MAZDA MX-5 1994 Workshop Manual

Page 621 of 1708

M DIFFERENTIAL Differential mount 1. Drill holes around the differential mount. 2. Hit the edge of the differential mount to remove it. Assembly note Differential mounting rubber 1. Install the new differential mount with the voids facing front and rear. 2. Press in the differential mount by using the SST. Press force: 19600 N (2000 kgf, 4400 Ibf) Oil seal (Output shaft) Apply lithium based grease to the new oil seal lip and install it by using the SST. Bearing outer race (front bearing) Instdl the bearing outer race (front bearing) by using the SST. Gartner Banana

Page 622 of 1708

DIFFERENTIAL M Bearing outer race (rear bearing) Install the bearing outer race (rear bearing) by using the SST. Bearing inner race (rear bearing), Bearing inner race (front bearing), Spacer 1. Adjust the drive pinion height as follows, by using the SST. (1) Install the previously-removed spacer onto the SST so that the beveled side of the spacer faces the drive pinion. Then install the rear bearing and O-ring onto the SSTIspacer as shown in the figure. (2) Assemble the spacer, bearing inner race (rear bear- ing), and SST. Secure the SST with the O-ring. Install this assembly in the carrier. Install the bearing inner race (front bearing), the SST, companion flange, washer, and nut. (3) Tighten the nut just enough so that the companion flange can still be turned by hand. Gartner Banana

Page 623 of 1708

M DIFFERENTIAL (4) Place the SST on the surface plate and set the dial indicator to "Zero". (5) Place the SST atop the drive pinion model. Set the gauge body atop the gauge block. (6) Place the feeler of the dial indicator so that it contacts where the bearing inner race (side bearing) is installed in the carrier. Measure the lowest position on the left and right sides of the carrier. (7) Add the two (left and right) values obtained in step (6) and divide the total by 2. Specification: Omm (0 in) Thickness mm {tP2"13 in} 3.11mm (0.1 224 in} 3.14mm (0.1 224 in} 3.1 7mm (0. I248 in} 3.20mm (0.1260 in} 3.23mm (0.1271 in] 3.26mm 40.1283 in} Thickness rnm {t&5 in} 3.32mm (0.1307 in} 3.35mm (0.1319 in] 3.38m (0.1331 in) 3.41 mm (0.1343 in) 3.44mm {0.1354 in) 3.47rnm (0.1366 in) 45UOMX-47: (8) If not within specification, adjust the pinion height by selecting a spacer. Select the spacer of the thickness closest to that necessary. Spacers are available in increments of 0.03mm (0.001 2 in). (9) Install the spacer, selected in the procedure above, with the beveled side facing the drive pinion. (1 0)Press the spacer onto the drive pinion until the force SPACER required starts to increase sharply. 2. Install the sDacer. 3. Press the bearing inner race (rear bearing) on with the SST. Gartner Banana

Page 624 of 1708

DIFFERENTIAL M 4. Without installing the oil seal, Install the drive pinion, spacer, new collapsible spacer, front bearing, washer, and companion flange to the carrier, and temporarily tighten the locknut by using the SST. Tightening torque: 128 N-m (13.0 kgf-m, 94.1 ft-lbf) 5. Turn the companion flange several turns by hand to seat the bearing. 6. Measure the drive pinion preload. Adjust the preload by tightening the locknut, and record the tightening torque. STANDARD "TORSEN" 45UOMX-07; Preload: 0.9-1.3 N.m (9-1 4 kgf.cm, 7.9-1 2.1 in4bf) Tightening torque: 128-284 N.m (13.0-29.0 kgf.m, 94.1-209.7 ft-lbf) 7. Remove the locknut, washer, and companion flange. 8. T~D a new oil seal into the differential carrier with the 9. Apply a light coat of grease to the end face of the com- panion flange. 10. Install the companion flange and washer; while holding the flange with the SST, and tighten a new locknut to the tightening torque recorded in step 6. Gartner Banana

Page 625 of 1708

M DIFFERENTIAL Thrust washers (Standard) 1. Adjust the backlash of the side gears and pinion gear as follows. (Standard) (1) Set a dial gauge against the pinion gear as shown. ,+, (2) Secure one of the side gears. (3) Move the pinion gear, and measure the backlash at the end of it. If not within specification, replace the dif- ferential gear as an assembly. ("TORSEN" LSD) Standard backlash: 04.1 mm (0-0.004 in) (4) If the backlash exceeds the standard, use the select- able thrust washers for adjustment. 2. Install the new knock pin to secure the pinion shaft. Stake the pin with a punch to prevent it from coming out of the case. Thrust washer thickness: 3. Apply thread-locking compound to bolt threads @ and points @I of the gear back face. Apply approximately 0.04 cm3 I0.04 cc, 0.0024 cu in} of thread-locking com- pound at each point and bolt thread. 4. lnstall the ring gear onto the gear case. Identification mark 0 0.5 1 1.5 2 Tightening torque: 69-83 N.m (7.0--8.5 kgf-m, 51-61 ft-lbf) Thickness 2.00mm i0.0787 in} 2.05mm (0.0807 in) 2.10mm {0.0827 in) 2.15mm (0.0846 in} 2.20mm i0.0866 in} 5. Press the bearing inner races (side bearing) on by using the SST. 6. Install the differential gear assembly in the carrier. 7. Note the identification marks on the adjusting nuts, and install them on their respective sides. 8. lnstall the differential bearing caps, making sure that the identification mark on the cap corresponds with the one on the carrier by using the SST. Then temporarily tighten the bolts. Gartner Banana

Page 626 of 1708

DIFFERENTIAL M (1) Mark the ring gear at four points at approx. 90" inter- vals. Mount a dial indicator to the carrier so that the feeler comes in contact at a right angle with one of the ring gear teeth. (2) Turn both bearing adjusters equally by using the SST until the backlash is 0.09-0.11mm {0.0036-€).0043 in). (3) Check the backlash at the three other marked points, and make sure the maximum backlash is less than 0.07mm (0.0028 in). 9. Tighten or loosen the adjusting nuts equally until the dis- tance between the pilot sections on the bearing caps is 185.428-1 85SOmm (7.3004--7.3031 in). 10. Recheck the back lash. Inspection and adjustment of teeth contact 1. Coat both surfaces of 6-8 teeth of the ring gear with a thin coat of red lead. 2. While moving the ring gear back and forth by hand, rotate the drive pinion several times and check the tooth contact. 3. If the tooth contact is good, wipe off the red lead. 4. If it is not good, adjust the pinion height, and then adjust the backlash. (1) Toe and flank contact Replace the spacer with a thinner one to move the drive pinion outward. Gartner Banana

Page 627 of 1708

M DIFFERENTIAL I HEEL CONTACT FACE CONTACT I (2) Heel and face contact Replace the spacer with a thicker one to bring the drive pinion in. d Bearing caps 1. Tighten the bearing cap bolts. Tightening torque: 37-52 N-m {3.8-5.3 kgf-m, 27-38 ft4bf) 2. Install the lock plates on the bearing caps. Tightening torque: 18-25 N.m (1.8-2.6 kgf-m, 13-19 ft.lbf) Differential case 1. Apply sealant to the housing face. 2. Tighten the bolts. Tightening torque: 23-26 N.m (2.3-2.7 kgf.m, 17-20 ft.lbf) Output shaft 1. Install a new clip. 2. Install the output shafts into the side gears by lightly tap- ping them with a plastic hammer. 3. Verify that the output shafts are hooked into the side gears by pulling them by hand. Gartner Banana

Page 628 of 1708

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

Page 629 of 1708

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

Page 630 of 1708

INDEX POWER STEERING STEERING WHEEL PLAY: [ 0-30mm (0-1.18 in) ] / DRIVE BELT DEFLECTION I=' I LIMIT: 11.5mm (0.45 in) at 98 N (1 0 kgf, 22 Ibf) 'I =!IS 1. Boot Replacement ................ page N- 6 2. Steering wheel. and column .... On-vehicle inspection pages N- 8,24 Removal / ................... page N- 9 Disassembly / Inspection 1 Assembly .................. page N-10 3. Steering gear and linkage Removal I Installation ......... page N-25 Air bleeding ................. page N-21 Disassembly I Inspection / Assembly .................. page N-26 4. Power steering oil pump ......... Removal / Installation page N-33 ................. Air bleeding page N-21 .......... Power steering fluid page N-22 5. Drive belt ................... Inspection page N-37 .................. Adjustment page N-38 ................ Replacement page N-38 Gartner Banana

Page:   < prev 1-10 ... 581-590 591-600 601-610 611-620 621-630 631-640 641-650 651-660 661-670 ... 1710 next >