wheel MAZDA MIATA 1991 Factory Workshop Manual

Raise and support vehicle. Remove rear wheels. Remove brake rotor. Remove upper and lower return springs.
See Fig. 21
. Remove hold-down springs and pins. Remove parking brake shoes. Separate adjuster and
operating lever. Minimum lining thickness is .04" (1 mm).
Fig. 21: Exploded View of Parking Brake Assembly (929)

Courtesy of MAZDA MOTORS CORP.
Installation
Connect operating lever to parking brake cable. Set marked side (with arrow) of operating lever to front side.
Position shoes and adjuster. Ensure threaded side of adjuster faces forward on left wheel and rearward on right
wheel. To complete installation, reverse removal procedure. Adjust parking brake. See PARKING BRAKE
under ADJUSTMENTS
at beginning of article.
REAR AXLE BEARING & OIL SEAL
Removal (B2200 & B2600i)
1. Remove wheel and brake drum. Disconnect parking brake cable and brake line. Remove backing plate
bolts. Remove backing plate and rear axle assembly. Remove axle bearing lock nut using Holder (49-
NOTE: For information on models with sealed wheel bearings, see appropriate article
in the SUSPENSION Section.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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S120-645A) and Wrench (49-0603-635A).
2. Using Puller (49-S120-520A) and Adapter (49-S120-523A), remove rear axle bearings. Remove oil seal
from axle housing.
Installation
1. Install oil seal in axle housing. Install bearing inner race. Install and position oil seal flush with end of
axle casing. Apply multipurpose grease to oil seal lip. Install spacer with concave side facing backing
plate.
2. Press axle bearing onto axle shaft. Using wrench, install and tighten lock nut to 145-217 ft. lbs. (197-295
N.m). Install axle shaft assembly. Install backing plate. Reconnect brake line and parking brake cable.
Install brake drum and wheel. Bleed brake system.
MASTER CYLINDER
Removal
1. Disconnect fluid level sensor coupler (if equipped). Disconnect and plug hydraulic lines at master
cylinder to prevent entry of dirt and loss of fluid.
2. Remove nuts attaching master cylinder to firewall or power brake unit. Remove master cylinder from
vehicle. On RX7, remove proportioning valve by-pass bolt.
Installation
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 it on power brake unit. Adjust push rod on power brake unit until there is
no clearance between push rod and adjuster gauge screw. Install master cylinder. Bleed hydraulic system.
POWER BRAKE UNIT
Removal & Installation
1. Remove master cylinder from power brake unit. See MASTER CYLINDER under REMOVAL &
INSTALLATION . Disconnect vacuum line at power brake unit. From inside vehicle, remove cotter pin
and clevis pin. Separate push rod from brake pedal.
2. Remove power brake unit-to-firewall nuts. Remove power brake unit. See Fig. 22
To install, reverse
removal procedure. Bleed hydraulic system. NOTE: Left wheel lock nut has left-hand threads.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
Rotor-To-Hub Bolt
B2200 & B2600i40-51 (54-69)
MX-6 & 62636-43 (49-58)
32333-40 (45-54)
Wheel Bearing Lock Nut
B2200 & B2600i (Rear)145-217 (197-295)
323 (Front)116-174 (158-237)
Wheel Lug Nut
B2200 & B2600i
Standard Wheel65-87 (88-118)
Styled Wheel87-108 (118-147)
Navajo85-115 (115-155)
All Others65-87 (88-118)
INCH Lbs. (N.m)
Parking Brake Cable Lock Nut
B2200 & B2600i60-84 (7-10)
All Others168-252 (19-29)
Wheel Cylinder Mounting Bolt
B2200 & B2600i 2WD108-144 (12-16)
B2600i 4WD180-216 (20-24)
Except B2200, B2600i & Navajo (2) 84-108 (10-12)
(1)These bolts secure caliper directly to steering knuckle. On Protege, tighten to 29-36 ft. lbs. (39-49
N.m). On RX7, tighten to 58-72 ft. lbs. (78-98 N.m).
(2)Information is not available from manufacturer for Navajo.
ApplicationIn. (mm)
B2200 & B2600i 2WD Front (1)
Original Thickness.79 (20)
Discard Thickness.71 (18)
B2600i 4WD Front (1)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Miata
Front (2)
Original Thickness.71 (18)
Discard Thickness.63 (16)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS
.71 (18)
Discard Thickness.63 (16)
(1)Maximum lateral runout is .006" (.15 mm).
(2)Maximum lateral runout is .004" (.10 mm).
(3)Maximum lateral runout is .003" (.08 mm).
ApplicationIn. (mm)
B2200 & B2600i
Drum Diameter
Original10.24 (260.0)
Minimum10.30 (261.5)
Wheel Cylinder Bore Diameter
B2200 & B2600i 2WD0.750 (19.05)
B2600i 4WD0.688 (17.46)
MPV
Drum Diameter
Original10.24 (260)
Minimum10.30 (261.5)
Wheel Cylinder Bore Diameter0.690 (17.50)
MX-6 & 626
Drum Diameter
Original9.00 (228.6)
Minimum9.06 (230.1)
Wheel Cylinder Bore Diameter0.875 (22.22)
Navajo
Drum Diameter
Original
9"9.00 (228.6)
10"10.00 (254.0)
Minimum
9"9.09 (230.8)
10"10.09 (256.3)
Protege & 323
Drum Diameter
Original9.00 (228.6)
Minimum9.04 (229.6)
Wheel Cylinder Bore Diameter0.875 (22.22)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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DIFFERENTIAL CAPACITY SPECIFICATIONS (1)
FLUID TYPE
DIFFERENTIAL LUBRICATION SPECIFICATIONS
(1)
TROUBLE SHOOTING
See TROUBLE SHOOTING - BASIC PROCEDURES article in the TROUBLE SHOOTING Section.
REMOVAL & INSTALLATION
REAR AXLE SHAFTS & BEARINGS
Removal (B2200 & B2600i)
1. Raise and support vehicle. Remove rear wheels. Remove brake drum and shoes. Using a dial indicator,
measure axle flange lateral movement. If bearing play is not within specification, bearing shim must be
adjusted during installation. See END PLAY SPECIFICATIONS
.
2. Disconnect brake line from wheel cylinder. Plug line openings. Disconnect parking brake cable. Remove
backing plate retaining nuts. Remove axle shaft and backing plate as an assembly.
ApplicationQts. (L)
B2200 (Front & Rear)1.3 (1.2)
B2600i
Front1.6 (1.5)
Rear1.8 (1.7)
Miata.69 (.65)
MPV 2WD1.6 (1.5)
MPV 4WD
Front1.8 (1.7)
Rear1.6 (1.5)
Protege 4WD.69 (.65)
RX7
Non-Turbo1.4 (1.3)
Turbo1.5 (1.4)
9291.4 (1.3)
(1)Fill to lower edge of filler plug hole.
ApplicationSpecification
Above 0°F (-18°C)GL-5/SAE 90W
Below 0°F (-18°C)GL-5/SAE 80W
(1)Fill to lower edge of filler plug hole.

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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3. Using Bearing Nut Wrench (49 0603 635A ) and Shaft Holder (49 S120 645A ), remove bearing lock nut
from axle shaft. Remove bearing and bearing retainer from axle using Puller (49 S120 520A ). Remove
outer race from hub.
END PLAY SPECIFICATIONS
(1)
Installation
1. Press new oil seal and bearing outer race into bearing retainer. Coat bearing race and outer seal with
grease. Tap inner oil seal flush with end of axle housing. Coat inner seal lip with grease.
2. Position brake backing plate onto axle shaft. Install spacer against backing plate with chamfer facing
backing plate. Using Press Attachment (49 S120 748 ) and a press, install wheel bearing onto axle shaft.
Standard press force is 4.6-6.7 tons (4200-6100 kg). If press fit force is too high or too low, replace the
bearing collar or shaft.
3. Using Bearing Nut Wrench (49 0603 635A ), install bearing lock nut to axle shaft and tighten to 145-217
ft. lbs. (196-245 N.m). Bend tab up into groove. Install one axle shaft into axle housing. Tighten backing
plate nuts to specification. Install dial indicator on backing plate and check drive axle end play.
4. To adjust end play, remove axle and insert appropriate size adjustment shim between axle hub and
housing. End play for second drive axle installed should be set to normal end play clearance of .002-
.010" (.05-.25 mm), with both axles installed.
5. Install parking brake cable, attaching pin and brake line. Install brake shoes and actuating hardware.
Bleed brake system. Install wheel and tire.
BEARING RETAINER SHIMS (B2200 & B2600i)
MPV 4WD
NOTE: On B2200 and B2600i, left axle bearing lock nut has left-hand threads.
ApplicationIn. (mm)
B2200 & B2600i
One Axle Installed.026-.037 (.65-.95)
Both Axles Installed.002-.010 (.05-.25)
(1)Check at axle flange with dial indicator.
NOTE: Ensure end play for first drive axle is within specification before inserting
second drive axle. Use shims to adjust end play if necessary.
Part NumberThickness In. (mm)
083 26 165.004 (.10)
083 26 166.006 (.15)
083 26 167.020 (.50)
083 26 168.030 (.75)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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1. Raise and support vehicle. Remove rear wheels. Remove brake drum and shoes. Using a dial indicator,
measure axle flange lateral movement. Replace bearing if play exceeds If bearing play exceeds .023" (.57
mm). Disconnect brake line from wheel cylinder. Plug line openings. Disconnect parking brake cable.
2. Remove backing plate retaining nuts. Remove axle shaft and backing plate as an assembly. Use puller or
slide hammer to pull axle and bearing from axle housing. With axle removed, remove retaining ring and
bearing collar. See Fig. 1
.
Fig. 1: Exploded View of Rear Drive Axle (MPV; Others Similar)

Courtesy of MAZDA MOTORS CORP.
3. To remove bearing collar, grind collar until a section of it is .020" (.5 mm) and cut through it with a
chisel. Use a puller or press to remove bearing and brake backing plate. Check axle shaft for straightness.
Maximum runout is .059" (1.5 mm).
4. Use a press to replace wheel studs (if necessary), never use a previously used wheel stud as a
replacement. Lubricate seal lips before replacement. DO NOT lubricate bearing retainer collar before
replacement. Use a press to install bearing collar. If press-fit of collar requires less than 2.7 tons (2699
kg.) replace collar or axle shaft. Reverse removal procedures to complete installation.
DIFFERENTIAL ASSEMBLY

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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Removal (Front - B2600i & MPV 4WD)
1. Raise and support vehicle. Remove engine skid plate. Drain differential. On MPV 4WD, remove tie rod
end and lower arm. Remove front axle shafts. See AXLE SHAFTS
- FRONT article. Mark drive shaft
position, and remove drive shaft.
2. On B2600i, remove differential subframe mounting bolts and nuts. Remove differential, Remote Free
Wheel (RFW) and subframe assembly from vehicle. Remove RFW assembly from right side of
differential housing. Pull drive coupler from carrier. Remove differential carrier retaining bolts. Remove
differential carrier.
3. On MPV 4WD, remove differential housing mounting bolts and mount at end of Remote Free Wheel
(RFW) extension housing. Remove differential and extension housing from vehicle. Remove RFW
assembly from right side of differential housing. Pull drive coupler from carrier. Remove differential
carrier retaining bolts. Remove differential carrier.
Installation
To install, reverse removal procedure. See Fig. 2 or Fig. 3 . Apply Sealant (8527 77 739 ) to carrier mating
flange. Align marks made during removal. Refill differential with lubricant. Tighten all fasteners to
specification. See TORQUE SPECIFICATIONS
.

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
Microsoft
Sunday, July 05, 2009 2:17:01 PMPage 5 © 2005 Mitchell Repair Information Company, LLC.

1991 TORQUE SPECIFICATIONS (B2200 & B2600i)
1990 TORQUE SPECIFICATIONS (MIATA)
Splash Shield23-34 (31-46)
Rear Drive Axle
Axle Bearing Lock Nut145-217 (197-294)
Backing Plate Bolt
2WD72-87 (98-118)
4WD65-80 (88-109)
Drive Shaft Companion Flange20-22 (27-30)
Wheel Lug Nuts
Standard Wheel65-87 (88-118)
Styled Wheel87-108 (118-146)
ApplicationFt. Lbs. (N.m)
Brake Pipe Union10-16 (14-22)
Differential Carrier-To-Housing Nuts17-20 (23-27)
Differential Carrier Bearings Cap Bolts
"P" Series Differential41-59 (56-80)
"M" Series Differential27-38 (37-52)
Differential Carrier Bearings Lock Plate Bolt13-19 (18-26)
Drive Pinion Lock Nut94-210 (127-284)
Drive Shaft Companion Flange Nuts20-22 (27-30)
Filler Plug29-40 (39-54)
Front Subframe Mounting Bolts69-85 (94-115)
Rear Axle Bearing Lock Nut145-217 (197-294)
Rear Backing Plate Bolt
2WD72-87 (98-118)
4WD65-80 (88-109)
Ring Gear Retaining Bolts51-61 (69-83)
Splash Shield Bolts23-34 (31-46)
Wheel Lug Nuts
Standard Wheel65-87 (88-118)
Styled Wheel87-108 (118-146)
ApplicationFt. Lbs. (N.m)
Differential Assembly
Differential Carrier-to-Housing17-20 (23-27)
Differential Carrier Bearings Cap Bolts50-66 (68-90)
Differential Carrier Bearings Lock Tab14-19 (19-26)
Differential Case Rear Mounts
Drive Pinion Lock Nut87-130 (118-176)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
Microsoft
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1991 TORQUE SPECIFICATIONS (MIATA)
1990 TORQUE SPECIFICATIONS (MPV 4WD)
Inner Nut61-72 (83-98)
Outer Nuts (2)13-20 (18-26)
Filler Plug29-40 (39-54)
Ring Gear Retaining Bolts51-61 (69-83)
Power Plant Frame-to-Differential Mounting
Spacer Bolt (Short)27-38 (37-52)
PPF-to-Differential Side Mounting Bolts (Long)77-91 (104-123)
PPF-to-PPF Bracket Bolt27-40 (37-54)
Power Plant Frame-to-Transmission
Side Mounting Bolts (Long)77-91 (104-123)
Transmission-to-PPF Bracket Bolts27-40 (37-54)
ApplicationFt. Lbs. (N.m)
Differential Carrier-To-Housing Nuts17-20 (23-27)
Differential Carrier Bearings Cap Bolts27-38 (37-52)
Differential Carrier Bearings Lock Plate Bolt13-19 (18-26)
Differential Case Rear Mount Nuts54-69 (73-94)
Drive Pinion Lock Nut87-130 (118-176)
Inner Nut61-72 (83-98)
Outer Nuts (2)13-20 (18-26)
Drive Shaft Companion Flange Nuts20-22 (27-30)
Filler Plug29-40 (39-54)
Ring Gear Retaining Bolts51-61 (69-83)
Power Plant Frame-To-Differential Mounting
Spacer Bolt (Short)27-38 (37-52)
PPF-To-Differential Bolts
Side Mounting Bolts (Long)77-91 (104-123)
PPF-To-PPF Bracket Bolt27-40 (37-54)
Power Plant Frame-To-Transmission
Side Mounting Bolts (Long)77-91 (104-123)
Transmission-To-PPF Bracket Bolts27-40 (37-54)
Wheel Lug Nuts65-87 (88-118)
ApplicationFt. Lbs. (N.m)
Brake Pipe Union10-16 (14-22)
Differential Assemblies
Differential Carrier Bearings Cap Bolts
Front Differential27-38 (37-52)
Rear Differential54-79 (73-107)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
Microsoft
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