torque spec MAZDA MX-5 1997 Factory Owner's Manual

Fig. 11: Exploded View Of Clutch Release Cylinder (Miata)
Courtesy of MAZDA MOTORS CORP.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE: Use exploded view of clutch release cylinder for overhaul procedure. See Fig.
11 .
ApplicationFt. Lbs. (N.m)
B2300, B2500, B3000 & B4000
Clutch Cover Bolts (1) 17-24 (23-32)
Crossmember Nuts39-53 (53-72)
Drive Shaft Bolts65-87 (88-119)
Flywheel-To-Crankshaft Nuts54-67 (73-91)
Gearshift Lever Bolt20-30 (27-40)
Starter Mounting Bolts17-20 (23-27)
Transfer Case Bolts (4WD) (2) 35-46 (47-62)
Transmission-To-Engine Block Bolts37-50 (50-68)
Miata
Clutch Cover Bolts (1) 13-19 (18-26)
Drive Shaft Nuts37-43 (50-58)
Flywheel-To-Crankshaft Bolts71-76 (96-103)
PPF-To-Differential Mounting Spacer Bolt (Short)27-38 (37-51)
PPF-To-Differential Side Mounting Bolts (Long)77-91 (104-123)
PPF-To-PPF Bracket Bolt27-40 (37-54)

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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DIFFERENTIAL LUBRICATION SPECIFICATIONS
TROUBLE SHOOTING
REMOVAL & INSTALLATION
FRONT DIFFERENTIAL OIL SEAL REPLACEMENT (MPV)
1. Jack up the vehicle and support it on safety stands.
2. Drain the differential oil.
3. Mark front drive shaft flange for reassembly reference. Remove drive shaft.
4. Before loosening the locknut, measure the rotation starting torque of the drive pinion (within the range of
the drive pinion and rin
g gear backlash).
Application(1) Specification
Warmer Than 0°F (-18°C)GL-5/SAE 90W
Cooler Than 0°F (-18°C)GL-5/SAE 80W
(1)Fill to lower edge of filler plug hole.
NOTE: See TROUBLE SHOOTING
article in GENERAL INFORMATION.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
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Sunday, July 05, 2009 1:52:42 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Installing Oil Seal (MPV)
Courtesy of MAZDA MOTORS CORP.
9. Install the companion flange and tighten the locknut to get the starting torque measured in step 4 .
10. Install the drive shaft. Tighten bolts to specfiication. See TORQUE SPECIFICATIONS
. Add
differential oil to the specified level. SeeFLUID TYPE
.
REAR AXLE SHAFTS & BEARINGS
Removal (MPV)
1. Raise and support vehicle. Remove rear wheel and tire assembly. Remove brake caliper and support
aside. Remove brake disc plate. See Fig. 5
. Using dial indicator, measure axle bearing play. Replace axle
bearing if play exceeds .023" (.57 mm).
2. Remove hold pin from parking brake shoe assembly and remove parking brake shoe assembly.
Disconnect parking brake cable. Using Flare Nut Wrench (49-0259-770B), disconnect brake pipe. Plug
brake pipe openings.
3. Remove rear axle shaft assembly-to-axle shaft housing retaining nuts. Using Puller (49-0223-630B) and
Attachment (49-8501-631A), remove rear axle shaft, backin
g plate and dust cover as an assembly from

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
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Sunday, July 05, 2009 1:52:42 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.

axle shaft housing. Remove axle oil seal. See Fig. 5. With axle shaft removed, remove retaining ring.
Remove ABS sensor rotor.
4. To remove bearing collar, grind collar until a section about .02" (.50 mm) remains. Using chisel, cut
remaining bearing collar from axle shaft. Using Puller (49-S121-520A), remove axle bearing from axle
shaft. Remove dust shield and backing plate.
5. Using dial indicator and "V" blocks, check axle shaft for straightness. Maximum axle shaft runout
is .059" (1.50 mm). Also check axle shaft splines for wear and damage. Use a press to replace wheel studs
as necessary. DO NOT reuse wheel studs if removed.
Installation
To install, reverse removal procedure. Lubricate oil seal lip before replacement. Use Attachment (49-1011-748)
and a press to install axle bearing onto axle shaft. DO NOT lubricate bearing collar before replacement. Use
Attachment (49-1011-748) and a press to install NEW bearing collar. If press fit of collar requires less than 2.7
tons (2699 k
g) to install, replace axle shaft. Tighten nuts to specification. See TORQUE SPECIFICATIONS.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Exploded View Of Rear Axle Shaft (MPV)
Courtesy of MAZDA MOTORS CORP.
DIFFERENTIAL ASSEMBLY
Removal (Front MPV 4WD)
1. Raise and support vehicle. Remove engine skid plate. See Fig. 6 . Drain front differential fluid. Remove
tie rod ends and lower control arms. Remove front axle shafts. See AXLE SHAFTS
- FRONT article.
2. Mark drive shaft and differential carrier flanges for reassembly reference, and remove drive shaft from
differential carrier. See Fig. 6
. Disconnect Automatic Free Wheel (AFW) vacuum hoses and electrical
connector.
3. Place floor jack under differential assembly. Remove differential-to-chassis mounting bolts and AFW
extension housing mounting nuts. Remove differential and AFW extension housing from vehicle.
Remove AFW assembly from left side of differential housing. Pull drive coupler from carrier. Remove
differential carrier-to-housing bolts. Remove differential carrier.
Installation
To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during
removal. Refill differential with lubricant. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 9 © 2005 Mitchell Repair Information Company, LLC.

See REAR AXLE SHAFTS & BEARINGS.
2. Remove ABS wheel speed sensor. Mark drive shaft and differential carrier flanges for reassembly
reference and remove drive shaft from differential carrier. Remove differential carrier-to-housing bolts.
Remove differential carrier.
Installation
To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during
removal. Refill differential with lubricant. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS .
Removal (Miata)
1. Raise and support vehicle. Remove wheel and tire assembly. Drain differential. Remove differential
mounting pipe. Remove exhaust pipe. Mark drive shaft and differential carrier flanges for reassembly
reference and remove drive shaft from differential carrier. See Fig. 7
. Disconnect speedometer cable
from transmission. Notin
g locations, disconnect wiring harness from Power Plant Frame (PPF).

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 11 © 2005 Mitchell Repair Information Company, LLC.

lubricant. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedure.
OVERHAUL
DIFFERENTIAL
Disassembly (Standard Type)
1. Mount carrier in Differential Carrier Hanger (49-M005-561). Mark side bearing caps for reassembly
reference. Remove adjuster lock plates (if equipped). See Fig. 10
.
2. Loosen side bearing cap bolts and slightly back off adjusters. Remove side bearing caps. Remove
differential assembly from carrier. Mark side bearing races for reassembly reference. Remove adjusters
and side bearing races from differential.
3. Remove drive pinion lock nut and washer. Remove companion flange using Puller (49-0839-425C).
Remove oil seal, spacer, front bearing and collapsible spacer from carrier. Remove drive pinion, spacer
and rear bearing assembly from carrier. Remove bearing races using a drift and hammer in slots provided
on inner lip (as necessary).
4. Remove ring gear retaining bolts. Separate ring gear from differential case. Mark side bearings for
reassembly reference. Using Puller (49-0839-425C), remove side bearings from differential case. Remove
knock pin. Remove pinion shaft, pinion
gears, thrust washers, and side gears. See Fig. 10. NOTE: Mark positions of all components before disassembly.
NOTE: Overhaul procedure for Limited Slip Differential (LSD) is not available.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Checking Drive Pinion Installation & Position
Courtesy of MAZDA MOTORS CORP.
6. Install dial indicator on Pinion Height Gauge (49-0727-570). Place pinion height gauge on a flat surface
and zero dial indicator. Position gauge block on top of dummy drive pinion assembly. See GAUGE
BLOCK SELECTION table.
GAUGE BLOCK SELECTION
7. Place pinion height gauge on top of gauge block. Position dial indicator to measure distance to a point
where side bearing sits. Measure lowest point. See Fig. 12
. Measure both sides. Add both measurements
together and divide by 2.
8. If result is not zero, replace pinion spacer. Spacers are available in a range of .1213-.1366" (3.080-3.470
mm) in .001" (.03 mm) increments. Remove dummy drive pinion. Press rear bearing onto drive pinion.
9. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential carrier.
DO NOT install pinion oil seal yet. DO NOT exceed one-ton force; collapsible spacer will be damaged.
10. Install washer and drive pinion lock nut. Temporarily tighten drive pinion lock nut. Turn companion
flange by hand to seat bearing. Using torque wrench, tighten drive pinion lock nut to specification. See
TORQUE SPECIFICATIONS
. Check pinion bearing preload at drive pinion lock nut. See PINION
PRELOAD SPECIFICATIONS table. If pinion bearing preload is not as specified, replace collapsible
spacer and recheck preload.
PINION PRELOAD SPECIFICATIONS
11. Remove drive pinion lock nut, washer and companion flange. Install pinion oil seal. Lubricate oil seal lip
with differential oil. Install companion flange and washer. Install NEW drive pinion lock nut and tighten
to specification. See TORQUE SPECIFICATIONS
. Recheck pinion bearing preload. Lubricate end of
companion flange with grease.
12. Position differential assembly into differential carrier. Install side bearing adjusters. Position side bearing
caps. Align marks made during disassembly. Install side bearing cap bolts and hand-tighten bolts.
13. Ti
ghten side bearing adjusters equally until adjusters contact bearing races. Mark ring gear in 4 locations,
ApplicationGauge Block No.
Front Differential
MPV
4WD49-0305-555
Rear Differential
Miata49-0305-555
MPV49-0660-555
ApplicationINCH Lbs. (N.m)
Miata7.8-12.1 (0.9-1.3)
MPV 2WD11.3-15.6 (1.3-1.8)
MPV 4WD
Front7.8-12.2 (0.9-1.4)
Rear11.3-15.6 (1.3-1.8)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 20 © 2005 Mitchell Repair Information Company, LLC.

90 degrees apart. Position dial indicator against ring gear to check ring gear backlash.
14. Check backlash at all 4 locations. Tighten side bearing adjusters equally until backlash is .0035-
.0043" (.09-.11 mm). Minimum backlash at any point is .002" (.05 mm). Difference between minimum
and maximum backlash should not exceed .0028" (.07 mm).
15. To set differential bearing preload, tighten adjusters equally until distance between measuring points on
carrier bearing caps is within specification. See Fig. 13
. See DIFFERENTIAL CARRIER
DIMENSIONS table.
16. Ensure backlash did not change when preload was set. Tighten side bearing cap bolts to specification. See
TORQUE SPECIFICATIONS. Check ring gear tooth patterns. See GEAR TOOTH CONTACT
PATTERNS article in GENERAL INFORMATION.
17. To complete reassembly, reverse disassembly procedure. Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS
.
DIFFERENTIAL CARRIER DIMENSIONS
Application(1) In. (mm)
Miata7.300-7.303 (185.43-185.50)
MPV 2WD8.022-8.050 (203.78-204.50)
MPV 4WD
Front7.275-7.303 (184.78-185.50)
Rear8.022-8.050 (203.78-204.50)
(1)See illustration for measuring point. See Fig. 13 .

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Measuring Carrier Case Spread
Courtesy of MAZDA MOTORS CORP.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (MIATA)
ApplicationFt. Lbs. (N.m)
Differential Carrier Bearings Cap Bolts28-38 (38-52)
Differential Carrier Bearings Lock Plate Bolt13-18 (18-25)
Differential Carrier-To-Housing Bolts17-19 (23-26)
Differential-To-Chassis Mount Nuts
Inner Nut61-72 (83-98)
Outer Nuts (2)13-20 (18-27)
Drive Axle Inner CV Joint Flange Nuts40-47 (54-64)
Drive Pinion Lock Nut94-209 (128-284)
Drive Shaft Companion Flange Nuts20-22 (27-30)
Exhaust Pipe Mount Nuts30-41 (40-55)
Filler Plug29-40 (39-54)
Power Plant Frame Bracket
To-Power Plant Frame Bolt (M/T)77-91 (104-123)
To-Transmission Bolts (M/T)27-40 (37-54)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.