boot MAZDA MX-5 1994 User Guide

TRANSMISSION J 9. Install the power plant frame bracket. Tightening torque @ : lO4--123 N.m (1 0.6-1 2.6 kgf.m, 76.7-91.1 ft-lbf) @: 37-43 N.m (3.7-5.5 kgf-m, 27-39 ftlbf) 10. Remove the jack, and connect the wire harness. 11. Measure distance A with a straightedge and vernier cali- pers. Distance A: 66.0 2 5mm (2.60 a 0.197 in) 12. If the distance is not within specification, reposition the PPF to the transmission. FRONT Shift lever 1. Pour the specified amount of oil into the change control case. The change control case must also be filled with the specified amount of oil whenever the extension housing has been removed or the transmission has been overhauled. Specified oil Grade: API service GL-4 or GL-5 All season: SAE 75W-90 Above 10°C (50°F): SAE 80W-90 Specified amount: 80-95 cc (4.9-5.8 cu in) 2. Apply oil to the shift lever as shown. 3. Apply sealant to the contact surfaces of the boot panel and the change control case. Gartner Banana

K SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Disassembly I Inspection I Assembly 1. Disassemble in the order shown in the figure. 2. Inspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. I N.m {kgf m, ftlbf} 45UOKX49 1. Spacer 8. Lock lever 2. Boot 9. Locknut 3. P range switch 10. Adjustment lever inspection . . . . . . . . . . . . . . . . page K-159 11. Cam 4. Shift lock actuator 5. Spindle 6. Push rod assembly 7. Bushing Assembly Note . . . . . . . . . . . page K-167 12. Bushing - 13. Selector lever bracket Gartner Banana

FRONT AXLE M Removal note Brake caliper assembly Note For easier installation, do not depress the brake pedal after removing the brake caliper assembly. Suspend the brake caliper assembly with a rope. Tie-rod end Loosen the nut and disconnect the tie rod end the SST. Caution The sharp edges of the SST can slice the tie-rod end dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. 1. Remove the cotter pin. 2. Loosen the nut until it is flush with the end of the ball stud. 3. Disconnect the tie rod end from the knuckle by using the SST. Lower arm Caution The sharp edges of the SST can slice the lower arm dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. Loosen the nut and disconnect the lower arm by using the SST. Upper arm Caution The sharp edges of the SST can slice the upper arm dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. Loosen the nut and disconnect the upper arm by using the SST. Installation note Locknut Install a new locknut and stake it. Tightening torque: 167-21 6 N.m (1 7-22 kgf.m, 123-1 59 ft-lbf) Gartner Banana

DRIVE SHAFT M DRIVE SHAFT b '1. Rear wheel 3. Drive shaft 2. Locknut Inspection ................. page M-17 Installation Note ........... page M-18 Removal Note ............. page M-17 Installation Note ........... page M-18 Overhaul .................. page M-19 lnspection 1 Drive shaft 1. Check the dust boot on the drive shaft for cracks, dam- age, leaking grease, and a loose boot band. 2. Check the drive shaft for bending, cracks, and wear of joints and splines. 3. Repair or replace the drive shaft if necessary. I I 45UOMX-024 Removal note Drive shaft Before removing the drive shaft, mark the drive shaft and output shaft for proper installation. 'L/ 25UOMX-012 Gartner Banana

DRIVE SHAFT M Overhaul 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. -- 3. Verify that all parts are free of dust, dirt and other foreign material immediately before reassembly. Do not wash the joint unless it is being dissasembled. 4. Assemble in the reverse order of disassembly, referring to Assembly Note. 1. Boot bands 9 REPLACE J r DISASSEMBLE w DO NO' (SPECIFIED MOLYBDENUM DlSULFlDE GREASE) Disassembly Note .......... page M-20 Assembly Note ............ page M-22 2. Clip Disassembly Note .......... page M-20 3. Outer ring lnspect inside bore for wear, corrosion, and scoring 4. Snap ring Disassembly Note .......... page M-20 5. Balls .......... u Disassembly Note page M-20 Assembly Note ............ page M-21 45UOMX426 6. Inner rina ~isasiembl~ Note .......... page M-20 Assembly Note ............ page M-21 7. Cage Disassembly Note .......... page M-20 Assembly Note ............ page M-21 8. Boots Disassembly Note .......... page M-21 Assembly Note ............ page M-21 9. Dust cover (STANDARD) 10. Sensor rotor (ABS) (section P) 11. Shaft and ball joint assembly lnspect splines for damage and wear lnspect wheel-side joint for excessive play and rough rotation Gartner Banana

M DRIVE SHAFT Disassembly note Boot bands To remove the boot bands, pry up the locking clip with a screwdriver, then raise the end of the band. d Clip 1. Mark the drive shaft and outer ring with paint as shown. 2. Remove the clip. Snap ring 1. Mark the drive shaft end and inner ring with paint as shown. 2. Remove the snap ring with snap ring pliers. Cage, inner ring, and balls Disassemble in the following order: 1. Insert a screwdriver between the inner ring and cage to remove the balls. 2. Mark the inner ring and cage with paint. 3. Turn the cage approximately 30°, then pull it away from the inner ring. Gartner Banana

DRIVE SHAFT M TAPE 45UOMX-031 DIFFERENTIAL SlDE WHEEL SlDE 45UOMX-031 SNAP RING GROOVE I 45UOMX-032 Boots 1. Wrap the shaft splines with tape. 2. Remove the boot. Assembly note Boots 1. Before putting the boot onto the shaft, wrap the shaft splines with tape. 2. lnstall the wheel-side and differential-side boots, noting the shape and size of each one in the figure. Outer diameter of large boot end Differential side : 87.4mm (3.441 in) Wheel side : 90.8mm (3.575 in) Cage, inner ring, and balls 1. Align the marks and install the balls to the inner ring. 2. Install the cage, inner ring, and ball assembly to the drive shaft in the direction shown in the figure. The larger diameter of the (age should be) facing the snap ring groove. 3. Install a new snap ring in the drive shaft snap ring groove. 4. Apply the specified grease (molybdenum disulfide) to the joints and boots. Total quantity Differential side : 75-95 g (2.65-3.35 oz) Wheel side : 55-75 g (1.94--2.65 oz) Gartner Banana

M DRIVE SHAFT 5. Align the marks, then install a new clip. Boot bands 1. Set the boots onto the rings. 2. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth-wrapped screwdriver. 3. Verify that the boots are not dented or twisted. 4. Measure the drive shaft length. Standard length: 623.7--658.8mm (24.556-25-936 in) 5. If not within specification, return to step 1. J Standard length (On-vehicle): 640.6mm (25,220 in) 6. Fold the new band back by pulling on the end of it with pliers. The band should be folded in the direction oppo- site the forward revolving direction of the drive shaft. 7. Lock the end of the band by bending the locking clips. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for I air bag system service warnings and audio antitheft system alarm conditions . STEERING SYSTEM INDEX ....................................... N- 2 OUTLINE ..................................... N- 4 SPECIFICATIONS ........................... N- 4 MANUAL STEERING .......................... N- 4 PREPARATION ............................. N- 4 ................ TROUBLESHOOTING GUIDE N- 5 BOOT ...................................... N- 6 STEERING WHEEL AND COLUMN ........... N- 8 ............. STEERING GEAR AND LINKAGE N-12 ENGINE SPEED SENSING POWER STEERING .......................... N-18 PREPARATION ............................. N-18 TROUBLESHOOTING GUIDE ................ N-20 AIR BLEEDING ............................. N-21 POWER STEERING FLUID ................... N-22 STEERING WHEEL AND COLUMN ........... N-24 STEERING GEAR AND LINKAGE ............. N-25 POWER STEERING OIL PUMP ............... N-33 DRIVE BELT ................................ N-37 25UONX-001 Gartner Banana

INDEX INDEX MANUAL STEERING STEERING WHEEL PLAY: [ (MOrnrn (0-1 .I 8 in) ] 1. Boot 3. Steering gear and linkage Replacement ................ page N- 6 Removal 1 Installation ......... page N-12 2. Steering wheel and column Disassembly / Inspection / On-vehicle inspection ......... page N- 8 Assembly .................. page N-13 -, Removal / Installation ......... page N- 9 Disassembly / Inspection / Assembly .................. page N-10 Gartner Banana