MAZDA MX-5 1994 Workshop Manual

N OUTLINEIMANUAL STEERING OUTLINE SPECIFICATIONS Steering wheel Steering shaft and joint d Type Steering gear Outer diameter mm {in) I 370 {I 4.6) I Manual steering Power steering Lock-to-lock turns Shaft ~oinr Power assist 3.36 2-cross joint - I Engine speed sensing Gear Gear ratio 2.8 Rack-and-pinion m (infinite) Rack stroke mm {in} Power steering fluid MANUAL STEERING Collapsible, non-tilt 121 .O i4.76) - I ATF DexronBII or M-111 ~luidca~acit~ L~S qt, Imp qt) I - PREPARATION SST 0.8 (0.85, 0.70) Preload attachment 25UONX-003 Hexagon wrench 49 GO30 797 Handle For removal of tie-rod end 49 1243 785 Installer, boot For measurement of pinion torque For installation of bushing 49 0208 701 A Boot air out tool - For removal and installation of adjusting cover For installation of tie-rod end boot 49 DO32 31 6 Protractor For removal of oil seal For tightening of adjusting cover Gartner Banana

MANUAL STEERING TROUBLESHOOTING GUIDE Problem Steering heavy Posslble Cause Poor lubrication, foreign material, or abnormal wear of steering ball joint Stuck or damaged lower arm ball joints lmproper steering pinion preload Damaged steering gear Malfunction of steering shaft joint lmproperly adjusted wheel alignment Malfunctioning steering gear Replace Replace gear Replace Replace Adjust Replace ~ction- Lubricate or replace section R N-12 N-12 N- 9 section R N-12 ~i&d~ection N-13 General instability while driving Steering wheel pulls to one side Shake (Steering wheel vibrates upidown) Worn or damaged stabilizer and/or suspension arm bushings Dragging brake Loose lower arm lmproperly adjusted wheel alignment lncorrect tire pressure Damaged or unbalanced wheel Worn or damaged steering joints lmproper steering pinion preload Weak front coil spring Worn or damaged stabilizer andlor suspension arm bushings Malfunctioning shock absorber lmproperly adjusted wheel alignment Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Incorrect tire pressure Incorrect tire pressure Unevenly worn tires Weak front spring Replace Repair Tighten Adjust Adjust Adjust or replace Replace Replace gear Replace Replace Replace Adjust Replace Tighten Adjust or replace section R section P section R section R section Q section Q N- 9 N-12 section R section R section R section R section Q section Q section Q Adjust Adjust Replace Replace section Q section Q section Q section R I Cracked or worn transmission mount I Cracked or worn engine mount 1 ~e~lace I section B lncorrect tire pressure Unevenly worn tires Malfunction of shock absorber Shimmy (Steering wheel vibrates circumferentially) Excessive steering wheel play Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Adjust Replace Replace Replace Replace Tighten Replace Replace Tighten Adjust or replace section Q section Q section R section J N-12 N-12 N-13 section Q section Q section Q I Loose shock absorber mounting bolts 1 Tighten I section R Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Worn steering gear Worn or damaged steering joints Worn or damaged suspension arm bushings Loose steering gear mounting bolts I lmproperly adjusted front wheel alignment Poor steering wheel return Replace Replace Replace Adjust Replace Replace Replace Tighten Replace Adjust Replace Adjust Worn linkage &-tie-rod ball joint lncorrect tire pressure Stuck or damaged steering joints section R section R section M section R N-12 N- 9 section R N-12 N-12 section Q N- 9 section R Abnormal noise from steering system 25UONX-00! Improper steering pinion preload Ball joint not operating smoothly Steering shaft contacting something Loose steering gear Malfunctioning steering gear Obstruction near steering column Loose steering linkage Worn steering joints Replace gear Replace Repair Tighten Replace Repair or replace Tighten or replace Replace N-12 N-13 N- 9 N-12 N-12 N- 9 N-12 N- 9 Gartner Banana

N MANUAL STEERING BOOT Replacement 1. Loosen the wheel lug nuts. 2. On level ground, jack up the front of the vehicle and support it on safety stands. 3. Remove the wheel. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to lnstallation Note. 6. After installation, check the steering angle and toe-in, and adjust if necessary. (Refer to section R.) Nm (kgfm, ftdbf) 1. Cotter pin 6. Tie-rod end boot 2. Nut Removal Note ................ page N-7 3. Tie-rod endfsteering knuckle Installation Note .............. page N-7 Removal Note ................ page N-7 7. Boot clamp J 4. Locknut 8. Boot wire Removal Note ................ page N-7 9. Steering gear boot 5. Tie-rod end Installation Note .............. page N-7 Gartner Banana

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