steering MAZDA MX-5 1994 Owner's Guide

MANUAL STEERING N Removal Note Locknut Before loosening the locknut from the tie-rod end, make a reference mark for proper reinstallation. Tie-rod endlsteering knuckle 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. Tie-rod end boot 1. Secure the tie-rod end in a vise. 2. Place a chisel against the boot and hold it at the angle shown. 3. Remove the boot by tapping it with a hammer. Installation Note Tie rod end boot 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot onto the tie-rod end by using the SST and a press. 4. Wipe away any excess grease. Steering gear boot Verify that the boot is not twisted or dented. Gartner Banana

N MANUAL STEERING STEERING WHEEL AND COLUMN Obtain the code number and deactivate the audio anti- theft system before disconnecting the battery. (Refer to section T.) On-vehicle Inspection Steering wheel play If the play exceeds specification, either the steering joints are worn or the backlash of the steering gear is excessive. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that the play is within specification. Play: 0--30mm (0-1.18 in) Looseness or play of steering wheel Move the steering wheel in directions a, 0, and @ to check for column bearing wear, steering shaft joint play, steering wheel looseness, and column looseness. Steering wheel effort 1. On level ground, jack up the front of the vehicle and sup- port it on safety stands. 2. Turn the steering wheel fully to the left and right at least 5 times. 3. Move the steering wheel to put the wheels in the straight ahead position. 4. Attach a pull scale to the outermost point of the steering wheel spoke. Then, starting with the wheels in the straight-ahead posi- tion, measure the effort required to turn the steering wheel to the left and to the right. Steering wheel effort: 5.0--29 N (0.S3.0 kgf, 1 .l--6.6 Ibf) (during one turn of steering wheel) 5. If not within specification, check the following: rotation starting torque of pinion, rotation torque of each ball joint, and steering joints. Gartner Banana

MANUAL STEERING , N Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. ,, 3. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal. 5. Tighten all necessary nuts and bolts to the specified torque. 6. After installation, check if the horn sounds. If the horn does not sound, remove the air bag module and connect the module connectors. (Refer to section T.) 1. Air bag module 6. Lower panel Removal 1 Installation .......... section T 7. Key interlock cable (Automatic transmission) 2. Locknut 8. Intermediate shaft bolt 3. Steering wheel 9. Steering shaft w ............... Removal Note page N-10 Disassembly 1 Inspection / 4. Column cover Assembly .................. page N-10 5. Combination switch Removal / Installation .......... section T Gartner Banana

N MANUAL STEERING Removal Note Steering wheel Caution '. Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will col- lapse. Remove the steering wheel with a suitable puller. Disassembly 1 Inspection 1 Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. L 1. Steering lock mounting bolts and bracket 3. Steering shaft ................... Disassembly Note ............ page N-1 1 Inspection page N-1 1 Assembly Note .............. page N-11 4. Intermediate shaft J 2. Steering lock assembly Inspect universal joint for looseness, abnormal noise, and sticking Gartner Banana

MANUAL STEERING N Disassembly Note Steering lock mounting bolts and bracket Use a chisel to make a groove in the heads of the steer- ing lock mounting bolts. Remove the bolts with a screw- driver. Remove the steering lock assembly. Inspection Check the following, and replace the column assembly if necessary. Steering shaft 1. Column bearing damage. 2. Steering shaft length. Length: 603.7--605.7mm (23.77-23.84 in) Assembly Note Steering lock mounting bolts and bracket Install the steering lock assembly on the jacket. Install the new steering lock mounting bolts. Tighten the bolts until the heads break off. Gartner Banana

N MANUAL STEERING STEERING GEAR AND LINKAGE Removal / Installation 1. Turn the wheels to the straight-ahead position. 2. Loosen the wheel lug nuts. 4 3. On level ground, jack up the front of the vehicle and support it on safety stands. 4. Remove the wheel. Note Turning the steering wheel while the steering gear is removed will make reinstallation difficult. Do not turn the steering wheel while the steering gear is removed. If the steering wheel is turned in that condi- tion, the clockspring connector may have to be adjusted. (Refer to section T.) 5. Remove the undercover. 6. With the wheels in the straight-ahead position, remove in the order shown in the figure. 7. Install in the reverse order of removal. 8. Adjust the front wheel alignment. (Refer to section R.) 1. Cotter pin 4. Intermediate shaft bolt 5. Mounting bracket bolt .i 2. Nut 3. Tie-rod endlsteering knuckle 6. Steering gear and linkage Removal Note . . . . . . . . . . . . . . . . page N-7 Gartner Banana

MANUAL STEERING N Disassembly 1 Inspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. i, 3. Assemble in the reverse order of disassembly, referring to Assembly Note. 1. Tie-rod end 15. Upper bearing Inspect ball joint for damage and malfunction Inspect for wear, damage, and malfunction 2. LocknLt (Tie-rod end) 16. Pinion shaft .............. 3. Boot band Assembly Note page N-16 4. Boot wire Inspect teeth for wear, damage and cracks 5. Boot 17. Rack ............ Inspect for cracks and other damage Disassembly Note page N-14 6. Tie-rod Inspection ................... page N-15 Disassembly Note ............ page N-14 Assembly Note .............. page N-16 Assembly Note .............. page N-32 18. Mounting bracket and mount 7. Washer 19. Lower bearing 8. Locknut (Adjusting cover) 9. Adjusting cover Disassembly Note ............ page N-14 Assembly Note .............. page N-17 10. Roller assembly lnspect parts for wear, damage, weakness and malfunction 11. Dust cover lnspect for cracks and other damage 12. Locknut (Rear cover) u 13. Rear cover Assembly Note .............. page N-17 14. Oil seal Disassembly note ............ page N-14 ~isassembl~ Note ............ page N-14 Assembly Note .............. page N-16 lnspect for wear, damage, and malfunction 20. Rack bushing Disassembly Note ............ page N-15 Assembly Note .............. page N-15 lnspect for wear and damage 21. Bushing Disassembly Note ............ page N-15 Assembly Note .............. page N-15 lnspect for wear and damage 22. Gear housing lnspect for cracks and other damage Gartner Banana

N MANUAL STEERING Disassembly Note Tie-rod 1. Uncrimp the washer. 2. Remove the tie rod. Adjusting cover Remove the adjusting cover by using the SST. Oil seal Remove the oil seal by using the SST. Rack Caution Removing the rack from the tube side can damage the rack bushing by dragging the rack teeth across it. When removing the rack, remove it slowly and carefully. Remove the rack from the tube side. Lower bearing Note The lower bearing does not need to be removed unless you are replacing it. 1. Heat the gear housing in water to about 80°C (180°F). 2. Tap the end of the housing with a plastic hammer to remove the lower bearing. Gartner Banana

MANUAL STEERING N LOCKING TAB Rack bushing Note The rack bushing does not need to be removed unless you are replacing it. Depress the locking tab, and carefully remove the rack bushing. Bushing Note The bushing does not need to be removed unless you are replacing it. Carefully break the bushing to remove it. Inspection Rack 1. Inspect for cracking, damage, and tooth wear. Replace if necessary. 2. Measure runout of the rack. ' BUSHING b TAB I I Runout: 0.3mm (0.012 in) max. 3. If not within specification, replace the rack. Assembly Note Bushing Align A and B and press a new bushing into the gear housing by using the SST until the bushing is fully seated. Rack bushing 1. Align the tab of a new rack bushing with the hole in the column. 2. Push the rack bushing in until it is locked in place by the tab. Gartner Banana

N MANUAL STEERING LOWER BEARING 1 IT-71 GEAR HOUSING FACE NSK MARK DOWNWARD 15UONX-018 VENTILATION HOLE 95AONX-02; RACK CENTRAL POSITION 95AONX-025 N-16 Lower bearing 1. Apply grease to a new lower bearing. 2. Set the lower bearing onto the pinion shaft so that the NSK mark on the bearing faces downward. u 3. Insert the pinion shaft together with the lower bearing. 4. Press the pinion shaft to seat the lower bearing. 5. Apply grease to the inside of the gear housing as shown. Rack 1. Secure the mounting bracket in a vise. 2. Apply grease to the rack bushing. 3. Apply grease to the rack teeth and the sliding surface. Caution Do not plug the ventilation holes with the grease. Caution Installing the rack from the tube side can damage the rack bushing by dragging the rack teeth across it. When installing the rack, install it slowly and carefully. 4. Slide the rack in from the tube side. Pinion shaft 1. Apply grease to the inner race of the upper bearing and install it to the pinion shaft. 2. Apply grease to the teeth of the pinion shaft. 3. Turn the flat section of the rack toward the pinion, and insert the pinion. Gartner Banana