brake MAZDA MX-5 1994 Manual PDF

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

FRONT AXLE WHEEL HUB, STEERING KNUCKLE Inspection / Removal / lnstallation 1. lnspect wheel bearing play, referring to Inspection. 2. Remove in the order shown in the figure, referring to Removal Note. 3. lnspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal, referring to Installation Note. 25UOMX-OC 1. Front wheel 9. Lower arm 2. Brake caliper assembly Removal Note .............. page M-7 3. Disc plate 4. Hub cap 5. Locknut Installation Note ............ page M-7 6. Front wheel hub assembly lnspect for cracks and damage Disassembly / Inspection / Assembly ................. page M-8 7. Wheel speed sensor (ABS) 8. Tie-rod end Removal Note .............. page M-7 Service ..................... section N .............. Removal Note page M-7 ..................... Service section R 10. Upper arm .............. Removal Note page M-7 ..................... Service section R 11. Dust cover and knuckle spindle lnspect dust cover for damage and distortion lnspect knuckle spindle for cracks and damage Disassembly / Inspection 1 ................. Assembly page M-8 lnspection Wheel bearing play 1. Remove the wheel, brake caliper assembly, and disc plate, referring to Removal note below. 2. Position a dial indicator against the wheel hub. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play. If the bearing play exceeds specification, check and adjust the locknut torque or replace the wheel hub i assembly if necessary. Maximum wheel bearing play: 0.05mm i0.002 in) Gartner Banana

FRONT AXLE M Removal note Brake caliper assembly Note For easier installation, do not depress the brake pedal after removing the brake caliper assembly. Suspend the brake caliper assembly with a rope. Tie-rod end Loosen the nut and disconnect the tie rod end the SST. 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. Lower arm Caution The sharp edges of the SST can slice the lower arm dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. Loosen the nut and disconnect the lower arm by using the SST. Upper arm Caution The sharp edges of the SST can slice the upper arm dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. Loosen the nut and disconnect the upper arm by using the SST. Installation note Locknut Install a new locknut and stake it. Tightening torque: 167-21 6 N.m (1 7-22 kgf.m, 123-1 59 ft-lbf) Gartner Banana

REAR AXLE M DISC BRAKE TYPE Inspection 1 Removal 1 Installation 1. lnspect wheel bearing play, referring to Inspection. 2. Remove in the order shown in the figure, referring to Removal Note. 3. lnspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal, referring to Installation Note. 5. After installation, adjust the rear wheel alignment. (section R.) @ REPLACE 21 6294 {2230,159-217) N.m {kgf m, Rlbf) 1. Rear wheel 2. Brake caliper assembly Removal Note . . . . . . . . . . . . . page M-12 3. Disc plate 4. Locknut Installation Note . . . . . . . . . . . page M-12 5. Wheel speed sensor (ABS) 6. Sensor bracket 7. Knuckle, wheel hub, and dust cover lnspect knuckle for cracks and damage lnspect wheel hub for cracks and damage lnspect dust cover for damage and distortion Disassembly / Inspection / Assembly . . . . . . . . . . . . . . . . page M-13 Gartner Banana

M REAR AXLE Inspection Wheel bearing play 1. Remove the wheel, brake caliper assembly, and disc plate, referring to Removal note below. d 2. Position a dial indicator against the wheel hub. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play. If the bearing play exceeds specification, check and adjust the locknut torque or replace the wheel bearing if necessary. Maximum wheel bearing play: 0.05mm (0.002 in) Removal note Brake caliper assembly Note For easier installation, do not depress the brake pedal after removing the brake caliper assembly. Suspend the brake caliper assembly with a rope. Installation note Locknut Install a new locknut and stake it. Tightening torque: 21 6-294 N-m {22-30 kgf-m, 159-217 ft4bf) 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 ENGINE SPEED SENSING POWER STEERING TROUBLESHOOTING GUIDE Steering feels heavy - - 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 Malfunctioning steering shaft joint Problem I lmproperly adjusted wheel alignment Possible Cause 1 Malfunctioning steering gear lncorrect tire pressure Loose or damaged oil pump drive belt Low fluid level or air in fluid I Leakage of fluid I Insufficient oil pump pressure Steering wheel pulls lncorrect tire pressure to one side Unevenly worn tires ( Weak front spring General instability while driving Worn or damaged stabilizer and/or upper or lower arm bushing Dragging brake Loose lower arm lmproperly adjusted wheel alignment lncorrect tire pressure Damaged or unbalanced wheel Worn or damaged steering joint(s) lmproper steering pinion preload Weak front coil spring Worn or damaged stabilizer and/or upper or lower arm bushing Malfunctioning shock absorber Cracked or worn engine mount Cracked or worn transmission mount Shake (Steering wheel vibrates up/ down) Shimmy (Steering wheel vibrates left1 right) lmproperly adjusted wheel alignment Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Excessive steering wheel play Poor steering wheel return 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@) lncorrect tire pressure Unevenly worn tires Malfunctioning shock absorber Loose shock absorber mounting bolts 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 lower arm bushing Loose steering gear mounting bolts Worn linkage or tie-rod ball joint lncorrect tire pressure Stuck or damaged steering joints lmproperly adjusted front wheel alignment lmproper steering pinion preload Ball joint not operating smoothly Steering shaft contacting something Action Lubricate or replace Replace Adjust Replace Replace Adjust Replace Adjust Adjust or replace Add fluid or bleed air Repair or replace Replace Adjust Replace Replace Replace Repair Tighten or replace Adjust Adjust Adjust or replace Replace Adjust Replace Replace Replace Adjust Replace Tighten Adjust or replace Replace Replace Replace Tighten Replace Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Replace Adjust Replace Replace Replace Tighten Replace Adjust Replace Adjust Adjust Replace Repair Pagelsection N-25 section R N-32 N-25 N- 9 section R N-25 section Q N-37 N-21,22 - N-34 section Q section Q section R section R section P section R section R section Q section Q N- 9 N-32 section R section R section R section R section Q section Q section Q section B section J N-26 N-25 N-25 section Q section Q section Q section Q section Q section R section R section R section R section M section R N-25 N- 9 section R N-25 N-25 section Q N- 9 section R N-32 N-25 N- 9 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 . BRAKING SYSTEM INDEX ....................................... P- 2 OUTLINE ..................................... P- 4 SPEClFlCATlONS ........................... P- 4 BRAKE SYSTEM ............................. P- 5 PREPARATION ............................. P- 5 TROUBLESHOOTING GUIDE ................ P- 6 AIR BLEEDING ............................. P- 7 BRAKE HYDRAULIC LINE ................... P- 7 BRAKE FLUID .............................. P- 8 ............................. BRAKE PEDAL P- 9 MASTER CYLINDER (STANDARD) ............ P-11 MASTER CYLINDER (ABS) .................. P-14 POWER BRAKE UNIT ....................... P-20 PROPORTIONING BYPASS VALVE ........... P-23 FRONT BRAKE (DISC) ...................... P-25 CALIPER ................................... P-28 REAR BRAKE (DISC) ........................ P-29 CALIPER ................................... P-32 PARKING BRAKE SYSTEM .................... P-34 TROUBLESHOOTING GUIDE ................ P-34 PARKING BRAKE LEVER .................... P-34 PARKING BRAKE CABLE .................... P-36 ANTILOCK BRAKE SYSTEM (ABS) ............ P-37 DESCRIPTION .............................. P-37 PREPARATION ............................. P-37 TROUBLESHOOTING GUIDE ................ P-38 CIRCUIT DIAGRAM ......................... P-52 HYDRAULIC UNIT ........................... P-53 ........................ ABS CONTROL UNIT P-55 RELAYS .................................... P-56 ABS WHEEL SPEED SENSOR (FRONT) ....... P-58 ABS SENSOR ROTOR (FRONT) .............. P-59 ABS WHEEL SPEED SENSOR (REAR) ........ P-60 ABS SENSOR ROTOR (REAR) ............... P-61 25UOPX-001 Gartner Banana

INDEX INDEX LEVER STROKE 7-9 NOTCHES AT 196 N (20 kgf, 44 IbfJ 9 MAX NOTCHES 19 NOTCHES FLUID SPECIFICATION FMVSS116, DOT-3 1. Brake hydraulic line 7. Front brake (Disc) On-vehicle inspection ......... page P- 7 Quick Inspection, On-vehicle . . page P-25 ...... Removal / Installation ......... page P- 8 Replacement (Disc pad) page P-25 2. Brake fluid Removal / Installation (Caliper) page P-26 ................... Inspection ................... page P- 8 Inspection page P-27 Replacement ................ page P- 8 8. Caliper 3. Brake pedal Disassembly / Inspection l On-vehicle inspection ......... page P- 9 Assembly .................. page P-28 Removal / Inspection / 9. Rear brake (Disk) Installation ................ page P-10 Quick Inspection, On-vehicle . . page P-29 ...... 4. Master cylinder Replacement (Disc pad) page P-29 (Standard) Removal / Installation (Caliper) page P-30 ................... Removal / Installation / Inspection page P-31 Inspection ................. page P-1 1 10. Caliper (ABS) Disassembly 1 Inspection / Removal / Installation / Assembly .................. page P-32 Inspection ................. page P-14 11. Parking brake lever ................... Disassembly / Inspection / Inspection page P-34 Assembly .................. page P-18 Adjustment .................. page P-34 5. Power brake unit Removal / Inspection / Quick Inspection, On-vehicle . . page P-20 Installation ................. page P-35 Removal / Installation ......... page P-22 12. Parking brake cable J 6. Proportioning bypass valve Removal / Inspection 1 Inspection ................... page P-23 Installation ................. page P-36 ................ Replacement page P-23 Gartner Banana