steering MAZDA MX-5 1994 Repair Manual

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

N ENGINE SPEED SENSING POWER STEERING Tie rod 1. Uncrimp the washer. 2. Carefully remove the tie rod. Pinion shaft assembly 1. Secure the mounting bracket in a vise. 2. Remove the retaining ring. 3. Tap the pinion shaft with a punch to remove it. Plug assembly 1. Remove the plug assembly from the pinion shaft. 2. Press out the upper bearhg and oil'seal by using the SST. 3. Remove the O-ring from the plug. Steering rack assembly 1. Remove the stop ring with a pin punch. 2. Temporarily tighten the tie rod to the tube side and pull it carefully to remove the rack. Backup ring and oil seal Tap the SST from the gear housing side to remove the backup ring and the oil seal. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N v SEAL RING Lower bearing Note The lower bearing does not need to be removed unless you are replacing it. Tap the end of the gear housing column to remove the lower bearing. Oil seal, spacer and center bearing Press out the oil seal, the spacer and the center bearing by using the SST. Inspection Pinion shaft assembly 1. lnspect the teeth of the pinion shaft for wear and damage.Replace the pinion shaft assembly if neces- sary. 2. lnspect the control valve for damage, oil passage clog- ging, seal ring and friction surface wear and damage. Replace the pinion shaft assembly if necessary. Assembly Note Oil seal, center bearing 1. Apply grease to the center bearing and set it in the gear housing. 2. Press in the center bearing by using the SST. 3. Set the spacer in the gear housing. 4. Apply grease to a new oil seal and set it in the gear hous- ing. 5. Press in the oil seal by using the SST. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING I HOLDER OIL' SEAL 10-14mm (0.39-0.55 in) Backup ring and oil seal 1. Apply grease to a new oil seal. 2. lnstall the oil seal to the SST (Protector body and guide). 3. Remove the SST (guide). 4. Slide the oil seal and the SST over the rack from the gear side to the piston. Remove the SST. 5. lnstall the backup ring. Steering rack assembly 1. Apply grease to the teeth and friction surface of the rack. 2. Using the SST, slide the rack into the gear housing from the tube side. Holder 1. Apply grease to a new Y-packing and install it into the holder. 2. lnstall a new O-ring onto the holder. 3. lnstall the SST over the rack end and install the holder. 4. lnstall the new stop ring. Oil seal 1. Press in a new oil seal from tube side with a suitable pipe (Dia. 22mm (0.87 in)). Do not press over 3,920 N (400 kgf, 880 Ibf). 2. Verify that the distance between the end of the rack and the holder is 10-1 4mm (0.40-0.55 in}. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N 60.5mm (2.38 in) Control valve 1. Install a new O-ring and a new seal ring onto the pinion shaft. 2. Pass the pinion shaft back and forth through the SST until the O-ring and the seal rings are set. 3. Fit new seal rings onto the control valve by using the SST. 4. Remove the SST from pinion shaft and align the pin posi- tion of the control valve with the thread of the pinion shaft assembly. lnstall the control valve assembly. 5. Install the new snap ring to the pinion shaft assembly. Pinion shaft assembly 1. Apply sufficient grease to the teeth of the pinion shaft. 2. Apply ATF to the seal ring and the friction surface of the control valve. 3. Attach the SST to the gear housing and install the pinion shaft. Plug assembly 1. Apply ATF to the upper bearing and the new oil seal. 2. Set the oil seal into the plug. 3. Press in the oil seal by using the SST. 4. Put the upper bearing into the plug. 5. Press in the upper bearing by using the SST. 6. Install a new O-ring to the plug assembly. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING 7. Attach the SST to the pinion and install the plug assem- bly. Adjusting cover 1. Tighten the mounting bracket in a vise. 2. Set the rack to the center position. 3. Tighten the adjusting cover to 4.9 N.m (50 kgf.cm, 43 in4bf) with the SST three times, then return it 25". 4. Apply sealant to the threads of the locknut. 5. Attach the locknut. 6. Measure the pinion torque by using the SST and a pull scale. Standard Center of rack + 90": 1 .O-1 .I N-m {I 0-1 2 kgf-cm, 8.7-1 0.4 in-lbf) ii Scale reading: 1 .&I .2 kg (2.2-2.64 Ib) 7. If not within specification, repeat steps 3 through 6. 8. Install the locknut. Tightening torque: 59-74 N.m (6.0-7.5 kgf.m, 44--54 ftdbf) Hermetic sealing inspection 1. Connect the SST to the power cylinder section of the gear housing. 2. Apply 53.3 kPa (400 mmHg, 15.7 inHg) vacuum with a vacuum pump and verify that it is held for at least 30 seconds. 3. If the vacuum is not held, replace the oil seal. Tie rod 1. Secure the rack gear in a vise, and tighten the tie rods with the wrench. Tightening torque: 79-98 N.m (8.0-10.0 kgf-m, 58-72 ft-lbf) 2. Align the washer with the rack groove, and crimp the washer. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N POWER STEERING OIL PUMP Removal / Installation 1. Remove in the order shown in the figure, referring to Removal Note. u 2. Install in the reverse order of removal. 3. After installation: (1) Check connections for fluid leakage. (Refer to page N-22.) (2) Bleed air from the system. (Refer to page N-21.) 1. Drive belt 3. Press~~re pipe ................... ............... w Inspection page N-37 Removal Note page N-34 Adjustment .................. page N-38 4. Return hose Replacement ................ page N-38 5. Power steering oil pump 2. Power steering pressure switch connector Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Removal Note Pressure pipe Mark the pressure pipe for reference during installation before loosening. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N Disassembly / Inspection / Assembly 1. The following precedure is for replacement of the O-rings only. Replace the pump assembly if other repairs are necessary. 2. Disassemble in the order shown in the figure, referring to Disassembly Note. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. N.m {kgfm, ftW] 1. Suction pipe 12. Cam ring ................... 2. O-ring Inspection page N-36 .............. 3. Pressure switch assembly Assembly Note page N-37 4, O-ring 13. Blade ................... 5. Connector Inspection page N-36 .............. 6. O-ring Assembly Note page N-37 7. Control valve 14. Rotor ................... Inspection ................... page N-36 Inspection page N-36 .............. 8. Spring Assembly Note page N-36 ................... Inspection page N-36 15. Side plate .................... 9. Bracket Inspection page N-36 10. Pump body rear 16. O-ring ................... w Inspection page N-36 17. O-ring 11. O-ring 18. Pin 19. Pump body front ................... Inspection page N-36 Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Disassembly Note Oil pump Use the SSTwhen securing the oil pump in a vise, so that force is not applied to the pulley or shaft. Inspection Pump body front, rear lnspect the front and rear of the pump body for cracks and damage, and the friction surface of the rotor for wear. Replace the pump assembly if a problem is found. Cam ring, rotor, blade, side plate 1. lnspect the blade friction surface of the cam ring for wear. 2. lnspect the pump body of the rotor and side plate friction surface for wear. 3. lnspect the cam ring friction surface of the blade for -, wear. 4. lnspect clearance between the rotor and blade. Control valve, spring 1. lnspect the control valve for cracks, damage and block- age, and the friction surface for wear. 2. lnspect the spring for damage. Assembly Note Rotor Install the rotor with the indentification mark facing upward. Gartner Banana