Mazda 323

since 1985 release

Repair and operation of the car

Check/dismantling of a driving shaft / replacement of cuffs

Power shaft with the internal "star" hinge (the tripodny hinge)


1 — a cuff collar 2 — a cuff collar 3 — a bracket 4 — the hinge case 5 — a lock ring 6 — the tripodny hinge 7 — a cuff 8 — a collar	9 — a counterbalance only on the right side 10 — a cuff collar 11 — a cuff collar 12 — a cuff 13 — the external hinge with shaft. (Not to sort whenever possible to grease. To use lubricant from a repair kit.)

Power shaft with the internal spherical hinge


1 — a cuff collar 2 — a bracket 3 — an external holder 4 — a lock ring 5 — an internal holder 6 — a separator 7 — balls 8 — a cuff collar	9 — a cuff 10 — a cuff collar 11 — a counterbalance Only on right side: 12 — a cuff collar 13 — a cuff 14 — the external hinge with shaft Not to sort whenever possible.

Depending on model the power shafts having difference in the internal hinge are established: power shafts with the internal spherical hinge are established on cars to 9/89 g of the issue and on the station wagon model with the mechanical transmission. Power shafts with tripodny hinges are established on cars from 10/89 g of the issue, except the station wagon models. All all-wheel drive cars have power shafts with internal spherical hinges, in connection with an intermediate shaft for the right power shaft.

Check

PERFORMANCE ORDER

To visually check cuffs, at once to replace faulty cuffs. For replacement of casings the power shaft has to be removed and sorted. As the external hinge should not understand, for removal of its cuff it is necessary to remove also a cuff of the internal hinge.

To clamp the removed power shaft in a vice with laying and to check mobility of hinges.

To stretch and squeeze the external hinge a hand, it should not have a side play.
The internal tripodny hinge has to move on a shaft.
To try to turn the internal hinge on a shaft. He should not have a notable radial side play.
If when checking malfunctions are revealed, the power shaft should be replaced.

Dismantling of a power shaft

PERFORMANCE ORDER

To mark edges of cuffs of hinges on a shaft before removing them, it will facilitate installation.

To remove collars of cuffs on the internal hinge by means of the screw-driver.

To shift cuffs of hinges on a shaft.

Power shaft with the internal tripodny hinge

PERFORMANCE ORDER

Before removal of the case to mark situation concerning an asterisk.

To mark with a center punch the provision of a shaft concerning an asterisk, so it has to be established on the former place.

To squeeze and remove a lock ring of an asterisk suitable nippers.

To bring down an asterisk from a shaft by means of the hammer and a brass core, without striking at the same time blows to rollers.

Power shaft with the internal spherical hinge

PERFORMANCE ORDER

Before removal of a shaft to mark its provision of rather external holder.

To hook a lock bracket the flat screw-driver. To remove the internal hinge.

To squeeze a lock ring of an internal holder suitable nippers and to remove it. To put with a tag center punch concerning a shaft that it could be established in former situation.

To bring down an internal holder from a shaft by means of the hammer and a brass core.

If necessary to sort an internal holder. For this purpose to insert the narrow screw-driver between an internal holder and a separator and to squeeze out balls.

To mark the provision of a separator of rather internal holder. To turn a separator on 30 ° and to remove from an internal holder.

All power shafts

PERFORMANCE ORDER

To remove a cuff of the internal hinge from a shaft.
Right power shaft: If is available, to weaken a collar of a counterbalance and to remove the balance weight.

To mark the provision of a counterbalance on a shaft that it could be established on the former place.

If are debugged on the external hinge: To remove a cuff of the external hinge through the party of the internal hinge, previously having weakened collars of cuffs.

The external hinge should not understand.

To carefully wipe internal cavities of the hinge, internal details, flanges, caps and cuffs. To remove old lubricant with solvent or compressed air. If dirt got into the hinge, to wash out it.
To check working surfaces for wear existence, if necessary to replace the hinge.

Assembly

PERFORMANCE ORDER

To replace the cracked and faulty cuffs. Anyway it is necessary to replace all collars of cuffs, and also lock rings.

To slightly grease a shaft surface that cuffs slid better. Besides to wrap up shaft vents a polymeric tape that at installation of a cuff not to damage it.

To put on a cuff of the external hinge with collars, still not to fix collars yet. Not to mix a cuff of hinges: To pick up a cuff according to the external diameter of the hinge, the table belongs to cars from 10/89 g of the issue (except the station wagon models).

Engine	diameter And, mm	diameter In, mm
1,3 l. Diesel	82,0	85,3
1,6 l	85,9	80,8
1,9 l of SOHC	^84,0/80,01	89,0
1,9 l of DOHC	89,9	85,2

1 — the left power shaft

The direction of installation of collars corresponds to rotation of a shaft forward, i.e. the bent end of collars has to be turned in the direction of rotation of a shaft.

Right power shaft: If is available, to put on a counterbalance, the collar of fastening has to lie in a groove of a power shaft. If there is no groove, to level a counterbalance on the mark put at removal.
To put on a cuff of the internal hinge with collars.

Power shaft with the internal tripodny hinge

PERFORMANCE ORDER

To put on an asterisk a power shaft, at the same time the center punch marks put at removal have to coincide. To chuck in an asterisk a shaft with the hammer and a brass core. At the same time not to apply force, to establish a core serially on various points.

To insert a new lock ring into a shaft groove.

To fill cavities of the external hinge between internal details on both sides special lubricant (black color). To watch that whenever possible less lubricant got to cuffs. Special lubricant is put in a repair kit of cuffs of MAZDA. To distribute all amount of lubricant, about 80 g; SOHC engine of 1,9 l: 140 g.

To distribute on the case of the internal hinge also all lubricant from a repair kit (yellow color). Amount of lubricant of 130 g; except the right power shaft of the SOHC engine of 1,9 l: 220 g.

To insert a hinge asterisk into the case in the same situation as at removal and to pull a cuff.

Power shaft with the internal spherical hinge

PERFORMANCE ORDER

To collect an internal holder with balls and a separator in the sequence, return in relation to removal. The put tags have to coincide.

To put on an internal holder a power shaft, at the same time the center punch marks put at removal have to coincide. To insert a new lock ring.

To insert an external holder of the hinge and to insert a new lock bracket.
To fill cavities of the external hinge between internal details on both sides special lubricant (black color) from a repair kit of MAZDA. The amount of new lubricant compensates amount of remote lubricant. If all old lubricant was removed, it is necessary to use all lubricant from a repair kit.

All power shafts

PERFORMANCE ORDER

To fix cuffs on big diameter by collars. Cuffs have to sit reliably in shaft grooves. To bend collars of cuffs the screw-driver and to fix, having bent fastenings.

To shift cuffs on small diameter to a tag or a groove on a shaft. Cuffs in the established state should not be neither are stretched, nor compressed.
To raise a little a cuff on small diameter the small screw-driver to compensate pressure. Then to pull a collar of a cuff and to fix it.
To establish a power shaft.

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