1992 MAZDA PROTEGE clutch

TRANSAXLE Jl
Clutch Housing and Transaxle Case Components
Caution
l Do not remove oil seals unless necessary.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
-
.ACE
23UOJl-O(
1. Speedometer driven gear 17. Boot 28. Adjust shim
assembly 18. Oil seal (Change rod) 29. Adjust shim
2. Oil seal (Differential) Disassembly Note 30. Bearing outer race
Disassembly Note ,.,,,..,............. page Jl-18 (Differential)
..................... page Jl-19 19. Bushing Disassembly Note
Replacement (On-vehicle) 20. Oil seal (Primary shaft) ..................... page Jl-19
.....................
page Jl-20 Disassembly Note 31. Adjust shim (Differential)
3. Pivot ..................... page Jl-19 Disassembly Note
4. Bleeder 21. Bearing outer race ..................... page Jl-19
5. Bleeder cover Disassembly Note 32. Transaxle case
6. Gasket ..................... page Jl-18 33. Roll pin
7. Roll pin 22. Funnel 34. O-ring
8. Blind plug Disassembly Note 35. Driven gear
Disassembly Note ..................... page Jl-18 36. Packing
..................... page Jl-18 23. Bearing outer race 37. Oil seal
9. Reverse lever shaft (Differential) (Speedometer gear cace)
Disassembly Note Disassembly Note Disassembly Note
..................... page Jl-18 ..................... page Jl-19 ..................... page Jl-19
10. Lever set spring 24. Clutch housing 38. Gear case
11. Reverse lever 25. Oil passage 39. Joint
Inspection ....... page Jl-27 26. Oil seal (Differential) 40. Change rod
12. Guide plate assembly Disassembly Note
13. Roll pin ..................... page Jl-19
14. Selector Replacement (On-vehicle)
15. Change arm ..................... page Ji-20
16. Change rod assembly 27, Bearing outer race
Jl-17

Jl TRANSAXLE
03UOJl-025
Disassembly note
Blind plug
1. Remove the roll pin with pliers.
03UOJi-027
03UOJ 1.029
Jl-18
Reverse lever shaft
1. Protect the reverse lever shaft with a rag and remove the
shaft with pliers.
Oil seal (Change rod)
1 .Remove the oil seal with a screwdriver.
Funnel and bearing outer race (Secondary shaft)
Note
l Remove the bearing outer race with a screwdriver
if necessary.
1) Insert a screwdriver between the clutch housing
and bearing outer race.
2)Pt-y the bearing outer race free.
03UOJl-028
1. Remove the bearing outer race by lifting out the funnel and
race together.

TRANSAXLE
L I
03UOJl-030
03UOJl-03 81
-”
/
23UOJl-004
03UOJ l-03
03UOJl.0:
Oil seal (Primary shaft)
Caution
l Do not damage the clutch housing.
1. Remove the oil seal with a screwdriver.
Oil seal (Differential)
1. Remove the oil seal with a screwdriver.
Bearing outer race (Differential)
1. Remove the bearing outer race with the SST.
Bearing outer race and adjust shim (Differential)
1. Install the SST to the bearing outer race.
2. Remove the bearing outer race and adjust shim.
Oil seal (Speedometer gear case)
1. Remove the oil seal as shown in the figure.
Jl-19

Jl TRANSAXLE
Primary Shaft Assembly
1. Measure the thrust clearances of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
REPLACE
1. Bearing
Disassembly Note.. . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . .., . . . . . . . . . . . . . . . . . . . . . page J l-28
2.4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . . . . . . . . . . . . . . . . . . . . . page J l-28
3. Synchronizer ring (4th)
Inspection.. . . . . . . . . . . . . . . . . . . . . . page J l-27
4. Retaining ring
5. Clutch hub assembly (3rd/4th)
Disassembly Note . . . . . . . . . . . . . . . . page Jl-23
inspection.. . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (3rd)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . . .., . . . . . . ,.. . . . . . . . . page J l-27 7. 3rd gear
Disassembly Note.. . . . . . . . . . . . page J l-23
Inspection.. . . . . . . . . . . page J 1-28
8. Bearing
Disassembly Note.. . ., . . . page J l-23
9. Primary shaft
Inspection., . . . . . . . . . . . page J 1-27
10. Synchronizer spring
11. Clutch hub sleeve
12. Synchronizer key
13. Clutch hub
. . /’
Jl-22

.
TRANSAXLE Jl
03UOJl-03: 3
03UOJl-040
03UOJ l-04
I 03UOJl-04
2
03UOJl-043
Preinspection
3rd gear thrust clearance
1. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.06-0.21 mm (0.002-0.008 in)
Maximum : 0.26mm (0.010 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 3rd gear, 2nd gear and clutch hub (3rd/4th).
Replace worn or damaged parts.
4th gear thrust clearance
1. Measure the clearance between 4th gear and the ball
bearing.
Clearance: 0.21-0.61 mm (0.008-0.024 in)
Maximum: 0.66mm (0.026 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 4th gear, ball bearing, and clutch hub
(3rd/4th). Replace worn or damaged parts.
Disassembly note
Bearing and 4th gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the ball bearing and 4th gear with the SST.
Clutch hub assembly (3rd/4th), synchronizer ring (3rd)
and 3rd gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the clutch hub assembly (3rd/4th), synchronizer
ring (3rd) and 3rd gear with the
SST.
Bearing
1. Remove the bearing with the SST.
Jl-23

Jl TRANSAXLE
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
0 REPLACE-
/
1. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
2. Secondary 4th gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
3. Retaining ring
4. Secondary 3rd gear
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
5.2nd gear
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (2nd)
Inspection.. . . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . . page J l-27
7. Retaining ring
8. Clutch hub assembly (lst/2nd)
Disassembly Note. . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-29 9. Synchronizer ring (1 st)
Disassembly Note . . . . . . . . . . . . . . . . . . . . . page Jl-25
Inspection.. ,,..... . . . . . . . . . . . . . . . . . . . . . . . . . page J l-27
10. 1st gear
Disassembly Note ..,..,,.,,,....,..,.. page Jl-25
Inspection ..,................,.............. page J l-29
11. Bearing inner race
Disassembly Note . . . . . . . . . . . . . . . . , . . . . page Jl -26
12. Secondary shaft
Inspection., , , . , . , . . , , . . . . . . . . , . , . . . . . , . . . . . page J l-28
13. Synchronizer spring
14. Clutch hub sleeve
15. Synchronizer key
16. Clutch hub
Jl-24

TRANSAXLE Jl
03UOJ 1.04!
03UOJ 1.041
03UOJl-047
, , .” ,,,,,..
03UOJl-04t
03UOJ l-04!
Preinspection
1st gear thrust clearance
1, Measure the clearance between 1 st gear and the differen-
tial drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 in)
Maximum: 0.33mm (0.013 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 1 st gear, differential drive gear of the secon-
dary shaft gear, and clutch hub assembly (1 st/2nd). Replace
worn or damaged parts.
2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary
3rd gear.
Clearance: 0.18-0.51 mm (0.007-0.020 in)
Maximum: 0.58mm (0.022 in)
2. If the clearance exceeds the maximum, check the contact
surfaces of the 2nd gear, secondary 3rd gear, and clutch
hub assembly (1 stMnd). Replace worn or damaged parts.
Disassembly note
Bearing inner race and secondary 4th gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race and secondary 4th gear with
the
SST.
Secondary 3rd gear and 2nd gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the secondary 3rd gear and 2nd gear with the
SST.
Clutch hub assembly (lst/2nd), synchronizer ring (1st)
and 1st gear
Caution
l Hold the shaft with one hand so that it does not fall.
1. Remove the clutch hub assembly (1 st/2nd), synchronizer
ring (1st) and 1st gear with the
SST.
Jl-25

TRANSAXLE
1ST 2ND
03UOJl-06 03UOJl-06
9MUOJX-05
03UOJl-05
1st Gear and 2nd Gear
1. Measure the clearance between the shaft gears and the
gears.
Oil Clearance mm (in)
Shaft (A) Gear (B) Sleeve (C) Oil (D)
(outer diameter) (inner diameter) (outer diameter)
Clearance
39.45-39.47 39.50-39.52 03 =(B)-(A)
’ st Gear (1.553-l 554) (1,555-l ,556) - 0.03-0.07
(0.001-0.003)
35.15-35.17 35.20-35.22 PI = (B)-(A)
2nd Gear (1.384-I ,385) (1,386-l ,387) - 0.03-0.07
(0.001-0.003)
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
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.
4. Measure the clearance between the hub sleeve and the shift
fork.
mm (in)
1 stMnd Standard clearance
0.1 O-O.36
(0.004-0.014) Maximum
0.86 (0.034)
I 3rd14th
I 0.20-0.50
(0.008-0.020)
I 1 .oo (0.039)
I
5th 0.40-0.75
(0.016-0.030) 1.25 (0.049)
51-29