lock MAZDA MX-5 1994 Workshop Manual

MANUAL STEERING , N Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. ,, 3. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal. 5. Tighten all necessary nuts and bolts to the specified torque. 6. After installation, check if the horn sounds. If the horn does not sound, remove the air bag module and connect the module connectors. (Refer to section T.) 1. Air bag module 6. Lower panel Removal 1 Installation .......... section T 7. Key interlock cable (Automatic transmission) 2. Locknut 8. Intermediate shaft bolt 3. Steering wheel 9. Steering shaft w ............... Removal Note page N-10 Disassembly 1 Inspection / 4. Column cover Assembly .................. page N-10 5. Combination switch Removal / Installation .......... section T Gartner Banana

N MANUAL STEERING Removal Note Steering wheel Caution '. Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will col- lapse. Remove the steering wheel with a suitable puller. Disassembly 1 Inspection 1 Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. L 1. Steering lock mounting bolts and bracket 3. Steering shaft ................... Disassembly Note ............ page N-1 1 Inspection page N-1 1 Assembly Note .............. page N-11 4. Intermediate shaft J 2. Steering lock assembly Inspect universal joint for looseness, abnormal noise, and sticking Gartner Banana

MANUAL STEERING N Disassembly Note Steering lock mounting bolts and bracket Use a chisel to make a groove in the heads of the steer- ing lock mounting bolts. Remove the bolts with a screw- driver. Remove the steering lock assembly. Inspection Check the following, and replace the column assembly if necessary. Steering shaft 1. Column bearing damage. 2. Steering shaft length. Length: 603.7--605.7mm (23.77-23.84 in) Assembly Note Steering lock mounting bolts and bracket Install the steering lock assembly on the jacket. Install the new steering lock mounting bolts. Tighten the bolts until the heads break off. Gartner Banana

N MANUAL STEERING STEERING GEAR AND LINKAGE Removal / Installation 1. Turn the wheels to the straight-ahead position. 2. Loosen the wheel lug nuts. 4 3. On level ground, jack up the front of the vehicle and support it on safety stands. 4. Remove the wheel. Note Turning the steering wheel while the steering gear is removed will make reinstallation difficult. Do not turn the steering wheel while the steering gear is removed. If the steering wheel is turned in that condi- tion, the clockspring connector may have to be adjusted. (Refer to section T.) 5. Remove the undercover. 6. With the wheels in the straight-ahead position, remove in the order shown in the figure. 7. Install in the reverse order of removal. 8. Adjust the front wheel alignment. (Refer to section R.) 1. Cotter pin 4. Intermediate shaft bolt 5. Mounting bracket bolt .i 2. Nut 3. Tie-rod endlsteering knuckle 6. Steering gear and linkage Removal Note . . . . . . . . . . . . . . . . page N-7 Gartner Banana

MANUAL STEERING N Disassembly 1 Inspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. i, 3. Assemble in the reverse order of disassembly, referring to Assembly Note. 1. Tie-rod end 15. Upper bearing Inspect ball joint for damage and malfunction Inspect for wear, damage, and malfunction 2. LocknLt (Tie-rod end) 16. Pinion shaft .............. 3. Boot band Assembly Note page N-16 4. Boot wire Inspect teeth for wear, damage and cracks 5. Boot 17. Rack ............ Inspect for cracks and other damage Disassembly Note page N-14 6. Tie-rod Inspection ................... page N-15 Disassembly Note ............ page N-14 Assembly Note .............. page N-16 Assembly Note .............. page N-32 18. Mounting bracket and mount 7. Washer 19. Lower bearing 8. Locknut (Adjusting cover) 9. Adjusting cover Disassembly Note ............ page N-14 Assembly Note .............. page N-17 10. Roller assembly lnspect parts for wear, damage, weakness and malfunction 11. Dust cover lnspect for cracks and other damage 12. Locknut (Rear cover) u 13. Rear cover Assembly Note .............. page N-17 14. Oil seal Disassembly note ............ page N-14 ~isassembl~ Note ............ page N-14 Assembly Note .............. page N-16 lnspect for wear, damage, and malfunction 20. Rack bushing Disassembly Note ............ page N-15 Assembly Note .............. page N-15 lnspect for wear and damage 21. Bushing Disassembly Note ............ page N-15 Assembly Note .............. page N-15 lnspect for wear and damage 22. Gear housing lnspect for cracks and other damage Gartner Banana

MANUAL STEERING N LOCKING TAB Rack bushing Note The rack bushing does not need to be removed unless you are replacing it. Depress the locking tab, and carefully remove the rack bushing. Bushing Note The bushing does not need to be removed unless you are replacing it. Carefully break the bushing to remove it. Inspection Rack 1. Inspect for cracking, damage, and tooth wear. Replace if necessary. 2. Measure runout of the rack. ' BUSHING b TAB I I Runout: 0.3mm (0.012 in) max. 3. If not within specification, replace the rack. Assembly Note Bushing Align A and B and press a new bushing into the gear housing by using the SST until the bushing is fully seated. Rack bushing 1. Align the tab of a new rack bushing with the hole in the column. 2. Push the rack bushing in until it is locked in place by the tab. Gartner Banana

MANUAL STEERING N Rear cover 1. Apply grease to the outer race of the upper bearing and install it in the gear housing. 2. Install a new oil seal to the rear cover. 3. Apply sealant to the threads of the rear cover and install it into the gear housing. 4. Rotate the pinion to the left and right a few times to seat the bearing. 5. Tighten the rear cover so that the starting torque of the pinion is 200-350 g (7.1-12.3 oz} as checked by using the SST and a pull gauge. 6. Tighten the locknut. Do not allow the rear cover to turn. Tightening torque: 50--68 N-m (5.0-7.0 kgf.m, 37-50 ft.lbf} Adjusting cover 1. Carefully move the rack so that the pinion is set to the center (neutral position) of the rack gear as shown. 2. Install the roller assembly, needle roller, holder, dish springs, friction block, and the spring as shown. 3. Torque the adjusting cover to 9.8 N.m (1 kgf-m, 85 in.lbf), then loosen it 25O45". Use the SST to secure the adjusting cover and the locknut. Tightening torque: 40-58 N.m (4.CL6.0 kgf-m, 29--43 ft-lbf} 4. Measure the starting torque of the pinion by using the SST. Center position + 90" Pull gauge reading: 1,000-1,400 g (35-50 oz} Any other position Pull gauge reading: less than 1,700 g (60 or) 5. If not within specification, repeat steps 2 and 3. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING ENGINE SPEED SENSING POWER STEERING PREPARATION SST For removal of tie-rod end For installation of tie-rod end boot 49 01 1 8 850C Puller, ball joint Installer, boot For inspection of power steering fluid pressure For inspection of power steering fluid pressure - --- - - Gauge (Part of 49 1232 670A) Gauge set, power steering For inspection of power steering fluid pressure For inspection of power steering fluid pressure 49 H002 671 Adapter, power steering gauge dP--= &--- Valve body (Part of 49 1232 670A) For removal and installation of upper bearing For pressurize oil seal For removal of backup ring and oil seal For inspection of power steering fluid pressure 49 DO32 306 Support block For removal of upper bearing For pressurize oil seal For removal of backup ring and oil seal 49 DO32 304 Installer, oil seal and bearing Handle / For installtion of oil seal and center bearing 49 DO32 301 Installer body, oil seal and bearing 49 NO32 303 Remover, backup ring and oil seal 49 DO32 31 6 Protractor For removal of oil seal and center bearing For installation of adjusting cover 49 DO32 307 Remover, oil seal and bearing For installtion of oil seal 49 DO32 303 Attachment For installation of center bearing Attachment Gartner Banana

ENGINE SPEED SENSING POWER STEERING N STEERING GEAR AND LINKAGE Removal / Installation 1. Turn the wheels to the straight-ahead position. 2. Loosen the wheel lug nuts. 3. On level ground, jack up the front of the vehicle and support it on safety stands. 4. Remove the wheels. Note Turning the steering wheel while the steering gear is removed will make reinstallation difficult. Do not turn the steering wheel while the steering gear is removed. If the steering wheel is turned in that condi- tion, the clockspring connector may have to be adjusted. (Refer to section T.) 5. Remove in the order shown in the figure, referring to Removal Note. 6. With the wheels in the straight-ahead position, install in the reverse order of removal. 7. Tighten all necessary bolts and nuts to the specified torque. 8. After installation: (1) Check for fluid leakage. (Refer to page N-22.) (2) Bleed air from the system. (Refer to page N-21.) (3) Adjust the front wheel alignment. (Refer to section R.) 1. Cotter pin 5. Pressure pipe 2. Nut ~emovai Note ............... page N-26 3. Tie-rod endlsteering knuckle 6. Return hose Removal Note ............... page N- 7 7. Mounting bracket bolt 4. Bolt 8. Steering gear and linkage Gartner Banana

ENGINE SPEED SENSING POWER STEERING N 1. Oil pipe lnspect for clogging and damage 2. Tie-rod end ................ u Disassembly Note below lnspect ball joint for damage and malfunction 3. Locknut (Tie-rod end) 4. Boot clamp 5. Boot wire 6. Boot lnspect for cracks and other damage 7. Housing cover 8. Locknut (Pinion shaft) 9. Tie rod ............ Disassembly Note page N-28 .............. Assembly Note page N-32 lnspect for bending lnspect ball joint for damage and malfunction 10. Washer 11. Locknut (Adjusting cover) 12. Adjusting cover .............. Assembly Note page N-32 13. Plate 14. Yoke spring lnspect for weakness and damage 15. Support yoke lnspect for damage and wear 16. Dust cover lnspect for cracks and other damage - 17. Retaining ring 18. Pinion shaft assembly ............ Disassembly Note page N-28 ................... Inspection page N-29 .............. Assembly Note page N-31 19. Plug assembly ............ Disassembly Note page N-28 .............. Assembly Note page N-31 20. Upper bearing lnspect for wear, damage and malfunction 21. Oil seal 22. O-ring 23. Plug 24. Snap ring 25. Control valve .............. Assembly Note page N-31 26. Seal ring 27. O-ring 28. Seal ring 29. Pinion shaft 30. Mounting bracket and mount 31. Stop ring 32. Steering rack assembly ............ Disassembly Note page N-28 .............. Assembly Note page N-30 33. Holder .............. Assembly Note page N-30 lnspect for wear and damage 34. O-ring 35. Y-packing 36. Seal ring 37. O-ring 38. Steering rack lnspect for cracks, damage and wear 39. Oil seal ............ Disassembly Note page N-28 .............. Assembly Note page N-30 40. Backup ring ............ Disassembly Note page N-28 .............. Assembly Note page N-30 lnspect for cracks and other damage 41. Lower bearing ............ Disassembly Note page N-29 lnspect for wear, damage and malfunction 42. Oil seal ............ Disassembly Note page N-29 .............. Assembly Note page N-29 43. Spacer ............ Disassembly Note page N-29 lnspect for cracks, damage and wear 44. Center bearing Disassembly Note ............ page N-29 .............. Assembly Note page N-29 lnspect for wear, damage and malfunction 45. Mounting bracket 46. Mount 47. Gear housing lnspect for cracks and other damage 25UONX-020 Disassembly Note Tie-rod end Mark the tie rod, locknut and tie-rod end for proper reas- sembly. Gartner Banana