1992 MAZDA PROTEGE clutch

CLUTCH UNIT
REMOVAL / INSTALLATION
Note
l Remove the clutch release cylinder with the clutch pipe connected.
l Do not remove the pilot bearing if not necessary.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
96-l 03
Kt.6-10.5. 71-761
(MOLYBDENUM SULFIDE)
N-m (m-kg, R-lb:
911 Im-4Y.fi,r
1. Clutch release cylinder
2. Transaxle
Service . . . . . . . . . . . . . . . . . . . . . . . . . ,....... Sections Jl , J2
3. Boot
4. Release bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-l 7
5. Clutch release fork
6. Clutch cover
Removal Note ..,...........,,,.........,, page H-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-l 7
Installation Note .,......................., page
H-l 7
7. Clutch disc
Removal Note ............................ page H-16
Inspection.. ................................. page H-l 7
Installation Note .......................... page H-l 7
8. Pilot bearing
Inspection ................................... page H-18
Removal Note ............................ page H-16
Installation Note.. ........................ page H-16
9. Flywheel
Removal Note ............................ page H-16
Inspection ................................... page H-18
Installation Note .......................... page H-16
H-15

H CLUTCH UNIT
/ 6fs 23UOHX-015
Removal Note
Clutch cover and disc
1. Install the SST or equivalent.
2. Loosen each bolt one turn at a time in a crisscross pattern
until spring tension is released. Then remove the clutch COV-
er and disc.
‘6
I
23UOHX-016
23UOHX-01
Pilot bearing
1. Remove the pilot bearing with the SST if necessary.
Flywheel
Note
l After removing the flywheel, inspect for oil leakage
past the crankshaft rear oil seal.
If necessary, replace the oil seal.
(Refer to Section B.) -J
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel.
Installation Note
Flywheel
1. Wipe the bolts clean and apply sealant to the bolt threads.
2. Install the flywheel and the
SST or equivalent.
3. Tighten the bolts in the pattern shown.
Tightening torque:
96-103 N,m (9.6-10.5 m-kg, 71-76 ft-lb)
Pilot bearing
Note
l Install the pilot bearing flush with the flywheel.
1. Install the new bearing with a suitable pipe.
Bearing outer diameter: 35mm (1.376 in) .-’

CLUTCH UNIT, RELEASE BEARING, CLUTCH COVER, CLUTCH DISC H
L
13UOHX-01;
03UOHX-03 8
23UOHX-018
5
03UOHX-032
03UOHX-03
Clutch disc
1. Clean the clutch disc splines and main drive gear splines;
then apply organic molybdenum sulfide grease.
2. Hold the clutch disc in position with the
SST.
Clutch cover
1. Install the SST or equivalent.
2. Align the dowel holes with the flywheel dowels.
3. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque:
18-26 Nom (1.8-2.7 m-kg, 13-20 ft-lb)
RELEASE BEARING
INSPECTION
Note
l The clutch release bearing Is a sealed bearlng and
must not be washed in solvent.
1. Turn the bearing while applying force in the axial direction.
If the bearing sticks or has excessive resistance, replace it.
CLUTCH COVER
INSPECTION
Note
l Minor scoring or burning should be removed with
emery paper.
1. Inspect the contact surface of the clutch disc for scoring,
cracks, and burning. Repair or replace as necessary.
2. Inspect the contact surface of the clutch release bearing
for wear and cracks.
If there is wear or cracks, replace the clutch cover.
CLUTCH DISC
INSPECTION
Note
l Use sandpaper if the trouble is minor.
1. Inspect the lining surface for burning and oil contamination.
Replace the clutch disc if it is badly burned or oil soaked.
2. Inspect for loose facing rivets and rubbers.
Replace the clutch disc if either is loose.
H-17

CLUTCH DISC, PILOT BEARING, FLYWHEEL
9
13UOHX-020
03UOHX-03
03UOHX-0:
3. Measure the thickness of the lining at a rivet head on both
sides with vernier calipers.
Replace the clutch disc if its thickness is less than minimum.
Thickness: 0.3mm (0.012 in) min.
4. Measure the clutch disc runout with a dial indicator.
Replace the clutch disc if runout is excessive.
Runout: 0.7mm (0.027 in) max.
PILOT BEARING
INSPECTION
1. Turn the bearing while applying force in the axial direction.
If the bearing sticks or has excessive resistance, replace it.
---
FLYWHEEL
INSPECTION
Note
l Minor scoring or burning should be removed with
emery paper.
1. Inspect the contact surface of the clutch disc for scoring,
cracks, and burning; repair or replace as necessary.
2. Inspect the ring gear teeth for wear and damage. If neces-
sary, replace the ring gear.
3. Measure the flywheel runout with a dial indicator. Replace
the flywheel if runout is excessive.
Runout: 0.2mm (0.008 in) max.

Jl TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem
Shift lever won’t shift
smoothly or is hard
to shift
Too much play in
shift lever
I------
Difficult to shift
Won’t stay in gear
Abnormal noise
I
Possible cause
Seized shift lever ball
Seized change control rod joint
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
Worn shift lever ball bushing
Bent change rod
No grease in transaxle control
Insufficient oil
Deterioration of oil quality
Wear or play of shift fork or shift rod
Worn synchronizer ring
Worn synchronizer cone of gear
Bad contact of synchronizer ring and cone of gear
Excessive longitudinal play of gears
Worn bearing
Worn synchronizer key spring
Excessive primary shaft gear bearing preload
improperly adjusted change guide plate
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
improperly installed extension bar
Worn shift fork
Worn clutch hub
Worn clutch hub sleeve
Worn gear sliding part of both shaft gears
Worn gear sliding part of each gear
Worn steel sliding groove of control end
Weak spring pressing against steel ball
Excessive thrust clearance
Worn bearing
Improperly installed engine mount
Insufficient oil
Deterioration of oil quality
Worn bearing
Worn sliding surfaces of gears or shafts
Excessive gear backlash
Damaged gear teeth
Foreign material in gears
Damaged differential gear or excessive backlash Remedy Replace
Replace
Replace
Replace
Replace
Replace
Replace
Lubricate with grease
Add oil
Replace with oil of
specified quality
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Replace
Replace
Replace
Tighten
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Tighten
Add oil
Replace
Adjust or replace
Replace
Replace
Replace with oil of
specified quality
Replace
Adjust or replace Page Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl- 7
Jl- 7
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-36
Jl-17
Jl-56
Jl-56
Jl-56
Jl-56
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-14
Jl-14
Jl-22, 24
Jl-22, 24
Jl-48
Jl- 7
Jl- 7
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-53
03UOJl-OC --
-../
51-6

TRANSAXLE Jl
1. Wheel and tire
2. Splash shield
3. Air hose and resonance chamber
4. Battery
5. Battery carrier
6. Speedometer cable
7. Back-up light switch connector
8. Neutral switch connector
9. Ground
10. Starter
11. Extension bar
12. Control rod
13. Engine mount member
Removal Note . . . . . . . . . . . . . . . . . . . . . . 14. Exhaust pipe
15. Engine mount No.2
16. Clutch release cvlinder
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-1 1
17. Tie-rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
18. Stabilizer (BP SOHC)
19. Driveshaft
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
20. Engine mount No.4
21. Transaxle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
page Jl-11
03UOJl-012
Removal Note
Engine mount member
1. Suspend the engine with the SST and remove the engine
mount member.
03UOJ2-015 Clutch release cylinder
Caution
l Do not damage the clutch pipe.
1. Remove the bolts shown.
2. Lay aside the clutch release cylinder and the clutch pipe
when removing the transaxle.
03UOJl-013
,Jl-11

TRANSAXLE Jl
1, Rear cover
2. Locknut (Primary shaft)
Disassembly Note .,......,,.,......... page Jl-15
3. Stop plate
4. Locknut (Secondary shaft)
Disassembly Note ,..,....,,.,......... page Jl-15
5. 5th shift fork
6. Clutch hub assembly (5th)
Inspection . . . . . . . . . . . . . . . . ..*............... page J l-29
7. Synchronizer ring (5th)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-27
8. 5th gear
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-28
9. Gear sleeve
Inspection . . . . . . . . . . . . . . . . ..*...*........... page Jl-28
10. Secondary 5th gear
11. Lock bolt and washer
12. Back-up light switch
13. Neutral switch
14. Transaxle case assembly
15. Magnet
16. Reverse idler shaft
17. Reverse idler gear
Inspection.. . . , . . . . . . . . . . . . . . . , , . , . . . . . . . . . . page J l-27
L ,
03UOJl-022
I
I I
03UOJl-023
18. 5th shift rod
19. 5th shift rod end
20. Pin
21. Crank lever shaft
22. Crank lever assembly
23. Shift fork and shift rod assembly
Disassembly Note ,.................... page Jl-16
24. Steel ball
25. Spring
26. Primary shaft gear assembly
27. Secondary shaft gear assembly
28. Differential assembly
29. Clutch housing
30. Synchronizer spring
31. Clutch hub sleeve
32. Synchronizer key
33. Clutch hub
34. 3rd/4th shift fork
35. Interlock sleeve
36. Control lever
37. lstl2nd shift fork
38. Control rod
39. Control end
03UOJl-021
Preinspection
5th gear thrust clearance
1. 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)
2. If the clearance exceeds the the maximum, check the con-
tact surfaces of 5th gear and the clutch hub. Replace worn
or damaged parts.
Disassembly note
Locknut
1, Mount the transaxle on the SST.
Jl-15

Jl TRANSAXLE
SHIFT ROD “I, -
CON-rPOL LEVE$:,
I I 03UOJ2.0
76U07A.22
2. Lock the primary shaft with the SST.
3. Shift to 1 st or 2nd gear to lock the rotation of the primary
shaft.
Caution
l Do not reuse the removed locknut.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary
shafts.
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control le-
ver (arrow). Turn the shift rod counterclockwise.
2. While holding the 1 st-2nd shift fork with one hand and the
3rd-4th shift fork with the other, raise them both at the same
time and shift each of the clutch hub sleeves.
3. Lift the control end and remove the steel ball, and, at the
same time, remove the shift rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each
of the clutch hub sleeves.
51-16