figure.
6. Install the transaxle case and tighten the
SST (bolts) to the
specified torque.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
7. To seat the bearings, mount the SST (bars) on parts @and
@of the selector, and turn the selector so the gaps are
widened.
Then turn the
SST in the reverse direction until the gaps
are eliminated.
J2-33

J2 TRANSAXLE
Note
l Check that each shaft turns smoothly.
8. Manually expand the selector until it no longer turns by hand.
Caution
l Measure the gap around the entire circumference
of the selector.
-
9. Use a feeler gauge and measure the gap in the selector.
03UOJ2-073 10. Take the maximum reading and determine the shim to be
used as follows:
_-..
mm (in) Thickness (Shaft gears)
0.20 (0.008) 0.50
(0.020)
0.25 (0.010) 0.55
(0.022)
0.30 (0.012) 0.60 (0.024)
0.35 (0.014) 0.65
(0.026)
0.40 (0.016) 0.70
(0.028)
0.45 (0.018)
13UOJ2-01
I
03UOJ2-07
I
I 03UOJ2-0’
J2-34
Note
l Use a maximum of two shims.
< Primary shaft adjust shim >
l Subtract the diaphragm spring thickness (0.70mm,
0.0276 in) from the gap determined in Step 9.
l Select the closest thinner shim from the table.
Example
1.22mm (0.0480 in) - 0.70mm (0.0278 in)
= 0.52mm (0.0205 in)
Shim: OSOmm (0.020 in)
< Secondary shaft adjust shim >
l Subtract the diaphragm spring thickness (0.70mm,
0.0276 in) from the gap determined in Step 9.
l Select the closest thicker shim from the table.
Example
1.22mm (0.0480 in) - 0.70mm (0.0278 in)
= 0.52m.m (0.0205 in)
Shim: 0.55mm (0.022 in)
11, Install the SST.
12. Adjust the selector with the SST until the specified preload
is obtained.
Preload: 0.5 N-m (5 cm-kg, 4.3 in-lb)

TRANSAXLE
i
03UOJ2-078
-
Thickness
0.10 (0.004)
0.20 (0.008)
0.25 (0.010)
0.30 (0.012)
0.35 (0.014)
0.40 (0.016)
0.45 (0.018)
050 (0020)
0.55 (0.022)
0 60 (0.024)
0.65 (0.026)
03UOJZO7 mm (in)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
1.00 (0.039)
1.05 (0.041)
1.10 (0.043)
1.15 (0.045)
1.20 (0.047)
03UOJ2-081
, T/RAkiXiE /CA/SE/////,///
BEARING OUTER RACE
,ADJUSTMENT SHIM
__________
po3u0J2-08i
Caution
l Measure the gap around the entire circumference
of the selector
13. Use a feeler gauge to measure the gap in the selector for
the differential.
14. Add 0.15mm (0.0059 in) to the measured clearance and
select the combination of shims closest in value to that meas-
urement.
Note
l Use a maximum of two shims.
See the table below for available shim sizes.
Example: 0.32mm (0.013 in)
0.32mm (0.013 in) + 0.15mm (0.006 in) = 0.47mm
(0.019 in).
So the nearest shim (on the thick side) to 0.47mm
(0.019 in) is 0.50mm (0.020 in).
15. Remove the SST and the transaxle case.
16. Remove the selectors, the primary shaft assembly and the
-differential.
17. Remove the bearing outer races.
Assembly note
Oil seals
1. Apply transaxle oil to outer periphery.
2. Install the new oil seals with the SST.
Diaphragm spring
1. Install the diaphragm spring as shown in the figure.
Boot
1. Install the boot with the drain hole facing downward.
03UOJ2-082
J2-35

J2 TRANSAXLE
03UOJ2-OE i3
03UOJ2-120
03UOJ2-08 4
03UOJF085
Bearing preload
Verify the shaft gears and the differential bearing preload.
Note Note
l Verify that the correct adjust shims were selected. l Verify that the correct adjust shims were selected.
l If the bearing preload is not within specification, ad- l If the bearing preload is not within specification, ad-
just again. just again.
1. Set the primary shaft gear and the differential into the clutch
housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 f&lb)
3. Connect the SST and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the
preload.
Preload:
1.4-2.0 N.m (14-20 cm-kg, 12-17 in-lb)
5. Remove the SST.
6. With the transaxle facing in the direction shown in the fig-
ure, install the
SST to the primary shaft gear.
7. Measure the preload.
Preload:
0.1-0.25 N-m (1.0-2.5 cm-kg, 0.87-2.18 in-lb)
8. Remove the SST, transaxle case, primary shaft gear and
differential.
9. Install the secondary shaft gear and transaxle case then
tighten to the specified torque.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
IO. Measure the secondary shaft preload with the SST
Preload:
0.2-0.4 N.m (2.0-4.0 cm-kg, 1.7-3.5 in-lb)
J2-36