boot MAZDA MX-5 1994 Owner's Manual

INDEX POWER STEERING STEERING WHEEL PLAY: [ 0-30mm (0-1.18 in) ] / DRIVE BELT DEFLECTION I=' I LIMIT: 11.5mm (0.45 in) at 98 N (1 0 kgf, 22 Ibf) 'I =!IS 1. Boot Replacement ................ page N- 6 2. Steering wheel. and column .... On-vehicle inspection pages N- 8,24 Removal / ................... page N- 9 Disassembly / Inspection 1 Assembly .................. page N-10 3. Steering gear and linkage Removal I Installation ......... page N-25 Air bleeding ................. page N-21 Disassembly I Inspection / Assembly .................. page N-26 4. Power steering oil pump ......... Removal / Installation page N-33 ................. Air bleeding page N-21 .......... Power steering fluid page N-22 5. Drive belt ................... Inspection page N-37 .................. Adjustment page N-38 ................ Replacement page N-38 Gartner Banana

N OUTLINEIMANUAL STEERING OUTLINE SPECIFICATIONS Steering wheel Steering shaft and joint d Type Steering gear Outer diameter mm {in) I 370 {I 4.6) I Manual steering Power steering Lock-to-lock turns Shaft ~oinr Power assist 3.36 2-cross joint - I Engine speed sensing Gear Gear ratio 2.8 Rack-and-pinion m (infinite) Rack stroke mm {in} Power steering fluid MANUAL STEERING Collapsible, non-tilt 121 .O i4.76) - I ATF DexronBII or M-111 ~luidca~acit~ L~S qt, Imp qt) I - PREPARATION SST 0.8 (0.85, 0.70) Preload attachment 25UONX-003 Hexagon wrench 49 GO30 797 Handle For removal of tie-rod end 49 1243 785 Installer, boot For measurement of pinion torque For installation of bushing 49 0208 701 A Boot air out tool - For removal and installation of adjusting cover For installation of tie-rod end boot 49 DO32 31 6 Protractor For removal of oil seal For tightening of adjusting cover Gartner Banana

N MANUAL STEERING BOOT Replacement 1. Loosen the wheel lug nuts. 2. On level ground, jack up the front of the vehicle and support it on safety stands. 3. Remove the wheel. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to lnstallation Note. 6. After installation, check the steering angle and toe-in, and adjust if necessary. (Refer to section R.) Nm (kgfm, ftdbf) 1. Cotter pin 6. Tie-rod end boot 2. Nut Removal Note ................ page N-7 3. Tie-rod endfsteering knuckle Installation Note .............. page N-7 Removal Note ................ page N-7 7. Boot clamp J 4. Locknut 8. Boot wire Removal Note ................ page N-7 9. Steering gear boot 5. Tie-rod end Installation Note .............. page N-7 Gartner Banana

MANUAL STEERING N Removal Note Locknut Before loosening the locknut from the tie-rod end, make a reference mark for proper reinstallation. Tie-rod endlsteering knuckle Caution The sharp edges of the SST can slice the tie-rod end dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. 1. Remove the cotter pin. 2. Loosen the nut until it is flush with the end of the ball stud. 3. Disconnect the tie-rod end from the knuckle by using the SST. Tie-rod end boot 1. Secure the tie-rod end in a vise. 2. Place a chisel against the boot and hold it at the angle shown. 3. Remove the boot by tapping it with a hammer. Installation Note Tie rod end boot 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot onto the tie-rod end by using the SST and a press. 4. Wipe away any excess grease. Steering gear boot Verify that the boot is not twisted or dented. 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

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 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

BRAKE SYSTEM P BRAKE SYSTEM PREPARATION - SST Wrench, flare nut 49 0221 600C Expand tool, disc brake 49 8043 001 Adjust gauge 49 8043 004 Wrench, socket Gauge, oil pressure (Part of 49 U043 OAO) - 49 U043 006 Hose (Part of 49 U043 OAO) For removal and installation brake PIPS For installation of disc pads 49 F043 001 Adjust gauge For Adjustment of push rod clearance For adjustment of push rod clearance 49 0208 701 A Boot air out tool For adjustment of push rod clearance For inspection of brake fluid pressure For removal of piston seal 49 8043 003 Lock tool, turning For inspection of brake fluid pressure For adjustment of push rod clearance 49 U043 OAO Gauge set, oil pressure & - For inspection of brake fluid pressure 49 U043 005 Joint (Part of ,-, 49 U043 OAO) For inspection of brake fluid pressure Gartner Banana

P BRAKE SYSTEM CALIPER Disassembly / Inspection / 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. REPLACE Up /REPLACE REPLACE kf'h \u b REPLACE 1. Dust seal lnspect for damage and poor sealing 2. Piston Disassembly Note ................ below Assembly Note .............. page P-33 lnspect for wear and rust 3. Manual adjustment gear 4. Snap ring 5. Adjusting bolt 6. O-ring 7. Connecting link 8. Piston seal Disassembly Note ............ page P-33 9. Spring 10. Operating lever 11. Boot 12. Cap and bleeder screw 13. Boot 14. Boot 15. Caliper body lnspect for damage and cracks Disassembly note Piston 1. Turn the manual adjustment gear clockwise with an Allen wrench. (Turn the manual adjustment gear until it turns easily.) 2. Remove the piston. Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ABS SENSOR ROTOR (REAR) Removal / Inspection 1. Inspect the ABS sensor rotor for missing and damaged teeth. Note The sensor rotor does not need to be removed unless you are replacing it. 2. Remove in the order shown in the figure, referring to Removal Note. 25uopx-o: 1. Drive shaft 2. Sensor rotor Removal . :. . . . . . . . . . . . . . . . . . . section M Removal Note . . . . . . . . . . . . . . . . . . . below 3. Boot band and boot Removal note Sensor rotor Tap the sensor rotor off the drive shaft with a chisel. Gartner Banana