1992 MAZDA PROTEGE Workshop Manual

TRANSAXLE J2
ShIReverse Gear and Housing Parts
1. Assemble in the order shown in the figure, referring to Assembly Note.
PPLY SPECIFIED OIL TO INDIVIDUAL PARTS
37-52 (3.8-8.3, 27-38)
, .-- 104-122 in-lb)
H50-210 cm-ka NEW
O/NEW 8 iN m ’ --13OL-i82 in-@
@mI - *
(80-l 15 Cm-kg,
NEW 89-l 00 In-lb)
128-198
(13-20, 94-145)
1. Differential assembly
2. Secondary shaft gear assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
3. Primary shaft gear assembly
6. Shift fork and shift rod assembly
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page Assembly
J2-38
7. Crank lever assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly page
Note . . . . . . . . . . . . . . . . . . . . . J2-38
page 4. Spring
J2-38
8. Crank lever shaft 5. Steel ball
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-38
9. Pin
10. 5thlReverse shift rod end
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-39
Il. 5th/Reverse shift rod and clip
Assembly Note . . . . . . . . . . . . . . . . . . . . . . page J2-39
12. Lock bolt
13. Reverse idler gear
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . page J2-39
14. Reverse idler shaft
Assembly Note.. . . . . . . . . . . . . . . page J2-39
15. Magnet
“J”“JL-“O)O
21. Secondary 5th gear 16. Clutch housing
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly
page J2-39
22. Gear sleeve Note . . . . . . . . . . . . . . . . . . . . . . . . . .
23. 5th gear page
24. Synchronizer ring (5th) J2-39
25. Clutch hub assembly (5thIReverse)
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . page J2-39
26. 5thlReverse shift fork 17. Transaxle case assembly
Assembly Note .,........................ page J2-39
27. Roll pin Assembly
28. Secondary reverse synchronizer gear Note . . . . . . . . . . . . . . . . . . . . . . . . . .
29. Synchronizer ring (Reverse) page
30. Primary reverse synchronizer gear J2-39
31. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-40
32. Locknut 18. Lock bolt, ball and spring
Assembly
19. Guide bolt
Note.. . . . . . . . . . . . . . . . . page J2-40
33. Rear cover 20. Lock bolt
52-37

J2 TRANSAXLE
03UOJ2-08
03UOJ2-09(
03UOJ2-09’
J2-38
Assembly note
Primary shaft gear assembly and secondary shaft gear
assembly
1. Install the primary shaft gear assembly and the secondary
shaft gear assembly together.
Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
2. Insert the spring seat and spring into the reverse lever shaft,
install the steel ball, and place a scraper so that it contacts
the steel ball.
3. With the edge of the control end against the scraper, when
the control end is pushed in the direction of the arrow in
the figure so that the ball goes into the shaft, at the same
time the rod will line up with the shift rod coupling hole in
the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap
the shift rod from above so that the steel ball goes into the
center groove (of the 3 grooves in the control end).
5. Pull the ball part of the control end forward so that the steel
ball goes into the detent in the groove.
Crank lever assembly and crank lever shaft
Note
l Use a new O-ring for the crank lever shaft.
1. Fit the crank lever between the change arm and the con-
trol end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch
housing, and insert the new pin.

TRANSAXLE 52
r
03UOJ2-09:
03UOJ2-09
03UOJ2-094
03UOJ2-09!
03UOJ2-09t
fith/Reverse shift rod end, Sth/Reverse shift rod and clip
Note
l The mark (indicated by the arrow in the figure) and
the shift rod end mounting bolt hole must be in the
same direction.
1. Install the shift rod end @ and the shift rod 0, and tighten
the gate mounting bolt.
Reverse idler gear and reverse idler shaft
1. install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever
(indicated by the arrow), and, at the same time, face the
reverse idler shaft screw hole in the direction shown in the
figure.
Clutch housing and 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.
Tlghtenlng torque:
37-52 Nsrn (3.8-5.3 m-kg, 27-38 ft-lb)
2. Insert the SST through driveshaft hole.
Secondary 5th gear
1. Install the secondary 5th gear as shown.
Clutch hub assembly (Sth/Reverse) and !%h/Reverse shift
fork
1. Install the clutch hub assembly (5thReverse) and the 5th/Re-
verse shift fork together.
52-39

52 TRANSAXLE
23UOJ2-01:
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:
128-198 N&m (13.0-20.0 m-kg, 94-145 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.1 O-0.22mm (0.0039-0.0087 in)
Maximum: 0.27mm (0.011 in)
6. If not as specified, reassemble the transaxle.
52-40

TRANSAXLE J2
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. Fill the transaxle with the specified amount of the specified transaxle oil after installation.
4. Warm up the engine and transaxle, and inspect for oil leakaae and transaxle ooeration.
37-52 (3.8-5.3, 27-38) 37-52 (3.8-5.3, 27-38)
9.8-12 (1.0-1.2, 7.2-8.7)
7.8-l 2 (0.8-l .2, 5.8-8.7)
1. Transaxle
6. Tie-rod end
2. Engine mount No.4 7. Clutch release cylinder
3. Joint shaft
8. Engine mount No.2
4. Driveshaft
9. Exhaust pipe
Installation Note
10. Engine mount member
. . . . . . . . . . . . . . . . . . . . .
page J2-42 11. Control rod
5. Stabilizer
12. Extension bar
Installation Note 13. Starter
. . . . . . . . . . . . ..______. page J2-42 14. Ground
31-48 (3.2-4. ‘8
88-l 18 (g-12,65-87)
(6.5-9.1, 47-88)
37-52 (3.8-5.3, 27-38)
N.m (m-kg, Mb)
15. Neutral switch connector
16. Back-up light switch
connector
17. Speedometer
cable
18. Battery carrier
19. Battery
20. Air hose and resonance
chamber
21. Splash shield
22. Wheel and tire
52-41

J2 TRANSAXLE
ONOJZ-09
03UOJ2-11
Installation Note
Driveshaft
Caution
l Do not damage the new oil seal.
1. Install the driveshaft with the end-gap of the new clip faC-
ing upward.
Stabilizer
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension @ : 17-19mm (0.67-0.75 in)
i-/’
J2-42

DIFFERENTIAL J2
DIFFERENTIAL
PREPARATION
SST
49 GO17 1AO
Bearing remover
set
49 8092 375
Attachment J
(Part of
49
GO17 1AO)
49 GO30 338
Attachment E For
removal of
bearing
For
removal of side
bearing inner
race
For
installation of side
bearing inner
race 49 F401 366A
Plate
(Part of
49 GO17 1AO) For
removal of side
bearing inner
race
49 0839 425C
Puller set,
bearing For
removal of side
bearing inner
race I
23UOJ2-01
J2-43

J2 DIFFERENTIAL
DISASSEMBLY / INSPECTION / ASSEMBLY
Caution
l Do not remove inner race if not necessary.
1. Before disassembly, inspect the backlash of side gear and pinion gear, referring to Pre-inspection.
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 Mwn~lre the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
1. Roll pin
2. Pinion shaft
3. Pinion gear
Inspection for wear and cracks
Pre-inspection .,...,........,............ page J2-44
Inspection of backlash. . . . ,.,.,..,,. page J2-45
4. Thrust washer
5. Side gear
Inspect for wear and cracks
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-44
Inspection of backlash . . . . . . . . . . . . . . page J2-45
6. Thrust washer
1
J ______ Ji
7. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page J2-45
Assembly Note, .., ,.,..,,,,....,...,..,. page J2-45
8. Speedometer drive gear
9. Side bearing inner race
Inspect for wear and rough rotation
Disassembly Note .., ..,...., . ,. . . . . . . . page J2-45
Assembly
Note.. . . . . . . ,.. . . . ..,.. . . . . . . . page J2-45
10. Ring gear and gear case assembly
Inspect ring gear for wear or damage
Pre-inspection
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-
sembly.
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)
J2-44