USA Haynes manual covering Mazda 323 and Protege 1990 – 2003 Haynes Owners Service . (This generation 323 was known in Australia as the BG-series)Engines covered: 1489 cc (1.5 litre) Z5 DOHC 4 cylinder 1598 cc (1.6 litre) B6 SOHC 4 cylinder 1598 cc (1.6 litre) ZM DOHC 4 cylinder 1840 cc (1.8 litre) BP SOHC DOHC 4 cylinder 1840 cc (1.8 litre) FP DOHC 4 cylinder IntroductionChapter 1: Tune-up and routine maintenanceChapter 2: Part A: EnginesChapter 2: Part B: General engine overhaul proceduresChapter 3: Cooling heating and air conditioning systemsChapter 4: Fuel and exhaust systemsChapter 5: Engine electrical systemsChapter 6: Emissions and engine control systemsChapter 7: Manual and automatic transaxlesChapter 8: Clutch and driveaxlesChapter 9: BrakesChapter 10: Suspension and steering systemsChapter 11: BodyChapter 12: Chassis electrical systemWiring Diagrams Please note: This manual does not include information specific to 4WD models. Inside this manual you will find: Routine Maintenance tune-up procedures engine repair cooling and heating air-conditioning fuel and exhaust emissions control ignition brakes suspension and steering electrical systems and wiring diagrams. Haynes repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and illustrations guide you through every job from basic maintenance and troubleshooting to complete teardown rebuild. here
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Gearbox replacement on a Mazda 323 Protege Manual involves the process of removing the existing manual transmission (gearbox) and installing a new or refurbished one. This procedure is typically necessary when the gearbox has become damaged, worn out, or is experiencing mechanical issues that affect the performance of the vehicle.
### Key Steps in the Gearbox Replacement Process:
1. **Preparation:**
– Gather tools and equipment, including wrenches, sockets, jacks, and possibly a transmission jack.
– Ensure the vehicle is on a stable surface, and the wheels are secured.
2. **Disconnecting the Battery:**
– Disconnect the negative terminal of the battery to prevent any electrical issues during the process.
3. **Draining Transmission Fluid:**
– Remove the drain plug and drain the fluid from the gearbox to prevent spills.
4. **Removing Components:**
– Detach any components obstructing access to the gearbox, such as the exhaust system, driveshafts, and shift linkage.
– You may need to remove the starter motor and any other accessories attached to the gearbox.
5. **Support and Remove the Gearbox:**
– Use a transmission jack to support the gearbox.
– Unbolt the gearbox from the engine and carefully lower it from the vehicle.
6. **Installing the New Gearbox:**
– Position the new or refurbished gearbox in place, ensuring it aligns correctly with the engine.
– Bolt the gearbox back into position, reattach the driveshafts, shift linkage, and any other components that were removed.
7. **Refilling Transmission Fluid:**
– Fill the new gearbox with the appropriate type and amount of transmission fluid.
8. **Reconnecting the Battery:**
– Reconnect the negative battery terminal and check for any electrical connections that may need to be reattached.
9. **Testing:**
– Start the vehicle and test the gearbox by shifting through the gears to ensure everything is functioning properly. Check for leaks and monitor the performance during a short test drive.
### Considerations:
– **Skill Level:** This is a complex task typically suited for those with mechanical experience or a professional mechanic.
– **Parts Quality:** Ensure that the replacement gearbox is compatible with the Mazda 323 Protege and of good quality to avoid future issues.
– **Safety:** Always prioritize safety by using proper lifting techniques and equipment.
Gearbox replacement can restore the drivability of the Mazda 323 Protege, ensuring smooth gear shifts and reliable performance.