MAZDA MX-5 1994 Workshop Manual

M DIFFERENTIAL 5. Separate the driveshaft from the differential and sus- pend it. 6. Remove the output shaft by using two pry bars as shown in the figure. J 7. Remove the oil seal. 8. Apply lithium-based grease to the new oil seal lip and install it by using'the SST. 9. Install the new clips. 10. Install the output shaft into the side gears by lightly tap- ping with a plastic hammer. 11. Verify that the output shaft is hooked into the side gears by pulling it by hand. ./ 12. Align the marks and install the drive shaft. Tightening torque: 54-64 N.m (5.5--6.5 kgf.m, 40-47 ft-lbf) 13. Install the upper arm installation bolt and nut. Tightening torque: 46-67 N.m (4.7-6.8 kgf.m, 34--49 ftlbf) 14. Add the specified oil. 15. Adjust the rear wheel alignment. (Refer to section R.) I Gartner Banana

DIFFERENTIAL M DIFFERENTIAL, STANDARD; DIFFERENTIAL, TORQUE SENSING LIMITED SLIP ("TORSEN" LSD) Removal 1 lnstallation 1. Drain the differential oil. ,, 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Add the specified oil to the specified level. 1. Rear wheels 7. Drive shafts 2. Differential mounting pipe Removal Note ............. page M-29 3. Exhaust pipe 8. Differential 4. Propeller shaft Removal Note ............. page M-29 Service ..................... section L Installation Note ........... page M-30 ' 5. Speedometer cable Overhaul .................. page M-32 ,, 6. Power plant frame (PPF), Differential mounting spacer Removal Note ............. page M-28 Installation Note ........... page M-30 Gartner Banana

M DIFFERENTIAL SLEEVE BLOCK BOLT (MI 4 x 1.5) dl Removal note Power plant frame (PPF) 1. Disconnect the wire harness from the PPF. 2. Support the transmission with a jack. 3. Remove the power plant frame bracket. (Manual trans- mission) 4. Remove the differential-side bolts, and pry out the spacer. 5. Remove the differential mounting spacer. 6. Turn a bolt (MI4 x 1.5) into the sleeve. 7. Twist and pull the bolt downward. 8. Install a bolt (M6 x 1) into the hole in the block to hold the sleeve, and remove the long bolt (MI4 x 1.5). 9. Remove the bolt ,(M6 x 1). Gartner Banana

DIFFERENTIAL M t- 900mm (35.43 in) 10. Remove the transmission-side bolts, and remove the PPF. Do not remove the spacers from the PPF. If they are removed, replace the PPF as an assembly. Drive shaft Mark the drive shaft and output shaft for proper installa- tion. Differential 1. Support the differential with a jack. 2. Lower the differential and move it forward. Note If the drive shaft will not separate easily from the out- put shaft, remove a bolt and nut from one side of the upper arm. 3. Separate the driveshaft from the output shaft. 4. To prevent damaging the fire wall, crank angle sensor, and engine mount, support the transmission as follows. (1) Prepare a steel plate (as shown in the figure), a wooden block, bolts (M8 x 1.25), and washers. (2) Install the parts as shown in the figure. Gartner Banana

M DIFFERENTIAL Installation note Differential 1. Connect the drive shaft to the output shaft with the marks aligned. 2. Install the differential. - JOMX- Tightening torque 0: 83-98 N-m (8.5-10 kgf.m, 61-72 ft4bf) @I: 18-26 N.m (1.8-2.7 kgf.m, 13-20 ft.lbf) 3. Adjust the rear wheel alignment if the upper arm installa- tion bolt and nut were removed. (section R.) Power plant frame (PPF) 1. Install the differential mounting spacer. Tightening torque: 37-52 N-m (3.8-5.3 kgf.m, 27-38 ftdbf} .i 2. Support the transmission with a jack so that it is level. 3. Position the PPF and snugly tighten the transmission- side bolts by hand. 4. Verify that the sleeve is installed into the block. 5. Install the spacer and bolts and snugly tighten them. The reamer bolt should be installed in the forward hole. 6. Snugly install the power plant frame bracket. 7. Tighten the transmission-side bolts. Tightening torque: lO4--123 N.m (1 0.6-1 2.6 kgf.m, 77-91 ft4bf) Gartner Banana

DIFFERENTIAL M 8. Tighten the differential-side bolts. Tightening torque: lO4--123 N.m (1 0.6-1 2.6 kgf.m, 77-91 ft~lbf) 9. Install the power plant frame bracket. (Manual transmis- sion) Tightening torque 0: 104-123 N-m (10.6-12.6 kgf.m, 77-91 ftlbf) 0: 36-54 N.m I3.7--5.5 kgf-m, 2740 ft-lbf) 10. Remove the jack, and connect the wire harness. Gartner Banana

M DIFFERENTIAL Overhaul 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. f - Gartner Banana

DIFFERENTIAL M 1. Output shafts Disassembly Note .......... page M-34 Assembly Note ............ page M-42 u 2. Differential case Disassembly Note .......... page M-34 Assembly Note ............ page M-42 3. Differential gear assembly Disassembly Note .......... page M-34 4. Lock plates 5. Bearing caps Disassembly Note .......... page M-34 Assembly Note ............ page M-42 6. Adjusting nuts Disassembly Note .......... page M-34 7. Bearing outer races (Side bearing) 8. Gear case assembly ("TORSEN" LSD) 9. Ring gear lnspect individual gear teeth for wear and cracks 10. Knock pin (Standard) Disassembly Note .......... page M-34 11. Pinion shaft (Standard) 12. Pinion gears (Standard) lnspect individual gear teeth for wear and cracks 13. Thrust washers (Standard) 14. Side gears (Standard) lnspect individual gear teeth for wear and cracks b 15. Thrust washers (Standard) Assembly Note ............ page M-40 16. Bearing inner races (Side bearing) Disassembly Note .......... page M-34 lnspect for damage and rough rotation 17. Gear case 18. Locknut (Companion flange) Disassembly Note .......... page M-35 19. Washer 20. Companion flange Disassembly Note .......... page M-35 lnspect splines for wear and damage 21. Oil seal (Companion flange) 22. Washer 23. Drive pinion Disassembly Note .......... page M-35 lnspect splines for wear and damage lnspect individual gear teeth for wear and cracks 24. Spacer Assembly Note ............ page M-37 25. Bearing inner race (Front bearing) lnspect for damage and rough rotation ............ Assembly Note page M-38 26. Collapsible spacer 27. Bearing outer race (Rear bearing) Disassembly Note .......... page M-35 Assembly Note ............ page M-37 28. Bearing outer race (Front bearing) Disassembly Note .......... page M-35 Assembly Note ............ page M-36 29. Bearing inner race (Rear bearing) Disassembly Note .......... page M-35 lnspect for damage and rough rotation Assembly Note ............ page M-37 30. Differential carrier 31. Oil seal (Output shaft) Assembly Note ............ page M-36 32. Baffle 33. Breather 34. Differential mount Disassembly Note .......... page M-36 Assembly Note ............ page M-36 45UOMX-053 Gartner Banana

M DIFFERENTIAL Disassembly note Output shafts Remove the output shafts with two pry bars as shown in the figure. -J Differential case Caution The differential case is made of aluminum, and is therefore easily dented and scratched by metal tools. When. separating the differential carrier from the case, use only a plastic hammer at the point shown in the figure. Strike the differential carrier with a copper hammer to separate it from the case. Differential gear assembly Mount the differential gear assembly on the SST. Bearing caps Mark one bearing cap and the carrier. Adjusting nuts Mark one adjusting nuts and the carrier. Knock pin Secure the gear case in a vise and tap out the knock pin toward the ring gear side. Bearing inner races (Side bearing) Note Mark the bearings so that they can later be reinstalled in the same position. Remove the bearing inner races (side bearing) from the gear case by using the SST. -1 Gartner Banana

DIFFERENTIAL id Locknut (Companion flange) Hold the companion flange by using the SST and remove the locknut. Companion flange Pull the companion flange off by using the SST. Drive pinion Push out the drive pinion by attaching a miscellaneous locknut to the drive pinion, and tapping it with a copper hammer. Bearing outer races (Front, and rear bearing) Remove the bearing outer races using the two grooves in the carrier and alternately tapping the sides of the races. Bearing inner race (Rear bearing) While supporting the drive pinion to keep it from falling, remove the bearing inner race (rear bearing) by using the SST. Gartner Banana