boot MAZDA MIATA 1991 Factory Service Manual

1990-93 DRIVE AXLES
Axle Shafts - MX-5 Miata
DESCRIPTION
The axle shaft is a double offset, constant velocity joint type.
TROUBLE SHOOTING
Check dust boot on axle shaft for cracks, damage, leaking grease, and loose boot bands. Check axle shaft for
bending, cracks, and wear of joints or splines. Repair or replace axle shaft if necessary.
REMOVAL & INSTALLATION
AXLE SHAFTS
Removal
1. Raise vehicle and support with safety stands. Remove wheel and tire assembly. See Fig. 1 . Loosen axle
shaft lock nut until flush with end of axle shaft. Mark differential and axle shaft flanges for installation
reference. See Fig. 2
. Remove axle shaft flange nuts. NOTE: See TROUBLE SHOOTING
- BASIC PROCEDURES article in GENERAL
INFORMATION.
NOTE: Manufacturer recommends using new axle shaft lock nut during
installation.

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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Fig. 4: Installing Axle Shaft Lock Nut
Courtesy of MAZDA MOTORS CORP.
OVERHAUL
AXLE SHAFTS
Disassembly
1. Place axle shaft assembly in soft-jawed vise. Keep axle shaft assembly clean during disassembly and
reassembly. To remove boot bands, pry up locking clip by using a screwdriver, then raise end of band.
See Fig. 5
.
NOTE: Before disassembling axle shaft, verify that joint moves smoothly. If a problem
is found, repair parts or replace axle shaft.
NOTE: DO NOT wash joint unless it is being disassembled.

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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Fig. 5: Removing Boot Band
Courtesy of MAZDA MOTORS CORP.
2. Mark axle shaft and outer ring with paint as shown. See Fig. 6
. Using a screwdriver, remove clip. Mark
axle shaft end and inner ring with paint as show. See Fig. 7
. Remove snap ring by using snap ring pliers.
See Fig. 8
.

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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Fig. 9: Removing Balls From Inner Ring
Courtesy of MAZDA MOTORS CORP.
4. Turn cage approximately 30 degrees and pull it away from inner ring. See Fig. 10
. Wrap shaft splines
with tape and remove boot. See Fig. 11
.

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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Fig. 11: Removing CV Joint Boot
Courtesy of MAZDA MOTORS CORP.
Reassembly
1. To reassemble, reverse disassembly procedure. Wrap tape around drive axle shaft ends before sliding CV
joint boots onto drive axle shaft. See Fig. 13
.
2. Align marks on cage and inner ring. Install balls to inner ring. Install cage, inner ring and ball assembly to
axle shaft in direction shown. See Fig. 14
. Larger diameter of cage should be facing snap ring groove.
CAUTION: When reassembling axle shaft, ensure to install cage with larger diameter
facing snap ring groove. If incorrectly installed, axle shaft may become
disengaged.
NOTE: Inner and outer CV joint boots differ in design and/or diameter. Ensure correct
boot is installed at proper end when reassembling axle shaft. See Fig. 12
. See
REAR AXLE SHAFT BOOT IDENTIFICATION
.

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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Fig. 12: Measuring Axle Shaft & Identifying Boots
Courtesy of MAZDA MOTORS CORP.
Fig. 13: Installing CV Joint Boot

Courtesy of MAZDA MOTORS CORP.

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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Sunday, July 05, 2009 2:16:33 PMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Fig. 14: Installing Balls In To Inner Ring
Courtesy of MAZDA MOTORS CORP.
3. Install a NEW snap ring in axle shaft snap ring groove. Apply specified amount of grease to joints and
boots. See LUBRICATION SPECIFICATION
table. Aling marks and install NEW clip.
LUBRICATION SPECIFICATION
4. Ensure that boots are not dented or twisted. Set axle shaft to standard length. See AXLE SHAFT
LENGTH table. Release any trapped air from boots by carefully lifting up small end of each boot with a
cloth-wrapped screwdriver. See Fig. 15
. Ensure that axle shaft length is within standard. If drive shaft
length is not within standard, repeat this step.
ApplicationQuantity
Wheel Side CV Joint Boot1.9-2.7 oz. (55-75 g)
Differential Side CV Joint Boot2.7-3.4 oz. (75-95 g)

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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Fig. 16: Installing Boot Band
Courtesy of MAZDA MOTORS CORP.
AXLE SHAFT LENGTH
REAR AXLE SHAFT BOOT IDENTIFICATION
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationIn. (mm)
1990
On Vehicle25.96 (659.3)
Off Vehicle25.97-26.37 (695.7-669.7)
1991-93
On Vehicle25.87 (657)
Off Vehicle25.30-26.68 (642.6-677.7)
ApplicationIn. (mm)
Wheel Side Diameter3.58 (90.8)
Differential Side Diameter3.44 (87.4)

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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LOWER CONTROL ARM
Removal
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield (if equipped). Remove
stabilizer bar from lower control arm. Remove strut rod (if equipped). Remove ball joint clamp bolt or pivot
nut, and separate ball joint from steering knuckle. Remove lower control arm pivot bolts. Remove lower control
arm.
Inspection
Check lower control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check
ball joint for excessive wear. Examine dust boot for damage. Replace parts as necessary.
Bushing Replacement (Miata)
Cut or press old bushing from control arm. Coat new bushing with paraffin-based oil. Press new bushing into
control arm. To install, reverse removal procedure.
Bushing Replacement (MPV 4WD)
Cut away bushing inner collar. Using a vise and Remover/Installer (49-G033-102 and 49-FO27-009), push out
front bushing. Press out rear bushing using a press and Remover/Installer (49-U034-202 and 49-GO26-103). To
install front bushing, apply soapy water to bushing and use remover/installer to press in. To install rear bushing,
align arrows on bushing with marks on lower arm and use remover/installer to press in.
Bushing Replacement (MX-6 & 626)
Cut away bushing inner collar. Using a vise and Remover/Installer (49-GO34-2A0), push out bushing. To
install, apply soapy water to bushing and use remover/installer to press in. Always install bushing from outer
side of arm. Press in bushing until collar contacts arm.
Bushing Replacement (Protege & 323)
Using a vise and Remover/Installer Set (49-BO34-2A0), push out bushing. To install, apply soapy water to
bushing and use remover/installer to press in. Always install bushing from outer side of arm. Press in bushing
until collar contacts arm.
Bushing Replacement (929)
Cut away bushing outer collar. Using a vise and Remover/Installer (49-HO34-202 and 49-HO34-201), remove
bushing from control arm. To install, reverse removal procedure.
Bushing Replacement (RX7)
NOTE: Lower control arm bushings are not replaceable on MPV 2WD models. Replace
control arm assembly if bushings are worn or damaged.

1991 Mazda MX-5 Miata
SUSPENSION - FRONT 1990-91 SUSPENSION Front
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Push out front bushing using a press and Remover (49-G030-627A). To remove rear bushing, install Bearing
Puller (49-0710-520) on bushing. DO NOT overtighten bearing puller nuts or lower arm will be distorted and
damaged. Press to push out rear bushing using Remover (49-G030-627A). To install both bushings, use
remover and Support Block (49-0823-146).
Installation (All Models)
To install, reverse removal procedure. Tighten lower control arm pivot bolts to specification with vehicle
resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS
.
UPPER CONTROL ARM
Removal (Miata)
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove ball joint pivot nut.
Use Puller (49-0118-850C) to separate ball joint from steering knuckle. Remove upper control arm pivot bolts.
Remove upper control arm.
Inspection
Check upper control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check
ball joint for excessive wear. Examine dust boot for damage. Replace parts as necessary.
Bushing Replacement
Using a chisel, remove old bushing from control arm. Coat new bushing with grease. Press new bushing into
control arm.
Installation
To install, reverse removal procedure. Tighten upper control arm pivot bolts to specification with vehicle
resting on ground and suspension unloaded.
SHOCK ABSORBER
Removal (Miata)
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove stabilizer link bolt.
Separate upper ball joint from steering knuckle. Loosen lower control arm pivot bolts. Remove shock absorber
upper mount nuts and lower bolt. Move lower control arm just enough to remove shock absorber. Be careful not
to damage brake line.
Disassembly
Clamp upper mount in vise. Loosen lock nut 2 turns only. Compress coil spring using coil spring compressor.
Remove lock nut and remainin
g components. Slowly release compressor tension.

1991 Mazda MX-5 Miata
SUSPENSION - FRONT 1990-91 SUSPENSION Front
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