oil MAZDA MX-5 1994 Workshop Manual

OIL COOLER K OIL COOLER REMOVAL / INSPECTION / INSTALLATION 1. Remove in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to lnstallation Note. 45UOKX-57 1. Connector bolts 4. Oil pipe Inspect for clogging ins~ect for damaae or cracks -- - - 2. Packing installation Note ................ below 3. Transmission 5. Oil hose Removal ................. page K- 45 Inspect for damage or cracks Installation ............... page K-148 6. Radiator I UP SIDE DOWN SlDE lnstallation Note Oil pipe 1. Align the marks, and slide the oil cooler hose onto the oil cooler pipe until it contacts the ridge. 2. Install the hose clamp onto the hose at the center of the mark and at the angle shown. If reusing the hose, posi- tion the new hose clamp in the mark left by the previous hose clamp. 3. Verify that the hose clamp does not interfere with any other parts. Gartner Banana

L OUTLINE, TROUBLESHOOTING GUIDE, PROPELLER SHAFT OUTLINE SPECIFICATIONS TROUBLESHOOTING GUIDE Enginefrransmission Problem I Possible Cause BP DOHC Vibration Worn universal joint Bent propeller shaft Worn slip yoke splines Runout of propeller shaft Unbalanced propeller shaft Item MI 5M-D Abnormal noise NC4A-EL Worn or damaged universal joint Worn slip yoke splines PROPELLER SHAFT PREPARATION SST 1,001 (39.41) 816 (32.1) 60.5 ( 2.38) Length mm {in) Outer diameter mm{in) Holder, main shaft Ll L2 D For prevention of oil leakage Action 1 Page Replace Replace Replace Replace Replace Replace Replace Gartner Banana

L PROPELLER SHAFT 2. Remove the propeller shaft from the extension housing, and immediately install the SST to prevent oil leakage. Inspection Propeller shaft Caution Cleaning sealed bearings with cleaning fluids or a steam cleaner can wash the grease out of the bearing. 1. Clean the propeller shaft (except for the universal joint) with a steam cleaner or solvent. 2. Measure the propeller shaft runout with a dial indicator. Replace the propeller shaft if runout is excessive. Maximum runout: 0.4mm (0.016 in} 3. Move the universal joints in the directions shown, and check for universal joint looseness. If there is looseness, replace the propeller shaft. ii 4. Check operation of the universal joint. If the universal joint has excessive resistance, replace the propeller shaft. Installation Note Propeller shaft 1. Align the marks, and install the propeller shaft. Tightening torque: 50-58 N.m (5.0-6.0 kgf.m, 37-43 ft4bf) 2. Verify that there is no abnormal noise or vibration when driving the vehicle. If noise or vibration comes from the propeller shaft, replace the propeller shaft. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . FRONT AND REAR AXLES ....................................... INDEX M- 2 ..................................... OUTLINE M- 3 SPECIFICATIONS ........................... M- 3 TROUBLESHOOTING GUIDE .................. M- 4 ............................... FRONT AXLE M- 4 ................................ REAR AXLE M- 4 ............................. DIFFERENTIAL M- 4 ................................. FRONT AXLE M- 5 PREPARATION ............................. M- 5 WHEEL HUB. STEERING KNUCKLE .......... M- 6 .................................. REAR AXLE M-10 PREPARATION ............................. M-10 ......................... DISC BRAKE TYPE M-11 ................................ DRIVE SHAFT M-17 .................... DOUBLE OFFSET JOINT M-17 ............................... DIFFERENTIAL M-23 PREPARATION ............................. M-23 DIFFERENTIAL OIL ......................... M-25 ................. OIL SEAL (OUTPUT SHAFT) M-25 DIFFERENTIAL. STANDARD; DIFFERENTIAL. TORQUE SENSING LIMITED SLIP ("TORSEN" LSD) ........................... M-27 45UOMX-001 "TORSEN" is a registered trademark of ZEXEL-GLEASON USA . INC Gartner Banana

INDEX INDEX OIL SPECIFICATION ABOVE -1 8°C (O°F1: GL-5. SAE 90 / I 1 ,BELOW -1 8°C Ioo~: GL-5, SAE 80 ..-.. - - - - .. - ...... SERVICE, SECTION L REAR'BRAKE PROPELLER SHACT SERVICE, SECTION P FRONT-BRAKE SERVICE SECTION P 1. Front axle Inspection / Removal / Installation ............... page M- 6 Disassembly 1 Inspection / Assembly. ............... page M- 8 2. Rear axle Inspection / Removal / Installation ............... page M-1 1 Disassembly 1 Inspection / Assembly ................ page M-13 M-2 3. Drive shaft Ins~ection / Removal 1 ............... Installation page M-17 Overhaul .................. page M-19 4. Differential (Standard, Torque sensing limited slip differential) Differential oil .............. page M-25 . Oil seal (Output shaft) ...... page M-25 Removal 1 Installation ....... page M-27 Overhaul .................. page M-32 Gartner Banana

OUTLINE OUTLINE Front axle Rear axle Differentlal Drive shaft Item I Specifications TY pe Bearing Double-wishbone Angular ball bearing Maximum wheel bearing play mm {in} TY pe Bearing 0.05 {0.002} Double-wishbone Angular ball bearing Maximum wheel bearing play mm {in} Type Reduction gear Reduction ratio Oil I Viscosity 0.05 {0.002} -- ---- Differential gear Ring gear size mm {in} Grade Above -1 8°C {O°F}: SAE 90 Below -1 8°C {O°F}: SAE 80 Standard Hypoid gear Straight-bevel gear 182.88 {7.20) API service GL-5 I Capacity L {US qt. imp qt} I 1 .OO {I .06,0.88) "TORSEN" LSD Worm gear 4.100 TY ~e Length mm {in} Constant velocity (double offset) joint 640.6 I25.220) 45UOMX-00 Gartner Banana

TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE FRONT AXLE I Problem Posslbk Cause Worn or damaged wheel bearing Worn or damaged wheel bearing Steering wheel vibration braking Action Replace Replace REAR AXLE Page M- 6 M-6 I Problem Possible Cause Bent drive shaft Page Action Replace I Abnormal nolse Worn or damaged wheel bearing Worn drive shaft spline Worn or deteriorated upper arm bushing M-13 Replace I M-17 Body "rolls" I Replace section R Body leans Weak upper arm bushing Abnormal nolse from suspension system Worn or deteriorated upper arm bushing DIFFERENTIAL Problem Posrlble Cause lnsufficient differential oil Incorrect differential oil lmproperly adjusted ring gear backlash Poor contact of ring gear teeth Worn or damaged side bearing Worn or damaged ring gear Worn or damaged drive pinion bearing Worn or damaged pinion and side gear (STANDARD) Worn or damaged gear in LSD assembly ("TORSEN" LSD) Seized side gear and case Worn side gear spline Worn pinion shaft Worn thrust washer Worn or damaged needle bearing ("TORSEN" LSD) lmproperly adjusted side gear backlash lmproperly adjusted drive pinion gear preload Action Add oil Replace Adjust Adjust Replace Replace Replace Replace Replace Page M-25 M-25 M40 M4l M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-40 M-39 Abnormal nolse Replace Replace Replace Replace Replace Adjust Adjust Heat buildup lnsufficient differential oil lnsufficient drive pinion gear backlash Excessive bearing preload Add oil Adjust Adjust Oil leakage Excessive differential oil Loose differential carrier Worn or damaged oil seal Remove oil Tighten or repair Replace I - No dlfferentlal operation I Misassembled or damaged Repair Gartner Banana

FRONT AXLE M FRONT AXLE PREPARATION SST 49 01 18 850C Puller, ball joint 49 VOOl 795 For installation of Installer, oil sensor rotor seal (AW 49 0839 425C Puller set, bearing For disconnection of lower arm ball joint For disconnection of tie-rod end and upper arm ball joint For removal of sensor rotor (AW 49 0727 575 Puller, ball joint For removal of sensor rotor (ABS) 49 F027 007 Attachment @72 Gartner Banana

M REAR AXLE REAR AXLE PREPARATION SST 49 F026 103 Puller, wheel hub L==l I. - I For disassembly and assembly of rear axle 49 8026 1 A0 Puller, wheel hub For disassembly and assembly of wheel hub 49 GO33 102 Handle (Part of 49 8026 1 AO) For removal and installation of rear wheel hub For removal and installation of rear wheel hub Attachment A (Part of 49 8026 1 AO) - --- 49 GO30 795 Installer, oil seal For installation of oil seal For removal and installation of wheel bearing Handle (Part of 49 GO30 795) For removal of wheel bearing 49 GO33 107 Installer, dust cover For installation of dust cover Puller, fan pulley boss 49 F027 OAI For installation of bearing 49 F027 005 Attachment $62 (Part of 49 F027 OAl ) For assembly of rear axle Installer set, bearing 49 F027 009 Attachment $68 & 77 (Part of 49 F027 OAl ) For assembly of rear axle For assembly of rear axle Attachment 9'72 (Part of 49 F027 OA1) For installation of oil seal Installer, oil seal Gartner Banana

REAR AXLE M Disassembly / Inspection / Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts and repair or replace as necessary. ,, 3. Assemble in the reverse order of disassembly, referring to Assembly Note. Q REPLACE REPLACE 9 REPLACE 1. Oil seal Assembly Note ............ page M-16 2. Rear wheel hub assembly Disassembly Note ............... below Assembly Note ............ page M-16 3. Retaining ring 4. Wheel bearing Disassembly Note .......... page M-14 Assembly Note ............ page M-15 5. Dust cover Disassembly Note .......... page M-14 Assembly Note ............ page M-15 6. Knuckle 7. Bushing 8. Hub bolt Disassembly Note .......... page M-15 Assembly Note ............ page M-15 Disassembly note Rear wheel hub assembly Press out the rear wheel hub assembly with the SST. Gartner Banana