MAZDA MX-5 1997 Factory Owners Manual

Fig. 13: Measuring Axle Shaft & Identifying Boots
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:37 PMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Fig. 14: Installing Balls In To Inner Ring
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
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Fig. 15: Installing Boot Band
Courtesy of MAZDA MOTORS CORP.
AXLE SHAFT BOOT IDENTIFICATION
LUBRICATION SPECIFICATION
AXLE SHAFT LENGTH
TORQUE SPECIFICATIONS
ApplicationWheel Side Diameter - In. (mm)
Differential Side Diameter - In.
(mm)
Miata3.58 (90.8)3.44 (87.4)
ApplicationQuantify
Differential Side CV Joint Boot3-3.71 oz. (85-105 g)
Wheel Side CV Joint Boot1.94-2.65 oz. (55-75 g)
ApplicationIn. (mm)
199730.21-30.60 (767.3-777.3)
1999-200130.42-30.81 (772.6-782.6)

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:38 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Axle Shaft Lock Nut
1997160-216 (216-294)
1999-2001174-235 (236-318)
Brake Caliper Mounting Bolt37-50 (50-68)
Lower Control Arm Bolt/Nut47-54 (64-73)
Wheel Lug Nuts66-86 (89-117)

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:38 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

BRAKE SYSTEM
1995-97 BRAKES Mazda - Disc & Drum
DESCRIPTION & OPERATION
All models use hydraulic-operated brake system with a tandem master cylinder, proportioning valve and a
power brake unit. All models are equipped with front disc brakes and either rear disc or rear drum brakes.
Rear Anti-lock System (RABS) is standard on B2300, B3000, B4000 and MPV models.
BLEEDING BRAKE SYSTEM
BRAKE LINE BLEEDING SEQUENCE
ADJUSTMENTS
MASTER CYLINDER PUSH ROD
Miata Without ABS, MPV, MX-6 M/T Without ABS & 626 M/T Without ABS
1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it
contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.
2. Invert adjuster gauge and place gauge on power brake unit. Adjust push rod on power brake unit until
there is no clearance between push rod and adjuster gauge screw.
B2300, B3000 & B4000
NOTE: For information on anti-lock brake systems, see appropriate ANTI-LOCK article
in BRAKES.
NOTE: If vehicle is equipped with anti-lock brakes, see appropriate ANTI-LOCK article
for brake bleeding procedure.
ApplicationSequence
B2300, B3000 & B4000(1) RR, LR, RF, LF
All Other ModelsLongest Line First
(1)Bleed master cylinder and RABS hydraulic unit before bleeding wheel cylinders and calipers.
NOTE: Push rod has an adjustment screw to maintain correct distance between
booster push rod and master cylinder piston. If push rod is adjusted too long, it
prevents master cylinder piston from completely releasing hydraulic pressure,
causing brakes to drag. If push rod is adjusted too short, it causes excessive
pedal travel and an undesirable clunk in booster area.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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Remove master cylinder to gain access to push rod. To check screw adjustment, fabricate a gauge. See Fig. 1.
With engine running and vacuum line connected to booster, place gauge against master cylinder mounting
surface of booster. Adjust push rod screw by turning it until end of screw just touches inner edge of gauge slot.
Fig. 1: Adjusting Brake Booster Push Rod (B2300, B3000 & B4000)

Courtesy of FORD MOTOR CO.
REAR BRAKE SHOES ADJUSTMENT
B2300, B3000 & B4000
NOTE: Rear brakes are self-adjusting and require manual adjustment only if brake
shoes have been replaced.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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1. Raise and support rear of vehicle. Remove rear wheel assemblies. If drums are installed on vehicle,
remove cover from adjusting hole at bottom of brake backing plate. Turn adjusting screw with a brake
adjusting tool until shoes drag against brake drum and lock drum.
2. When shoes are against drum, loosen adjusting screw an additional 10-12 notches so drum rotates freely.
If drum does not rotate freely, remove wheel and drum and vacuum dust and dirt from linings. Use
sandpaper and remove rust from points where shoes touch backing plate. Apply a light coating of
molybdenum grease to brake shoe-to-backing plate contact points. Install wheel and drum and adjust
shoes.
3. To adjust brakes with rear drums removed, first clean all rust and dirt on points where shoes touch
backing plate and apply a small amount of molybdenum grease to those areas. Using a brake shoe
adjustment gauge, measure inside diameter of drum braking surface.
4. Reverse tool and adjust brake shoes until they touch gauge. Gauge contact points on shoes must be
parallel to vehicle with center line through center of axle. Hold automatic adjusting lever out of
engagement while rotating adjusting screw to prevent burring screw slots. Ensure adjusting screw rotates
freely.
MX-3, MX-6, Protege & 626
Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake. Remove brake drum.
Insert screwdriver between adjusting plate and quadrant. Twist screwdriver to disengage teeth. See Fig. 2
. Push
quadrant adjusting lever toward backing plate. Install brake drum. Operate parking brake a few times to reset
ad
juster. Adjust parking brake.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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Fig. 2: Moving Quadrant On Rear Drum Brake Adjuster (MX-6 & 626 Shown; MX-3 & Protege Are
Similar)
Courtesy of MAZDA MOTORS CORP.
PARKING BRAKE SHOES ADJUSTMENT
Millenia, MPV & 929
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove service plug from rotor. Insert
a screwdriver into service plug hole and turn adjuster in direction of arrow marked on rotor until rotor
will not turn.
2. On Millenia and MPV, rotate adjuster 3-5 notches in opposite direction. On 929, rotate adjuster 6-8
notches in opposite direction. On all models, ensure rotor rotates freely. Install service plug.
PARKING/EMERGENCY BRAKE
Miata, MX-3, MX-6, Protege & 626
NOTE: B2300, B3000 & B4000 are equipped with self-adjusting parking brake system.
Manual adjustment is not required.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

1. On models with rear disc brakes, depress brake pedal several times. On models with rear drum brakes,
start engine and depress brake pedal several times while vehicle is moving in reverse. Stop engine.
2. On Miata, pull parking brake lever with a force of 44 lbs. (20 kg). On all other models, pull parking brake
lever with a force of 22 lbs. (10 kg). If stroke is 7-9 notches on Miata or 5-7 notches on all others, parking
brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle. Release parking
brake lever.
3. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within
specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake
lever is pulled one notch.
Millenia
1. Depress brake pedal several times. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 3-5
notches, parking brake is properly adjusted. If stroke is not 3-5 notches, raise and support rear of vehicle.
Release parking brake lever.
2. Remove parking brake lever cover. Rotate cable adjusting nut at lever end of cable until stroke is within
specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake
lever is pulled one notch.
MPV (1995-96)
1. Depress brake pedal several times. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 3-6
notches, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle.
Release parking brake lever.
2. Remove adjusting nut clip and rotate cable adjusting nut at lever end of cable, located under console
cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning
light illuminates when brake lever is pulled one notch.
MPV (1997)
1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 6-9
notches, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle.
Release parking brake lever.
2. Remove adjusting nut clip and rotate cable adjusting nut at lever end of cable, located under console
cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning
light illuminates when brake lever is pulled one notch.
RX7
1. Depress brake pedal several times. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 7-
10 notches, parking brake is properly adjusted. If stroke is not 7-10 notches, raise and support rear of
vehicle. Release parking brake lever.
2. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within
specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake
lever is pulled one notch.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 5 © 2005 Mitchell Repair Information Company, LLC.

929
1. Depress brake pedal several times. Depress parking brake pedal several times with a force of 44 lbs. (20
kg). If stroke is 5-7 notches, parking brake is properly adjusted. If stroke is not 5-7 notches, rotate
adjusting nut, located under parking brake pedal, until stroke is within specification.
2. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake pedal is
depressed one notch.
BRAKE PEDAL FREE PLAY
With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal
free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS
. Adjust play by loosening push rod lock
nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).
BRAKE PEDAL FREE PLAY SPECIFICATIONS
BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH
Miata, MPV, MX-3, MX-6, RX7, 626 & 929
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Rotate switch away
from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is obtained. See
BRAKE PEDAL HEIGHT SPECIFICATIONS
.
2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock nut to 18-25 ft. lbs.
(24-34 N.m).
3. Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight
switch lock nut 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.
4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure.
5. Measure applied pedal hei
ght. See BRAKE PEDAL HEIGHT SPECIFICATIONS . If distance is not NOTE: On B2300, B3000 & B4000, brake pedal free play is built into pedal linkage and
is not adjustable.
ApplicationIn. (mm)
Miata, MPV & MX-3.16-.28 (4-7)
Millenia, MX-6, Protege & 626.16-.47 (4-12)
RX7.12-.31 (3-8)
929.12-.47 (8-12)
NOTE: B2300, B3000 & B4000 are equipped with dual brake master cylinder and
vacuum booster. System is designed to permit full stroke of master cylinder
when brake pedal is fully depressed. Brake pedal height adjustment is not
required.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.