wheel MAZDA MX-5 1994 Service Manual

DRIVE SHAFT M TAPE 45UOMX-031 DIFFERENTIAL SlDE WHEEL SlDE 45UOMX-031 SNAP RING GROOVE I 45UOMX-032 Boots 1. Wrap the shaft splines with tape. 2. Remove the boot. Assembly note Boots 1. Before putting the boot onto the shaft, wrap the shaft splines with tape. 2. lnstall the wheel-side and differential-side boots, noting the shape and size of each one in the figure. Outer diameter of large boot end Differential side : 87.4mm (3.441 in) Wheel side : 90.8mm (3.575 in) Cage, inner ring, and balls 1. Align the marks and install the balls to the inner ring. 2. Install the cage, inner ring, and ball assembly to the drive shaft in the direction shown in the figure. The larger diameter of the (age should be) facing the snap ring groove. 3. Install a new snap ring in the drive shaft snap ring groove. 4. Apply the specified grease (molybdenum disulfide) to the joints and boots. Total quantity Differential side : 75-95 g (2.65-3.35 oz) Wheel side : 55-75 g (1.94--2.65 oz) Gartner Banana

M DIFFERENTIAL 5. Separate the driveshaft from the differential and sus- pend it. 6. Remove the output shaft by using two pry bars as shown in the figure. J 7. Remove the oil seal. 8. Apply lithium-based grease to the new oil seal lip and install it by using'the SST. 9. Install the new clips. 10. Install the output shaft into the side gears by lightly tap- ping with a plastic hammer. 11. Verify that the output shaft is hooked into the side gears by pulling it by hand. ./ 12. Align the marks and install the drive shaft. Tightening torque: 54-64 N.m (5.5--6.5 kgf.m, 40-47 ft-lbf) 13. Install the upper arm installation bolt and nut. Tightening torque: 46-67 N.m (4.7-6.8 kgf.m, 34--49 ftlbf) 14. Add the specified oil. 15. Adjust the rear wheel alignment. (Refer to section R.) I Gartner Banana

DIFFERENTIAL M DIFFERENTIAL, STANDARD; DIFFERENTIAL, TORQUE SENSING LIMITED SLIP ("TORSEN" LSD) Removal 1 lnstallation 1. Drain the differential oil. ,, 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Add the specified oil to the specified level. 1. Rear wheels 7. Drive shafts 2. Differential mounting pipe Removal Note ............. page M-29 3. Exhaust pipe 8. Differential 4. Propeller shaft Removal Note ............. page M-29 Service ..................... section L Installation Note ........... page M-30 ' 5. Speedometer cable Overhaul .................. page M-32 ,, 6. Power plant frame (PPF), Differential mounting spacer Removal Note ............. page M-28 Installation Note ........... page M-30 Gartner Banana

M DIFFERENTIAL Installation note Differential 1. Connect the drive shaft to the output shaft with the marks aligned. 2. Install the differential. - JOMX- Tightening torque 0: 83-98 N-m (8.5-10 kgf.m, 61-72 ft4bf) @I: 18-26 N.m (1.8-2.7 kgf.m, 13-20 ft.lbf) 3. Adjust the rear wheel alignment if the upper arm installa- tion bolt and nut were removed. (section R.) Power plant frame (PPF) 1. Install the differential mounting spacer. Tightening torque: 37-52 N-m (3.8-5.3 kgf.m, 27-38 ftdbf} .i 2. Support the transmission with a jack so that it is level. 3. Position the PPF and snugly tighten the transmission- side bolts by hand. 4. Verify that the sleeve is installed into the block. 5. Install the spacer and bolts and snugly tighten them. The reamer bolt should be installed in the forward hole. 6. Snugly install the power plant frame bracket. 7. Tighten the transmission-side bolts. Tightening torque: lO4--123 N.m (1 0.6-1 2.6 kgf.m, 77-91 ft4bf) Gartner Banana

Before beginning any service procedure. refer to section T of this manual for I air bag system service warnings and audio antitheft system alarm conditions . STEERING SYSTEM INDEX ....................................... N- 2 OUTLINE ..................................... N- 4 SPECIFICATIONS ........................... N- 4 MANUAL STEERING .......................... N- 4 PREPARATION ............................. N- 4 ................ TROUBLESHOOTING GUIDE N- 5 BOOT ...................................... N- 6 STEERING WHEEL AND COLUMN ........... N- 8 ............. STEERING GEAR AND LINKAGE N-12 ENGINE SPEED SENSING POWER STEERING .......................... N-18 PREPARATION ............................. N-18 TROUBLESHOOTING GUIDE ................ N-20 AIR BLEEDING ............................. N-21 POWER STEERING FLUID ................... N-22 STEERING WHEEL AND COLUMN ........... N-24 STEERING GEAR AND LINKAGE ............. N-25 POWER STEERING OIL PUMP ............... N-33 DRIVE BELT ................................ N-37 25UONX-001 Gartner Banana

INDEX INDEX MANUAL STEERING STEERING WHEEL PLAY: [ (MOrnrn (0-1 .I 8 in) ] 1. Boot 3. Steering gear and linkage Replacement ................ page N- 6 Removal 1 Installation ......... page N-12 2. Steering wheel and column Disassembly / Inspection / On-vehicle inspection ......... page N- 8 Assembly .................. page N-13 -, Removal / Installation ......... page N- 9 Disassembly / Inspection / Assembly .................. page N-10 Gartner Banana

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

MANUAL STEERING TROUBLESHOOTING GUIDE Problem Steering heavy Posslble Cause Poor lubrication, foreign material, or abnormal wear of steering ball joint Stuck or damaged lower arm ball joints lmproper steering pinion preload Damaged steering gear Malfunction of steering shaft joint lmproperly adjusted wheel alignment Malfunctioning steering gear Replace Replace gear Replace Replace Adjust Replace ~ction- Lubricate or replace section R N-12 N-12 N- 9 section R N-12 ~i&d~ection N-13 General instability while driving Steering wheel pulls to one side Shake (Steering wheel vibrates upidown) Worn or damaged stabilizer and/or suspension arm bushings Dragging brake Loose lower arm lmproperly adjusted wheel alignment lncorrect tire pressure Damaged or unbalanced wheel Worn or damaged steering joints lmproper steering pinion preload Weak front coil spring Worn or damaged stabilizer andlor suspension arm bushings Malfunctioning shock absorber lmproperly adjusted wheel alignment Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Incorrect tire pressure Incorrect tire pressure Unevenly worn tires Weak front spring Replace Repair Tighten Adjust Adjust Adjust or replace Replace Replace gear Replace Replace Replace Adjust Replace Tighten Adjust or replace section R section P section R section R section Q section Q N- 9 N-12 section R section R section R section R section Q section Q section Q Adjust Adjust Replace Replace section Q section Q section Q section R I Cracked or worn transmission mount I Cracked or worn engine mount 1 ~e~lace I section B lncorrect tire pressure Unevenly worn tires Malfunction of shock absorber Shimmy (Steering wheel vibrates circumferentially) Excessive steering wheel play Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Adjust Replace Replace Replace Replace Tighten Replace Replace Tighten Adjust or replace section Q section Q section R section J N-12 N-12 N-13 section Q section Q section Q I Loose shock absorber mounting bolts 1 Tighten I section R Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Worn steering gear Worn or damaged steering joints Worn or damaged suspension arm bushings Loose steering gear mounting bolts I lmproperly adjusted front wheel alignment Poor steering wheel return Replace Replace Replace Adjust Replace Replace Replace Tighten Replace Adjust Replace Adjust Worn linkage &-tie-rod ball joint lncorrect tire pressure Stuck or damaged steering joints section R section R section M section R N-12 N- 9 section R N-12 N-12 section Q N- 9 section R Abnormal noise from steering system 25UONX-00! Improper steering pinion preload Ball joint not operating smoothly Steering shaft contacting something Loose steering gear Malfunctioning steering gear Obstruction near steering column Loose steering linkage Worn steering joints Replace gear Replace Repair Tighten Replace Repair or replace Tighten or replace Replace N-12 N-13 N- 9 N-12 N-12 N- 9 N-12 N- 9 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