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Transaxle Reassembly: Adjustments

WARNING: This page is about a different car, the 1991 Mazda Protege and 1990 Mazda Protege. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: For location of thrust bearings and races, see Fig 1 .
  1. Install bearing cover into converter housing. Before installing bearing housing, adjust output gear bearing preload.
  2. Remove bearing outer race and adjustment shims from bearing housing. Mount output gear assembly on converter housing. Install outer race to appropriate selector gauge. Mount selector gauge on output gear assembly. Eliminate gap by turning bar "A" or "B" of selector gauge. See Fig 2 .
  3. Mount bearing housing on selector gauge. Mount 4 collars between converter housing and bearing housing. Tighten bolts to 14-19 ft. lbs. (19-25 N.m). See Fig 3 .
    Fig 1: Locating Bearing & Races; GF4A-EL Shown; Others Similar
    G95H20195Courtesy of MAZDA MOTORS CORP.
    Fig 2: Installing Selector Gauge On Output Gear Assembly
    G93G24774Courtesy of MAZDA MOTORS CORP.
    Fig 3: Mounting Bearing Housing On Selector Gauge
    G93H24775Courtesy of MAZDA MOTORS CORP.
    Fig 4: Measuring Output Gear Bearing Preload
    G93I24776Courtesy of MAZDA MOTORS CORP.
  4. Turn selector in a direction which widens the gap between "A" and "B" of selector gauge until it will no longer turn. Turn selector in opposite direction (reducing gap) until gap is eliminated.
  5. Mount preload adapter to output gear. See Fig 4 . Measure preload with torque wrench or pull scale. Widen gap on selector gauge to obtain 10-17 INCH lbs. (1.1-1.9 N.m) for GF4A-EL preload with torque wrench or reading on pull scale of 2.5-4.4 lbs. (11-19 N) for GF4A-EL.
  6. Measure clearance between "A" and "B" of selector gauge when specified preload is obtained. Measure clearance around entire circumference and select shim(s) equal to maximum clearance measured. Refer to the the OUTPUT GEAR SHIMS  chart. Maximum number of shims allowed is 7 for all except the GF4A-EL which has a maximum allowable number of one shim.
    OUTPUT GEAR SHIMS

    Application (1) Shims Available
    G4AX-EL .020-.057" (.50-1.45 mm)
    (1) In increments of .001" (.02 mm).
  7. Remove bearing housing and selector gauge. Install required shim(s), press bearing race into bearing housing and install bearing housing. Tighten bearing housing to specified torque. See the TORQUE SPECIFICATIONS  table. After installing bearing cover, check output gear bearing preload. Preload should be 10-17 INCH lbs. (1.1-1.9 N.m) for GF4A-EL with torque wrench or 2.5-4.4 lbs. (11-19 N) for GF4A-EL when using a pull scale.
  8. Remove bearing outer race and adjustment shims from side bearing of transaxle case. Mount differential assembly on converter housing. Install bearing outer race to selector gauge. Mount selector gauge on differential assembly. See Fig 5 . Eliminate gap by turning "A" and "B" of selector gauge.
  9. Mount 6 collars on differential assembly. See Fig 6 . Mount transaxle case onto selector gauge. Tighten Bolts to 27-38 ft. lbs. (37-52 N.m).
  10. Turn assembly over. Install and tighten bolts to 27-38 ft. lbs. (37-52 N.m). See Fig 7 . Using bars on "A" and "B" of selector, turn selector in a direction which widens the gap between "A" and "B" of selector. Turn selector (to widen gap) until it will no longer turn. Turn selector in opposite direction (reducing gap) until preload is eliminated.
  11. Measure preload with pull scale or INCH-lb. torque wrench. See Fig 8 . Widen gap on selector to obtain 4.4 INCH lbs. (.5 N.m) preload, using torque wrench or pull scale reading of 1.1 lbs. (5.0 N).
  12. Measure clearance between "A" and "B" of selector gauge when specified preload is obtained. Measure clearance around entire circumference and select shims equal to maximum clearance measured. Add .012" (.30 mm) to measured clearance. Maximum number of shims is 3. For available shims, see DIFFERENTIAL BEARING SHIM  chart.
    Fig 5: Installing Selector Gauge On Differential
    G93J24777Courtesy of MAZDA MOTORS CORP.
    Fig 6: Positioning Collars On Differential
    G93A24778Courtesy of MAZDA MOTORS CORP.
    Fig 7: Installing Collar Bolts
    G93B24779Courtesy of MAZDA MOTORS CORP.
    Fig 8: Measuring Differential Side Bearing Preload
    G93E24780Courtesy of MAZDA MOTORS CORP.
    DIFFERENTIAL BEARING SHIM

    Application Thickness of Shim - In. (mm)
    G4AX-EL (1) .004-.047 (.10-1.20)
    (1) In increments of .001" (.02 mm).
  13. Remove transaxle case and selector. Install the required amount of shims and press bearing race into bearing housing. Install bearing housing. Check differential side bearing preload of 26-35 INCH lbs. (2.9-3.9 N.m) with torque wrench or 6.6-8.8 lbs. (29-39 N) on the pull scale. If preload is not correct, repeat measuring and adjusting procedure (as necessary).
  14. Remove transaxle case and bearing housing. Install output gear with idler gear; tap idler gear in position with a plastic hammer. Install bearing housing. Align groove on idler shaft with matching mark on bearing housing and install roll pin. Install differential assembly. On GF4A-EL models, install 2-3 accumulator piston assembly.
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