lamp MAZDA MIATA 1991 Factory Service Manual

procedure.
Fig. 5: Exploded View of Front Disc Brake Assembly (Protege & 323)

Courtesy of MAZDA MOTORS CORP.
Removal (Navajo)
1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake
fluid from master cylinder. Raise vehicle, and support using safety stands.
2. Remove front wheel assembly. Place a large "C" clamp on caliper. See Fig. 9
. Tighten clamp to bottom
piston in cylinder bore. Remove clamp.
3. Remove dirt around caliper pin tabs. Tap upper caliper pin toward inboard side of vehicle until pin tabs

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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touch spindle face.
4. Insert screwdriver into slot provided behind pin tabs on inboard side of pin. Using pliers, compress end of
pin while using screwdriver to pry until tabs slip into spindle groove.
5. Place a 7/16" diameter punch on end of pin, and drive caliper pin out of caliper slide groove. Repeat
procedure for lower pin. Remove caliper from rotor. Remove outer brake pad. Compress anti-rattle spring
clip, and remove inner brake pad. Support caliper aside. Replace pad if lining thickness is less than
specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE.
Installation
Use "C" clamp to push caliper piston into piston bore until it bottoms out. To install, reverse removal procedure.
Bleed air from brake system.
Removal & Installation (RX7 With 4-Piston Caliper)
Raise and support front of vehicle. Remove wheels. Remove pad pins and pad springs. See Fig. 6 . Remove
brake pads and shims. Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING
SPECIFICATIONS (FRONT) . To install, reverse removal procedure. CAUTION: During installation, DO NOT tap caliper pin too far into spindle groove. If
this happens, tap pin in other direction until tabs snap back into place.
Tabs on each end of caliper pin must be free to catch on spindle flanks.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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Fig. 18: View of Rear Drum Brake Assembly (Typical)
Courtesy of MAZDA MOTORS CORP.
Installation
1. Apply brake grease to brake shoe contact areas on backing plate. When installing adjuster between shoes,
insert a flat-tipped screwdriver between adjuster quadrant and meshing teeth on MX-6 and 626, or
between quadrant and knurled pin on Protege and 323. See Fig. 2
.
2. To fully retract adjuster, move quadrant until it touches backing plate. To complete installation, reverse
removal procedure. Adjust wheel bearings and stake lock nut.
Removal (Navajo)
1. Remove wheel assembly and drum. Place a wheel cylinder clamp over ends of wheel cylinder. Disengage
ad
justing lever from adjusting screw by pulling backwards on lever cable. See Fig. 19 .

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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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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Inspection
Check for damage, oil leakage and abnormal noise. Check rubber parts for deterioration or damage. Inspect coil
spring for signs of fatigue or damage. Replace parts as needed.
Reassembly
Clamp shock absorber in vise. Install coil spring and components in reverse order of disassembly. Ensure coil
spring is well seated in upper and lower spring seats.
Installation
To install, reverse removal procedure. Final tighten all bolts with vehicle resting on ground and suspension
unloaded. See appropriate See SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT
section for checks and adjustments.
STRUT ASSEMBLY
Removal
1. Raise and support vehicle. Remove wheel assembly. Disconnect brake line from strut assembly. Remove
bolts attaching steering knuckle arm to strut assembly.
2. Disconnect harness connector from actuator (if equipped). Remove bolts, actuator and actuator mounting
bracket from upper mounting block. Remove nuts attaching upper strut assembly to body panel. Remove
strut assembly.
Disassembly
Clamp strut in vise. Compress coil spring using coil spring compressor. Remove piston lock nut. Slowly release
compressor tension. Remove components. Remove coil spring. Remove strut from vise.
Inspection
Check strut tube for cracks, damage, oil leakage and abnormal noise. Check rubber parts for deterioration or
damage. Inspect coil spring for signs of fatigue or damage. Check actuator control rod of strut assembly for
smooth rotation (if equipped). Replace parts as needed.
Reassembly
Clamp strut in vise. Install coil spring and components in reverse order of disassembly. Ensure that coil spring
is well seated in upper and lower spring seats. On MX-6 and 626, ensure upper spring seat positioning hole
faces inside of vehicle. NOTE: Prior to removing strut-to-steering knuckle bolts, make an alignment mark for
reassembly reference. Note position of mounting mark on top of strut assembly
before removing strut.

1991 Mazda MX-5 Miata
SUSPENSION - FRONT 1990-91 SUSPENSION Front
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drive axle lock nut. Check axial play. See WHEEL BEARING under ADJUSTMENTS & INSPECTION.
STRUT ASSEMBLY
Removal & Disassembly
1. Raise vehicle and remove fuel tank filler pipe protector. Remove rear wheel assembly. Remove stabilizer
bar nut and bolt. Remove 2 upper strut mount-to-body nuts. Remove lower strut bolt. Loosen upper and
lower arm bolts. Lower arms and remove strut assembly.
2. Clamp strut securely in soft-jawed vise. Compress coil spring. Remove lock nut and washer. Remove
remaining components and note order for reassembly.
Inspection
Check strut for leaks or abnormal noise. Inspect parts for wear or damage. Check for loose installation of bolts
and nuts. Replace parts as necessary.
Reassembly & Installation
To reassemble, reverse disassembly procedure. To install, reverse removal procedure. Ensure coil spring is well
seated in upper and lower seats. Check rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in
the WHEEL ALIGNMENT section.
LOWER ARM
Removal
Raise and support vehicle. Remove wheel assembly. Remove stabilizer bar control link nut and bolt. See Fig.
1 . Remove lower strut bolt. Remove lower arm-to-crossmember bolts. Remove lower arm-to-knuckle bolts.
Remove lower arm. Inspect arm for dama
ge, cracks and deformation. Check for damaged or worn bushings.

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear
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Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MPV, MX-6 & 626)
1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and
COMBINATION SWITCH
under REMOVAL & INSTALLATION. Remove steering lock assembly.
See IGNITION SWITCH & STEERING LOCK
under REMOVAL & INSTALLATION.
2. Remove lower dash panel and A/C duct. Remove lower column cover and steering shaft-to-intermediate
shaft "U" joint bolt. On MPV with A/T, remove shift lever mechanism.
3. On all models, separate steering shaft from intermediate shaft. Remove steering column upper bracket
bolts. Remove steering column. To install, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS TABLE
at end of article.
OVERHAUL
STEERING COLUMN
Disassembly
Remove wiring and switches. Clamp column in vise. Turn steering shaft to remove. With a hammer and chisel,
make a groove in steering lock assembly shear screws. Remove shear screws. Remove steering lock.
Inspection
Check all components for damage or wear. Check steering shaft for bends, damage or sheared plastic pins.
Check bearings for excessive play. Replace parts as necessary. Measure length of steering shaft. See Fig. 9
.
Reassembly
To reassemble, reverse disassembly procedure. Grease steering shaft, bushings and bearings. Always use NEW
shear screws.
STEERING SHAFT DIMENSIONS
(1) NOTE: Steering shaft dimension for 929 is not available from manufacturer.
ApplicationLength - In. (mm)
B2200 & B2600i32.69-32.99 (830.0-835.6)
Miata22.09-23.02 (561.1-584.7)
MPV24.05-24.17 (611.0-614.0)
MX-6 & 62624.00-24.05 (609.6-611.1)
Protege & 32323.86-23.94 (606.0-608.0)
RX732.05-32.17 (814.0-817.0)
929(2)
See Fig. 9 for measuring points.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
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