bushings MAZDA MX-5 1994 Workshop Manual

J TRANSMISSION Assembly note Oil seal 1. Apply the specified oil to a new oil seal. 2. Install the new oil seal by using the SST. Rod cover 1. Apply transmission oil to the rubber bushings on the rod cover. 2. Install the rod cover with the mark facing forward. L I 35UOJX-058 Roll pin Install a new roll pin into the control rod end. The split in the roll pin must be facing in the direction shown in the figure. L I 45UOJX-031 Select-lock spindle, spring, and spring cap 1. Install the select-lock spindle, spring, and spring cap. Tightening torque: 7.9-10.7 Nm (80-11 0 kgfan, 70-95.4 in-lbf) 2. Push the select-lock spindle down by pushing on the control rod. This will ensure that the steel ball correctly engages the select-lock spindle. 45UOJX-032 Gartner Banana

TRANSMISSION K Procedure 1. Place wooden blocks under the transmission at the con- verter housing and the extension housing positions. 2. Remove the oil pan and gasket. Examine any material found in the pan or on the magnet to determine the condition of the transmission. Clutch facing material . . . . . Drive plate and brake band wear Steel (magnetic) . . . . . . . . . . Bearing, gear, and driven plate wear Aluminum (nonmagnetic) . . Bushings or cast alumi- num parts wear If large amounts of material are found, replace the torque converter and carefully check the transmission for the cause. 3. Install the oil pan and gasket with a few bolts to protect the valve body. 4. Remove the vacuum diaphragm, lockup control solenoid valve, vehicle speed pulse generator, and O-rings. 5. Remove the parwneutral switch. 6. Remove the speedometer driven gear from the exten- sion housing. 7. Remove the O-ring from the speedometer driven gear. 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

BRAKE SYSTEM Disassembly / Assembly / lnspection 1. After removing the brake fluid, disassemble in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of removal, referring to Assembly Note. Caution The brake master cylinder Is made of aluminum, and can be easily damaged by tightening in a vise. When securing the master cylinder in a vise, tighten only the master cylinder flange. 1. Fluid level sensor connector 7. Snap ring Inspection ................... page P-17 8. Snap ring and spacer (ABS) 2. Screw 9. Primarv ist ton assemblv 3. Reservoir assembly inspect for abnormal wear, rust, and damage Inspect for damage and deformation 10. Secondary piston assembly 4. Bushings Inspect for abnormal wear, rust, and damage 5. Stop screw and O-ring 11. Master cylinder body e Assembly Note .............. page P-19 Inspect for abnormal wear, rust, and damage 6. Stop pin and O-ring (ABS) Replace unit as an assembly if damaged Assembly Note .............. page P-19 Gartner Banana

Q OUTLINE, TROUBLESHOOTING GUIDE OUTLINE Wheels SPECIFICATIONS Tires -2 TROUBLESHOOTING GUIDE Temporary spare 14x4T - - TY Pe Item Size Offset mm {in) Pitch circle diameter mm {in) Material Size Air pressure kPa {kgf/cm2, psi} Standard 14x5 112-JJ 45 11.77) 1 00 (3.94) Aluminum Alloy 185160R14 82H 177 {I .8, 26) Page Excessive or irregu- tar tire wear Premature tire wear Tire squeal body vibration I Unbalanced wheel@) 1 Adjust I Q-5 Steel T1 l5/7ODl4 41 2 {4.2,60) Action Problem 1 Tre deterioration 1 Replace I - I Deformed wheel(s) or tire(s) I Repair or replace I - Possible Cause Refer to page Q-4 for details. Road noise or I Insufficient tire pressure [ Adjust Incorrect tire pressure ( Adjust Incorrect tire pressure 1 Adjust Q-3 Q-3 0-3 Shake [Steering wheel "Ibrates Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) Insufficient tire pressure Unevenly worn tires Malfunction of shock absorber Loose shock absorber mounting bolts Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Shimmy (Steering wheel vibrates lefiIright) Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Irregular tire wear Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) - Q4 Q-5 Q-3 - section R section R section R section R Cracked or worn engine mount Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint I Damaged or worn front wheel bearing ( Replace ( section M Replace Replace Tighten Adjust or replace I Improperly adjusted front wheel alignment 1 Adjust I section R Uneven (one-sided) I Unequal tire pressures 1 Adjust 1 Q-3 - - Q-4 Q-5 Replace Replace Tighten Replace section B section N section N section N braking Steering wheel I Incorrect tire pressure 1 Adjust doesn't return properly or pulls to either left or right . General driving Instability Excessive steering (2-3 wheel play Irregular tire wear (lefthight) Unequal tire pressures Different types or brands of tires mixed (leftlright) Loose lug nuts Unequal tire pressures Damaged or unbalanced wheel(s) Loose lug nuts Loose lug nuts I 15UOQX-00 Replace Adjust Replace Tighten Adjust Replace or adjust Tighten Tighten - Q-3 - Q-4 Q-3 Q-5 Q-4 Q-4 Gartner Banana

TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Problem General instabllity Body "rolls" "Heavy" steering wheel operation Steering wheel pulls to one side Excessive steering wheel play Body leans Abnormal noise from suspension system Shake (Steering wheel tibrates upldown) Shimmy (Steering wheel vibrates leftlright) Possible cause Weak coil spring Malfunction of shock absorber Worn or damaged stabilizer and/or suspension arm bushings Worn or damaged upper or lower arm ball joint Improperly adjusted wheel alignment Weak stabilizer Worn or damaged stabilizer and/or suspension arm bushings Insufficiently lubricated or stuck upper arm lower arm ball joint lmproperly adjusted wheel alignment Weak coil spring Worn or damaged stabilizer and/or suspension arm bushings Deformed upper or lower arm or knuckle Loose upper or lower arm bushing Worn or damaged upper or lower arm bushing Worn or damaged upper or lower arm ball joint Weak coil spring Weak stabilizer andlor suspension arm bushings Loose mounting component Poorly lubricated or worn upper or lower arm ball joint Malfunction of shock absorber Worn or damaged stabilizer and/or suspension arm bushings Excessive tire or wheel runout Loose lug nuts Unbalanced wheel@) Cracked or worn engine mounting rubber Cracked or worn steering gear mounting rubber Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire or wheel runout Loose lug nuts Unbalanced wheel(s) Insufficient tire pressure Unevenly worn tires Malfunction of shock absorber Loose shock absorber mounting bolts Stuck or damaged upper or lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Action Replace Replace Replace Replace Adjust Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replace Tighten Replace Replace Replace Replace Tighten Adjust or replace Replace Replace Tighten Replace Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Replace Adjust Page R-13 R-12,22 R-16, 18, 19, 23,24,25 section M R-15,17 R- 6 R-19,25 R-16, 18,19, 23, 24,25 section M R-15,17 R- 6 R-13 R-16, 18,19, 23, 24,25 R-15,17 section M R-16,18 R-16,18 R-15,17 R-13 R-16, 18, 19, 23,24,25 section M 7 R-15,17 R-l2,22 R-16, 18,19, 23,24,25 section M - section Q section Q section B section N section N section N - section Q section Q section Q section Q R-l2,22 R-12,22 R-15, 17 R-16,18,19 section M R- 6 15UORX-00 Gartner Banana