drain bolt MAZDA MIATA 1991 Factory Service Manual

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
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B2600i and MPV, remove brake drum and drive axles. See REAR AXLE SHAFTS & BEARINGS. On
Protege 4WD, RX7 and 929, disconnect CV joint drive axles from differential assembly and wire aside.
2. On all models, mark flanges and disconnect drive shaft. Remove ABS sensor (if equipped). On RX7,
remove rear exhaust system and differential mount on left side of pinion flange. Remove hanger mounts
and allow left side to hang down. Disconnect sublinks and remove differential.
3. On Protege 4WD and 929 models, remove differential housing assembly-to-chassis mounting bolts.
Remove differential housing assembly from vehicle. On all models, remove differential carrier-to-
housing nuts. Remove differential carrier.
Installation
To install, reverse removal procedure. Apply Sealant (8527 77 739 ) to carrier mating flange. Align marks made
during removal. Refill differential with correct type and amount of lubricant. Tighten all fasteners to
specification. See TORQUE SPECIFICATIONS
.
Fig. 4: Exploded View of Differential Assembly (RX7)

Courtesy of MAZDA MOTORS CORP.
Removal (Miata)
1. Raise and support vehicle. Drain differential. Mark flanges and remove drive shaft. Note locations and
disconnect wiring harness from Power Plant Frame (PPF). See Fig. 5
.

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. Remove pressure and return hose connections from steering gear. Remove mud flap on driver's side.
Remove steering gear mounting bolts. Remove steering gear through wheelwell on driver's side.
4. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
table.
Removal & Installation (Protege & 323)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove
engine undercover. Remove cotter pins and castle nuts from tie rod ends.
2. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-to-
steering gear pinion shaft bolt. Remove pressure and return hose connections from steering gear box.
3. Remove all accessible steering gear mounting bracket upper nuts and lower bolts. On Protege, support
drive train from above. Loosen stabilizer bar left mounting bracket and remove engine mount
crossmember.
4. Remove transmission control cable clip. Remove transfer case mount nuts. Lower engine gradually until
rear engine mount bolts can be removed. Remove lower left steering gear mounting bolt from between
transaxle and transfer case.
5. On all models, remove steering gear. To install, reverse removal procedure. Fill and bleed system.
Tighten bolts to specification. See TORQUE SPECIFICATIONS
table.
Removal & Installation (RX7)
1. Remove battery. Drain cooling system. Remove fan shroud and radiator. Raise and support front of
vehicle. Remove front wheels and engine undercover.
2. Remove control links and stabilizer bar. Remove cotter pins and castle nuts from tie rod ends. Remove tie
rods from steering knuckles with puller.
3. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove pressure and
return hose connections from steering gear box.
4. Remove steering gear mounting bolts. Lower steering gear brackets, steering gear and linkage from
vehicle as an assembly.
5. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
table.
Removal & Installation (929)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove
engine undercover. Disconnect pressure and return hose connections in front of steering gear.
2. Drain fluid. Disconnect return hose fitting to control valve. Remove starter for access to control valve.
Disconnect control valve and pressure switch connectors. Remove control valve. Remove cotter pins and
castle nuts from tie rod ends.
3. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-to-
steering gear pinion shaft bolt. Remove steering gear mounting bolts. Remove steering gear from bottom
of vehicle.
4. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS

1991 Mazda MX-5 Miata
STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion
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Fig. 5: Aligning Camshaft Timing Marks (DOHC 1.8L Engines)
Courtesy of MAZDA MOTORS CORP.
Removal (MX-5 Miata - DOHC)
1. Disconnect negative battery cable. Drain cooling system. Remove radiator hose and by-pass hoses from
thermostat housing. Remove air cleaner intake duct assembly from throttle body to air cleaner filter
housing. Remove splash shield.
2. Remove drive belt(s) and water pump pulley. See Fig. 6
. Align crankshaft pulley timing mark with
cylinder No. 1 at TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft
pulley bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub.
3. Remove cylinder head cover. Remove upper, center and lower timing belt cover. If timing belt is to be
reused, mark timing belt rotation direction. Ensure timing marks on camshaft sprockets are aligned. See
Fig. 7
. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully
expanded. Remove timin
g belt.

1991 Mazda MX-5 Miata
MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95
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