manual transmission MAZDA MX-5 1994 Owner's 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

TECHNICAL DATA MEASUREMENTS ......................... TD- 2 ................................... ENGINE TD- 2 .................... LUBRICATION SYSTEM TD- 5 ........................ COOLING SYSTEM TD- 5 FUEL AND EMISSION CONTROL SYSTEMS . TD- 6 ENGINE ELECTRICAL SYSTEM ............. TD- 7 .................................. CLUTCH TD- 7 .................. MANUAL TRANSMISSION TD- 8 AUTOMATIC TRANSMISSION ............... TD- 9 ....................... PROPELLER SHAFT TD-11 FRONT AND REAR AXLES ................. TD-12 STEERING SYSTEM ....................... TD-12 BRAKING SYSTEM ........................ TD-13 WHEELS AND TIRES ...................... TD-13 ............................. SUSPENSION TD-14 BODY ELECTRICAL SYSTEM ............... TD-15 HEATER AND AIR CONDITIONING SYSTEM . TD-15 STANDARD BOLT AND NUT TIGHTENING ................................. TORQUE TD-15 45UTDX-001 Gartner Banana

TECHNICAL DATA Engine ------ BP DOHC I Clutch disc I Sinale drv date I u - w- ., Runout limit rnrn {in) 0.7 (0.026) Wear limit rnm linl 0.3 10.01 2) from rivet head . a, 1 outer diameter mm {in) I 215 (8.46) 1 J. MANUAL TRANSMISSION 150 (5.91) 3.5 (0.14) 3.8 (0.15) Inner diameter mm {in) Type _____L- Transmission ___2_ M15M-D Clutch cover Facing thickness mm {in) Diaphragm spring Flywheel side Pressure plate side Set load N {ksrf. Ibn 1 4,310 /440. 968) Gear ratio Runout rnm {in) Mainshaft Clearance between main- shaft and gear (or bush) mm {in} t-- Reverse Oil capacity L {US qt, Imp qt) 1 Maximum 3rd 4th 5th 3.758 2.0 (2.1, 1.8) 0.03 10.001 2) Clearance between shift fork and clutch sleeve Shift fork and rod rod gate and control lever 1.330 1 .OOO 0.814 Reverse idle gear Clearance between reverse idle gear bushing and shaft mrn {in) Synchronizer ring Wear limit Wear limit Clearance between syn- chronizer ring and side of gear when fitted mm {in} Wear limit 0.1 5 {0.006) Wear limit Wear limit I 1 mm {in) ( 75 i2.953) Standard 1.5 (0.059) 22.5 (0.886) 22.5 i0.886) 17.0 (0.669) Detent ball spring (I sV2nd) Detent ball spring (3~94th) Detent ball spring (5thlReverse) Lubricant Free length mm (in) Free length mrn {in) Free length mm {in) Above 10°C {50°F} All seasons API Service GL-4 or GL-5 SAE 80W-90 API Service GL-4 or GL-5 SAE 75W-90 Gartner Banana

SPECIAL TOOLS .................... GENERAL INFORMATION ST- 2 ..................................... ENGINE ST- 3 CLUTCH AND MANUAL TRANSMISSION ...... ST- 4 ................. AUTOMATIC TRANSMISSION ST- 5 .............................. DIFFERENTIAL ST- 6 ................... FRONT AND REAR AXLES ST- 7 ......................... STEERING SYSTEM ST- 7 .......................... BRAKING SYSTEM ST- 9 ........... FRONT AND REAR SUSPENSIONS ST-1 0 CHECKERS AND OTHER EQUIPMENT ........ ST-10 4SUOTX-001 Gartner Banana

ST SPECIAL TOOLS CLUTCH AND MANUAL TRANSMISSION TOOL NUMBER d DESCRIPTION PRIORITY ILLUSTRATION PRIORITY ILLUSTRATION 49 SEOl 310A Centering tool, clutch disc Wrench, flare nut 49 0259 440 Holder, mainshaft Guide, interlock pin assembly Wrench, mainshaft lock nut Guide, shift fork assembly 49 0500 330 Installer, bearing Puller, fan pulley boss Puller set, bearing 'usher, main jrive shaft 49 H017 101 Hook $9 071 0 520 Uler, bearing 19 8025 OAO nstaller, dust seal nstaller, main hive gear maring 19 1285 071 'uller, bearing nstaller set, ~aring Gartner Banana

u GENERAL SERVICE INFORMATION TIEDOWN HOOK - FRONT /'-- TIEDOWN HOOK - REAR -?-A TOWING Proper towing equipments are necessary to prevent damage to the vehicle during any towing operation. Laws and regulations applicable to vehicles in tow must always be observed. Release the parking brake, place the shift lever in neutral, and set the ignition switch in the ACC posi- tion. As a rule, towed vehicles should be pulled with the driving wheels off the ground. WITH MANUAL TRANSMISSION If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use a towing dolly. CAUTION The power assist for the brakes and steering are inoperable while the engine is off. Do not use the tiedown hooks under the front or rear of the vehicle for towing. These hooks are designed ONLY for transport tiedown. If the tiedown hooks are used for towing, the front or rear skirt and bumper will be damaged. IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER (VIN) ENGINE MODEL AND NUMBER L i Gartner Banana

1700 -1 * TRANSHf5s:ON CASE (MANUAL) 17110 TRANSMISSION CASE (MANUAL) CASE T/MISSION BOLT PLUG ,M4BNET COVER, BEAR1 HG HOUSING, EXTENSION SEAL ,OIL GEAR, DR I VEN N.22 SLEEVE, SPEEDOHETGR SEAL 4 &REAT ON OIL HEH,AIR-+TIMISSI Gartner Banana