lock MAZDA MIATA 1991 Factory Manual PDF

Fig. 7: Removing Reamer Bolt Sleeve (Miata)
Courtesy of MAZDA MOTORS CORP.
OVERHAUL
DIFFERENTIAL HOUSING & DRIVE PINION
Disassembly
1. Mount carrier in repair stand. Mark side bearing caps for reassembly purposes. Remove adjuster lock
plates. See Fig. 8
.
2. Loosen side bearing and slightly back off adjusters. Remove bearing caps and adjusters. Withdraw
differential assembly from carrier. Ensure side bearing races remain with their respective bearings.
3. Remove drive pinion lock nut. Remove companion flange using a gear puller. Remove drive pinion,
spacer, rear bearing and collapsible spacer assembly from carrier. Remove oil seal and front bearing.
NOTE: Mark position of all components before disassembly.

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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reassembly purposes. Separate ring gear from gear case. On standard differentials, remove knock pin.
Remove pinion shaft, pinion gears, thrust washers and side gears. See Fig. 8
.
2. On Limited Slip Differentials (LSD) models, gradually loosen attaching screws until distance between
left and right half of differential case is about 0.12" (3 mm). On all models, mark differential halves for
reassembly reference.
3. Carefully separate differential halves. On LSD models, remove thrust washer, conical springs, friction
plates, friction discs, pressure ring, side gears, carrier pinion (spider) gears and spider. See Fig. 9
. Keep
parts in order for reassembly.
Fig. 9: View of Limited Slip Differential (LSD) Assembly (RX7)

Courtesy of MAZDA MOTORS CORP.
STANDARD DIFFERENTIAL
Reassembly & Adjustment
1. Install side gears, thrust washers, thrust block, pinion gears, pinion shaft and knock pin. Stake knock pin.
Press side bearings onto differential assembly. Position a dial indicator against pinion gear. Secure one
side gear. See Fig. 10
.
2. Check side gear and pinion gear backlash. If backlash exceeds .004" (.10 mm), replace thrust washers.
Apply locking compound to rear face of ring gear. Install ring gear and tighten ring gear retaining bolts to
51-61 ft. lbs. (69-83 N.m). See CARRIER PINION THRUST WASHER SPECIFICATIONS
.

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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Sunday, July 05, 2009 2:17:01 PMPage 14 © 2005 Mitchell Repair Information Company, LLC.

4. Subtract thickness from 3.701" (94.00 mm). Difference should be .004-.016" (.10-.40 mm). If clearance is
not as specified, install oversize thrust washers. See RX7 DIFFERENTIAL SPECIFICATIONS
.
5. Install parts in proper order. See Fig. 8
. Before installing thrust washers, coat with grease. When
installing conical springs, ensure concave side faces side gears. Align differential case and cover
alignment marks. Apply locking compound to rear face of ring gear. Install ring gear and tighten ring gear
retaining bolts to 51-61 ft. lbs. (69-83 N.m).
RX7 DIFFERENTIAL SPECIFICATIONS (LIMITED SLIP)
Pinion Assembly (B2200, B2600i, Miata, Protege 4WD & 929)
1. Using a press, install pinion bearing races in differential housing. Place original spacer, rear bearing and
Bearing Collar (49 H027 001 ) onto Drive Pinion (49 8531 565 ). Secure collar with "O" ring. Install
assembly into differential housing.
2. Install front bearing, Collar (49 8531 567 on 929 or 49 U027 001 on B2200 and B2600i), companion
flange, washer and original drive pinion nut. See Fig. 11
. Tighten flange nut so assembly can be turned
by hand.
3. Place a 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 Drive Pinion (49 F027 001 ). See GAUGE
BLOCK SELECTION .
GAUGE BLOCK SELECTION
ApplicationIn. (mm)
Friction Disc Thickness
Standard.079 (2.0)
Limit.075 (1.9)
Friction Plate
Standard.079 (2.0)
Limit.075 (1.9)
Oversize.083 (2.1)
Thrust Washer
Standard.063 (1.6)
Limit.055 (1.4)
Oversize.071 (1.8)
ApplicationUse Gauge Block No.
Front Differential
B2600i
& MPV
4WD49 0305 555
Rear Differential
B220049 0305 555
B2600i,
Protege 49 0660 555

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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Sunday, July 05, 2009 2:17:01 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to a point where
side bearing sits. Measure lowest point. See Fig. 11
. Measure both sides. Add both measurements
together and divide sum by 2.
5. If measurement is not zero, replace pinion spacer. Spacers are available in a range of .1213-
.1366" (3.081-3.470 mm), in .001" (.03 mm) increments. Remove dummy pinion shaft. Press rear pinion
bearing on pinion shaft.
6. Install pinion shaft, spacer, front bearing, collapsible spacer and companion flange in differential housing.
DO NOT install pinion seal at this time. DO NOT exceed one ton force or collapsible spacer will be
damaged.
7. Temporarily tighten drive pinion nut. Turn companion flange by hand to seat bearing. Tighten drive
pinion nut to 94-130 ft. lbs. (128-177 N.m). Check pinion bearing preload, at drive pinion nut. See
PINION PRELOAD SPECIFICATIONS
. If pinion bearing preload is not as specified, replace
collapsible spacer and recheck preload.
8. Remove drive pinion nut and companion flange. Install pinion seal. Apply oil to seal lip. Install
companion flange. Using a new drive pinion nut, tighten nut to 94-130 ft. lbs. (128-177 N.m). Recheck
pinion bearing preload.
PINION PRELOAD SPECIFICATIONS
4WD &
929
Miata49 N027 001
ApplicationINCH lbs. (N.m)
B2200 & 92911.3-15.6 (1.3-1.8)
B2600i 4WD
Front11.3-15.6 (1.3-1.8)
Rear7.8-12.2 (0.9-1.4)
Miata & Protege 4WD (Rear)2.6-6.1 (0.3-0.7)
MPV 4WD
Front7.8-12.2 (0.9-1.4)
Rear11.3-15.6 (1.3-1.8)
RX7
Non-Turbo7.8-12.1 (0.9-1.4)
Turbo11.3-15.6 (1.3-1.8)

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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Sunday, July 05, 2009 2:17:01 PMPage 17 © 2005 Mitchell Repair Information Company, LLC.

Fig. 11: Checking Pinion Installation & Position
Courtesy of MAZDA MOTORS CORP.
Pinion Assembly (RX7)
1. Using a press, install rear pinion bearing outer race in differential housing. Install center bearing outer
race. Using original rear bearing spacer, install rear bearing on Setting Pinion (49 F027 001 ).
2. Position drive pinion in carrier and install center bearing, long collar and companion flange. Tighten
pinion nut just enough so pinion can be turned by hand.
3. Place a dial indicator on Pinion Height Gauge (49 0727 570 ). Place pinion height gauge on a flat surface
and zero dial indicator. Position Gauge Block (49 0305 555 ) on top of Setting Pinion (49 F027 001 ).
4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to lowest point
where side bearing sits. See Fig. 11
. Measure both sides. Add both measurements together and divide
sum by 2.
5. If measurement is not zero, replace pinion spacer. Spacers are available in a range of .1213-
.1366" (3.081-3.470 mm) in .001" (.03 mm) increments. Remove setting pinion, select spacer and press
rear pinion bearing on drive pinion shaft.
6. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential
housing. DO NOT install pinion seal yet. Press center bearing onto drive pinion using Adapter (49 1243
465A ). DO NOT exceed one-ton force or collapsible spacer will be damaged. Two different collapsible
spacers are available, ensure correct one is used.
RX7 DRIVE PINION COLLAPSIBLE SPACERS
7. Lubricate ends of long collar with grease and install. Using a press, install front bearing using Adapter
(49 F027 009 ). Press fit with a 2-3 ton force. DO NOT install oil seal yet. Install companion flange and
nut. Tighten drive pinion nut to 94 ft. lbs. (128 N.m). Turn companion flange by hand to seat bearing.
8. Pinion bearing preload at drive pinion nut should be 11.3-15.6 INCH lbs. (1.3-1.8 N.m). Adjust preload
by tightening drive pinion nut. If correct preload cannot be obtained within drive pinion nut tightening
range of 94-210 ft. lbs. (128-284 N.m), replace collapsible spacer and recheck preload.
9. Remove drive pinion nut and companion flange. Install pinion seal. Apply oil to seal lip. Install
companion flange. Using a new drive pinion nut, tighten nut to specification established for correct
preload.
Carrier Assembly (All Models)
1. Position differential assembly into differential housing. Install side bearing adjusters. Position side
bearing caps. Align marks made during disassembly. Install side bearing cap bolts. DO NOT tighten yet.
2. Tighten side bearing adjusters equally until adjuster contact bearing races. Mark ring gear in 4 locations,
90 degrees apart. Position a dial indicator against ring gear to check ring gear backlash.
3. Check backlash at all 4 locations. Ti
ghten side bearing adjusters equally until backlash is .0035-
ApplicationLength In. (mm)
Non-Turbo1.923-1.935 (48.85-49.15)
Turbo2.238-2.250 (56.85-57.15)

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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Sunday, July 05, 2009 2:17:01 PMPage 19 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Measuring Carrier Case Spread
Courtesy of MAZDA MOTORS CORP.
TORQUE SPECIFICATIONS
1990 TORQUE SPECIFICATIONS (B2200 & B2600i)
ApplicationFt. Lbs. (N.m)
Brake Pipe Union10-16 (14-22)
Differential Assembly
Differential Carrier-to-Axle Housing17-20 (23-27)
Differential Carrier Bearings Cap Bolts
"P" Series Differential41-59 (56-80)
"M" Series Differential27-38 (37-52)
Differential Carrier
Bearings Lock Tab13-19 (18-26)
Drive Pinion Lock Nut94-130 (127-176) 90
Filler Plug29-40 (39-54)
Ring Gear Retaining Bolts51-61 (69-83)
Front Suspension & Differential
Drive Shaft Companion Flange20-22 (27-30)
Sub-Frame Mounting Bolts69-85 (94-115)

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 21 © 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
Sunday, July 05, 2009 2:17:01 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.

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
Sunday, July 05, 2009 2:17:01 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.

1991 TORQUE SPECIFICATIONS (MPV)
1990 TORQUE SPECIFICATIONS (PROTEGE 4WD)
Differential Carrier Bearings Lock Tab13-19 (18-26)
Differential Carrier-to-Housing17-20 (23-27)
Drive Pinion Lock Nut94-210 (127-285)
Filler Plug29-40 (39-54)
Ring Gear Retaining Bolts51-61 (69-83)
Front Axle Components
Differential-to-Chassis Mounts49-72 (66-98)
Drive Shaft Companion Flange36-43 (49-58)
Extension Housing-to-Differential Housing27-40 (36-54)
Lower Ball Joint-to-"A" Frame75-101 (102-137)
Splash Shield12-17 (16-23)
Rear Axle Components
Axle Bearing Retainer Nuts72-87 (98-118)
Brake Drum Retaining Screws10-11 (14-15)
Drive Shaft Companion Flange36-43 (49-58)
ApplicationFt. Lbs. (N.m)
Brake Pipe Union10-16 (14-22)
Differential-To-Chassis Mount Nuts (4WD)49-72 (66-98)
Differential Carrier Bearings Cap Bolts
Front Differential27-38 (37-52)
Rear Differential54-79 (73-107)
Differential Carrier Bearings Lock Plate Bolt13-19 (18-26)
Differential Carrier-To-Housing Nuts17-20 (23-27)
Drive Pinion Lock Nut94-210 (127-285)
Drive Shaft Companion Flange Nuts36-43 (49-58)
Filler Plug29-40 (39-54)
Lower Ball Joint-To-Control Arm Bolts (4WD)75-101 (102-137)
Lower Ball Joint-To-Control Arm Nut (4WD)94-127 (128-172)
Rear Axle Bearing Retainer Nuts72-87 (98-118)
Rear Brake Drum Retaining Screws7-11 (10-15)
RFW Extension Housing Mount Nut (4WD)149-72 (66-98)
Ring Gear Retaining Bolts51-61 (69-83)
Splash Shield Bolts (4WD)12-17 (16-23)
Tie Rod End Nut (4WD)43-58 (59-78)
Wheel Lug Nuts65-87 (88-118)
ApplicationFt. Lbs. (N.m)
Differential Assembly

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 24 © 2005 Mitchell Repair Information Company, LLC.

1991 TORQUE SPECIFICATIONS (PROTEGE 4WD)
1990-91 TORQUE SPECIFICATIONS (RX7)
Differential Carrier Bearing Cap Bolts27-38 (37-52)
Differential Carrier Bearing Lock Tab14-19 (19-26)
Differential Carrier-to-Housing17-20 (23-27)
Differential Case
Front Mounts33-50 (45-68)
Rear Mounts80-97 (109-132)
Drive Pinion Lock Nut87-130 (118-176)
Filler Plug29-40 (39-54)
Ring Gear Retaining Bolts51-61 (69-83)
Suspension & Mounts
Drive Axle Inner CV Joint Nut40-47 (54-64)
Drive Shaft Companion Flange20-22 (27-30)
Front Mount33-50 (45-68)
Lateral Link46-55 (62-75)
Rear Mount80-97 (109-132)
Stabilizer Bar10-13 (14-18)
Trailing Link69-86 (94-117)
Wheel Lug Nuts65-87 (88-118)
ApplicationFt. Lbs. (N.m)
Differential Carrier Bearing Cap Bolts27-38 (37-52)
Differential Carrier Bearing Lock Plate Bolt13-19 (18-26)
Differential Carrier-To-Housing Nuts17-20 (23-27)
Differential Case
Front Mounts39-47 (53-63)
Rear Mounts68-86 (93-116)
Drive Axle Inner CV Joint Nut40-47 (54-64)
Drive Pinion Lock Nut87-130 (118-176)
Drive Shaft Companion Flange Nuts20-22 (27-30)
Filler Plug29-40 (39-54)
Lateral Link Bolts46-55 (62-75)
Ring Gear Retaining Bolts51-61 (69-83)
Stabilizer Bar Bolts31-43 (43-58)
Trailing Link Bolts68-93 (93-126)
Wheel Lug Nuts65-87 (88-118)
ApplicationFt. Lbs. (N.m)
Differential Carrier-to-Housing17-20 (23-27)
Differential Carrier

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 25 © 2005 Mitchell Repair Information Company, LLC.