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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mazda 626 / MX-6 (from 1982 to 1991, the year of issue)

general info. full specifications. diagnostics. hints. tips. tricks
Mazda 626 / MX-6
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626 / MX-6
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Manual Transmission



Overview
Transmission converts the torque transmitted from the engine, in magnitude and direction. This is necessary for optimal speed, high flotation vehicle and engine efficiency, as well as to drive the vehicle in reverse. Transmission separates the engine and transmission during a stop and parking lot, and when it is coasting with the engine running.
All models with manual transmission are equipped with a 5 or a 4-speed manual transmission, combined in a single unit with the differential and final drive. Torque from the engine is transmitted through the gearbox and final drive by the differential, which in turn distributes it between the drive shafts. All forward gears are equipped with synchronizers, and the shift lever includes an internal switching mechanism by means of a rod of switching transmission.
Procedures for removing and repairing the gearbox described considering the fact that the gearbox bearings do not require replacement and drive elements are installed into the initial position. Install new bearings or shafts means that the thickness must be determined preload spacers, but it uses special tools and methods that are not available amateur mechanics.
Therefore, if the gearbox is damaged or worn out as a result of normal use, the best solution may be to install new or repair the unit.

Technical data

Torques Nm
Front nuts and bolts rear cross ..... 44-55
Rear rear crossmember bolts ..... 95-118
Lower swivel ball screw ..... 44-55
Bolts transmission case ..... 37-55
Bolts flap ..... 12-16
Lock nut pinion shaft ..... 130-210
Guide Bolt ..... 9-14
Bolt rear housing ..... 9-11
Bolt locking intermediate shaft ..... 21-31
Bolts of fastening of a transmission to the engine ..... 91-119
Bracket bolts transmission to the engine ..... 55
Bracket bolts to the transmission gearbox ..... 38-54
Bracket bolts the gearbox to the body ..... 44-55

Supports transmission
Check
Watch supports transmission at a time when an assistant lifts and presses down on the transmission. If the rubber element support is separated from the steel substrate, or the transmission housing moves upwards, but does not fall, thereby indicating achievement support lower limit, replace the support.
Replacement
Disconnect the negative battery terminal.
Jack through wooden block support gearbox.
Remove the mounting bolts of the power unit to the engine or transmission.
Remove the nuts of support to the body and remove the support.
Correctly position the new support, and screw the bolts to the engine or transmission. Tighten bolts the demanded moment.
Screw nuts of support to the body and tighten their demanded moment.
Remove the jack and connect the wire to the negative terminal of the battery.

The shift lever
Withdrawal

Elements of the gear lever
Fig. 9.12. Elements of the shift lever 1 - shift knob;
2 - Case; 3 - details of the shift lever; 4 - spring; 5 - upper ball seat; 6 - the shift lever; 7 - the plug; 8 - the lower ball seat; 9 - the holder; 10 - plate; 11 - Case; 12 - a nut and washer; 13 - the plug; 14 - bolts and nuts; 15 - draft of switching; 16 - Rod extension and suspension unit; 17 - nuts suspension assembly


In the car, remove the handle from the gear lever, gear shift cover and front and rear rack (Fig. 9.12).
Lift the front of the vehicle and secure the stand.
Remove the retaining nuts and bolts and lower the shift rod from the car.

Use a screwdriver to release the spring clamp gear lever
Fig. 9.13. Use a screwdriver to release the spring clamp gear lever


Using a screwdriver, loosen the clamp spring gear lever and remove from the vehicle arm assembly (Fig. 9.13).
Remove the nuts and bolts of extension rods, remove the stem extension, suspension and lining.
Setting
Installation is spent to sequences, return to removal, taking into account the following.
Apply lithium grease to the moving parts and sliding the gear lever.

Removing and installing transmission
Withdrawal
Disconnect the negative battery terminal.
Disconnect the cable from the gearbox speedometer drive connector from the reverse gear switch and, if the model is equipped switch 5th gear.
Remove the bolts of suspension cable of coupling and disconnect the cable from the clutch release lever.
Remove the bolt wire of "weight" and clip the harness.
Remove the starter.
There are two basic ways to support the weight of the engine during operations to remove the cross and gearbox. You can use a special attachment to the support, which relies on the support suspension or a winch for lifting the motor. If you use a mount support, install it first. If you use a winch to lift the engine to increase the workspace previously remove the hood.

Location of the upper bolts (1) for transmission to the engine
Fig. 9.14. Location of the upper bolts (1) for transmission to the engine


Remove the four screws on the upper transmission to the engine (Fig. 9.14).
Lift the front of the vehicle securely on supports and drain the oil from the gearbox.
Remove the front wheels, mudguards panel and disconnect the traction antiroll bars. Remove the protective plate sump, if installed.
Remove the lower ball joint, and connecting bolts knuckle, then separate the front suspension lower arms from the steering knuckle.
Separate the left drive shaft from the transmission.
Remove the intermediate drive shaft. Insert a wooden plug or the like to hold the plug in place of the differential side gears.
Separate adjustment of the rail switching shift rod and separate thrust extension of the transmission.
Remove the lower bolts of a transmission to the engine.

Removing cross and lower left arm front suspension
Fig. 9.15. Removing cross and lower left arm front suspension


Remove the bolt and remove the crossmember and the lower block of the left arm front suspension (Fig. 9.15).
Supporting transmission jack, attach the power unit to the jack.

Support the engine and use an industrial lift to remove the gearbox
Fig. 9.16. Support the engine and use an industrial lift to remove the gearbox


Remove the two remaining bolts, separate the transmission from the engine and lower it down from the engine compartment (Fig. 9.16). Do not hang on transmission input shaft when separating the engine from the transmission. Secure the gearbox in case it fall off the jack.
Setting
Cover with a thin layer of lubricant Moly splines primary shaft gearbox.
Lift gearbox, attach to the engine and fix bolts, having tightened their demanded moment.
Connect the extension rod to the transmission and switching to rail traction control switch.
Install the lower arm and the crossmember.
Screw the lower bolts gearbox.
Install the intermediate drive shaft.
Install the left drive shaft.
Connect the lower ball joints and screw the nuts and bolts, having tightened their demanded moment.
Connect traction stabilizer bar.
Set mud flaps and the front wheels. Set the plate to protect the oil pan.
Install the starter.
Remove the jack supporting the gearbox and lower the car.
Replace the four screws on the upper transmission to the engine. Tighten bolts to torque.
Install the wiring harness bracket bolt and wire the "masses", then connect the cable grip.
Fill the gearbox oil sump.
Connect the speedometer cable and connectors to the backup light switch and circuit breaker 5th gear.
Attach the wire to the negative terminal of the battery.

Dismantling gearbox

Basic elements of the gearbox
Fig. 9.17. The main elements of the gearbox: 1 - the main transfer and differential; 2 - crank assembly; 3 - steel ball; 4 - spring;
5 - magnet; 6 - lock bolt; 7 - a spring pin; 8 - O-ring seal; 9 - crank shaft; 10 - an intermediate gear wheel of a backing;
11 - a shaft of the intermediate reverse gear; 12 - valve; 13 - unit input shaft; 14 - a plug of switching node and traction gear; 15 - draft of a gear (5th gear and reverse gear) and bracket; 16 - gear 5th gear; 17 - lock nut (5th gear); 18 - bush gear (5th gear); 19 - gear 5th gear; 20 - a lock bolt; 21 - ring of the synchronizer of 5th transfer; 22 - a nave of the synchronizer of 5th transfer; 23 - restrictor plate (5th gear); 24 - lock nut (5th gear); 25 - spring pin (5th gear); 26 - a plug of switching (5th gear);
27 - rear case (5th gear); 28 - guide bolt; 29 - a lock bolt with a ball and spring; 30 - the transmission housing; 31 - unit output shaft


Loosen the screws and remove the rear case (5th gear) (Fig. 9.17).
Using a hammer and chisel, unbend a fillet on each of the lock nuts (5th gear).
Carefully lock the gears from turning by inserting a screwdriver or similar tool between the teeth of the gears; loosen the lock nut.
Remove the dowel pin shift fork 5th gear and shift fork.
Remove the restrictor plate 5th gear, hub, synchronizer ring, hub gears and gear.
Remove the locking bolt from the gearbox housing.
Remove the guide bolt from the transaxle. Remove the retaining bolt and remove the ball and spring.
Turn the switch of the reversing of the gearbox housing.
Mark the position of the wiring terminals to facilitate subsequent assembly and remove bolts of the gearbox housing compounds.
Carefully separate the halves of the gearbox from the clutch housing.

Carters for gearboxes and components gearshift
Fig. 9.18. Gearbox housing and elements of the gearshift: 1 - drive shaft seal; 2 - a bolt and washer; 3 - breather; 4 - a casing breather; 5 - seal; 6, 8, 30, 31 - an external ring of bearings; 7, 13 - funnel; 9 - reversing lever shaft; 10 - a spring pin; 11 - an external ring of the bearing; 12 - diaphragm spring; 14 - Drain plug and washer; 15 - the lever of the reverse gear; 16 - shim; 17 - a bolt; 18 - the gear change; 19 - a tube; 20 - guide plates; 21 - bolts; 22 - lever to 5th gear; 23 - a spring pin; 24 - a spring; 25 - reverse valve (5th gear); 26 - oil supply channel; 27 - the switch of light of a backing; 28 - gland; 29 - shim; 32 - switching rod; 33 - Case; 34 - gland; 35 - speedometer drive gear assembly; 36 - driven gear; 37 - a spring pin; 38 - O-ring seal; 39 - gear housing; 40 - a bolt


Remove the oil supply passage to the 5th gear (Fig. 9.18).
Remove the magnet from the transaxle case.
Remove the intermediate shaft and the reverse gear.
Remove the locking bolt 5th gear and the locking plate.

Removing the shift gate 4th gear and reverse gear lever assembly
Fig. 9.19. Removing the shift gate 4th gear and reverse gear lever assembly


On models with 4-speed gearbox, remove the rocker switch and reverse gear lever assembly, and the switch should be in a neutral position (Fig. 9.19).
Remove gear 5th gear and reverse gear rod.
Remove the shift gate 5th gear and reverse gear.
Knock out the dowel pin and remove the crank pin of the 5th gear.
Moving thrust gear (5th gear) Remove the crank.
After confirming that the end surface of the locking sleeve is flush with the end surface of the adjusting lever, shift rod rotate counterclockwise as possible.
Pick up from the slot switching rod, thus, you may need to lift up the locking ball.
Knock out the dowel pin with the switching rod.
Turn the 4th gear by moving up the upper shift fork.
Gently pull the shift rod from the transmission case. If the draft is released from the housing, steel ball falls from the shaft of the lever of a backing.
Hiking, remove the output shaft and the gear assembly shift forks of the gearbox.
Remove the primary shaft.
Remove the differential.
Remove the switch of neutral position switch or 5th gear.
Remove the primary shaft seals and bearing ring.
Remove the funnel from the gearbox housing.
Remove the bolt and the guide plate and the switch lever.
Knock out the dowel pin gear lever, making sure that the shift lever is in the middle position.
Remove the cover from the switch shaft gearbox housing and remove the shaft.
Remove the spring pin backstage reverse gear selector.
Gently knock the bearing ring.
Remove the stem seal switch from the transmission case.
Remove the drive axle seal from the gearbox, beating him with a hammer and tapping knockout.
Remove the differential bearing race.
Remove the breather vent.
Remove the spring adjusting lever.
Output shaft
Remove the secondary shaft of the gearbox.
Clamp the shaft in the grip of two pieces of wood to protect it from damage. Probe check axial clearance of gears.

Details of the primary and secondary shafts
Fig. 9.20. Details of the primary and secondary shafts 1 - inner ring of the bearing; 2 - the input shaft; 3 - a gear wheel of 3rd transfer; 4 - ring of the synchronizer of 4th transfer; 5 - the synchronizer of 3rd and 4th transfers; 6 - a lock ring; 7 - lock cracker; 8 - a nave of the synchronizer; 9 - sliding sleeve of the synchronizer; 10 - a lock ring; 11 - ring of the synchronizer; 12 - a gear wheel of 4th transfer; 13 - an internal ring of the bearing; 14 - thrust ring; 15 - an internal ring of the bearing; 16 - a secondary shaft; 17 - a gear wheel of 1st transfer; 18 - ring of the synchronizer; 19 - a lock ring; 20 - ring of the synchronizer; 21 - a gear wheel 2nd transfers; 22 - a gear wheel of 3rd transfer; 23 - a lock ring; 24 - a gear wheel of 4th transfer; 25 - an external ring of the bearing; 26 - synchronizer; 27 - a lock ring; 28 - lock cracker; 29 - a nave of the synchronizer; 30 - sliding sleeve of the synchronizer; 31 - a spring pin; 32 - a control lever; 33 - a plug of switching of 1st and 2nd transfers; 34 - draft of management; 35 - Sleeve lock; 36 - a spring pin; 37 - a control lever; 38 ??� ?????�???� ???�???�???�???�?�?????? 3-?? ?? 4-?? ???�???�???�?�; 39 ??� ???????�?????????�?�?�????; 40 ??� ???�?????????????� ?????�???�??; 41 ??� ?????�?�???? ?�???????�?�?????�; 42 ??� ???�???????�?� ???????�?????????�?�?�?????�; 43 ??� ???????�???�???�?�?? ?????�?�?� ???????�?????????�?�?�?????�


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Install idler gear and reverse gear shaft. Position the gear, insert the shaft of the shaft with the hole aligned along the edge of the gearbox.
On models with the 5-speed manual transmission use a type of RTV sealant to install the oil passage on the gearbox casing.
Install gearbox housing on a differential box, carefully placing it so that the primary and secondary shafts entered the tides. You may need to combine the magnet with the slot in the upper half of the crankcase.
Screw bolts the gearbox and crosswise tighten their demanded moment.
Screw the locking bolt primary thrust gear and sealing washer. You may need to raise the output shaft to properly align the locking bolt. Tighten the bolt (5-speed).
Screw the locking bolt back countershaft transmission (5-speed).
Install the input shaft of the hand screw the nut (5-speed).
Grease the primary shaft sleeve clean transmission fluid and slide the sleeve into place (5-speed).
Lubricate and install gear 5th gear.
Establish a synchronizer ring 5th gear.
Install the shift fork and synchronizer, aligning tabs with slots in the ring of the synchronizer of a cylindrical pin, holding the plug (5-speed).
Install the restrictor plates synchronizer (5-speed).
By hand, screw the locknut secondary shaft (5-speed).
Tighten both locknuts, hammer punch and hammer beads nuts in the groove shaft to protect them from loosening (5-speed).
Apply sealant to the mating surface of the crankcase 5th gear, install it, and fix bolts, having tightened their demanded moment.
Set the drive shaft seals.
Install the backup light switch.
Lightly clean the O-ring with gear oil and install it at the site of the speedometer drive gear. Install the speedometer drive gear.
Install transmission.

Replacement seals gearbox
Input shaft lip seal can be replaced only after the removal of the gearbox. Seals the drive shafts can be replaced with the gearbox installed. Replace the wire as follows.
Disconnect the drive shaft from the transmission.
Blunt screwdriver or similar tool carefully pull out the old packing.
Oil a new epiploon. Install the gland, the gland sealing lips should be directed into the transmission housing. To install the oil seal using a tubular mandrel of appropriate diameter.
Set the drive shaft.




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