differential MAZDA MX-5 1997 Factory Owner's Manual

Fig. 9: Removing Reamer Bolt Sleeve (Miata)
Courtesy of MAZDA MOTORS CORP.
Installation
1. To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during
removal and install axle shafts. Install differential. Raise transmission until engine and transmission are
level.
2. Position Power Plant Frame (PPF) in place. Install PPF/differential mounting spacer. Tighten bolts to 27-
38 ft. lbs. (37-52 N.m). Install and tighten PPF-to-transmission side mounting bolts.
3. Ensure sleeve is installed into PPF housing block. Install spacer and bolts. Ensure reamer bolt is installed
into front hole and tighten bolt. See Fig. 8
.
4. Install transmission-to-PPF bracket (M/T only). Install remaining PPF bolts. Refill differential with
NOTE: Front PPF-to-differential side mounting bolt is reamer bolt which aligns
PPF. See Fig. 8
.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
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lubricant. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedure.
OVERHAUL
DIFFERENTIAL
Disassembly (Standard Type)
1. Mount carrier in Differential Carrier Hanger (49-M005-561). Mark side bearing caps for reassembly
reference. Remove adjuster lock plates (if equipped). See Fig. 10
.
2. Loosen side bearing cap bolts and slightly back off adjusters. Remove side bearing caps. Remove
differential assembly from carrier. Mark side bearing races for reassembly reference. Remove adjusters
and side bearing races from differential.
3. Remove drive pinion lock nut and washer. Remove companion flange using Puller (49-0839-425C).
Remove oil seal, spacer, front bearing and collapsible spacer from carrier. Remove drive pinion, spacer
and rear bearing assembly from carrier. Remove bearing races using a drift and hammer in slots provided
on inner lip (as necessary).
4. Remove ring gear retaining bolts. Separate ring gear from differential case. Mark side bearings for
reassembly reference. Using Puller (49-0839-425C), remove side bearings from differential case. Remove
knock pin. Remove pinion shaft, pinion
gears, thrust washers, and side gears. See Fig. 10. NOTE: Mark positions of all components before disassembly.
NOTE: Overhaul procedure for Limited Slip Differential (LSD) is not available.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
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Sunday, July 05, 2009 1:52:42 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Exploded View Of Standard Differential & Carrier Assembly
Courtesy of MAZDA MOTORS CORP.
Reassembly & Adjustment (Standard Type)
1. Install side gears, thrust washers, pinion gears and pinion shaft. Position dial indicator against pinion
gear. See Fig. 11 . Secure one side gear.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
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Sunday, July 05, 2009 1:52:42 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 11: Measuring Side Gear & Pinion Gear Backlash
Courtesy of MAZDA MOTORS CORP.
2. Check side gear and pinion gear backlash. If backlash exceeds .004" (.10 mm), replace thrust washers.
See THRUST WASHER SPECIFICATIONS
table. Install and stake knock pin. Noting marks made
during disassembly, press side bearings onto differential assembly using Bearing Installer (49-G030-338
or 49-UB71-525) and Body (49-F401-331).
THRUST WASHER SPECIFICATIONS
3. Apply locking compound to rear face of ring gear. Install ring gear and tighten ring gear retaining bolts to
51-61 ft. lbs. (69-83 N.m). Using appropriate bearing installer set and press, install drive pinion bearing
races into differential carrier.
4. Put original spacer, rear bearing and Collar (49-H027-001) on Dummy Drive Pinion (49-8531-565). See
Fig. 12
. Secure collar with "O" ring. Install assembly into differential carrier.
Identifying MarkThickness - In. (mm)
0.0787 (2.000)
05.0807 (2.050)
1.0827 (2.100)
15.0846 (2.150)
2.0866 (2.200)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
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Sunday, July 05, 2009 1:52:42 PMPage 17 © 2005 Mitchell Repair Information Company, LLC.

5. Install front bearing and collar on dummy drive pinion. See COLLAR SELECTION table. Install
companion flange, washer and original drive pinion lock nut. Tighten drive pinion lock nut so dummy
drive pinion assembly can be turned by hand.
COLLAR SELECTION
ApplicationCollar No.
Miata49-8531-567
MPV49-U027-001

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
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1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 19 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Checking Drive Pinion Installation & Position
Courtesy of MAZDA MOTORS CORP.
6. Install dial indicator on Pinion Height Gauge (49-0727-570). Place pinion height gauge on a flat surface
and zero dial indicator. Position gauge block on top of dummy drive pinion assembly. See GAUGE
BLOCK SELECTION table.
GAUGE BLOCK SELECTION
7. Place pinion height gauge on top of gauge block. Position dial indicator to measure distance to a point
where side bearing sits. Measure lowest point. See Fig. 12
. Measure both sides. Add both measurements
together and divide by 2.
8. If result is not zero, replace pinion spacer. Spacers are available in a range of .1213-.1366" (3.080-3.470
mm) in .001" (.03 mm) increments. Remove dummy drive pinion. Press rear bearing onto drive pinion.
9. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential carrier.
DO NOT install pinion oil seal yet. DO NOT exceed one-ton force; collapsible spacer will be damaged.
10. Install washer and drive pinion lock nut. Temporarily tighten drive pinion lock nut. Turn companion
flange by hand to seat bearing. Using torque wrench, tighten drive pinion lock nut to specification. See
TORQUE SPECIFICATIONS
. Check pinion bearing preload at drive pinion lock nut. See PINION
PRELOAD SPECIFICATIONS table. If pinion bearing preload is not as specified, replace collapsible
spacer and recheck preload.
PINION PRELOAD SPECIFICATIONS
11. Remove drive pinion lock nut, washer and companion flange. Install pinion oil seal. Lubricate oil seal lip
with differential oil. Install companion flange and washer. Install NEW drive pinion lock nut and tighten
to specification. See TORQUE SPECIFICATIONS
. Recheck pinion bearing preload. Lubricate end of
companion flange with grease.
12. Position differential assembly into differential carrier. Install side bearing adjusters. Position side bearing
caps. Align marks made during disassembly. Install side bearing cap bolts and hand-tighten bolts.
13. Ti
ghten side bearing adjusters equally until adjusters contact bearing races. Mark ring gear in 4 locations,
ApplicationGauge Block No.
Front Differential
MPV
4WD49-0305-555
Rear Differential
Miata49-0305-555
MPV49-0660-555
ApplicationINCH Lbs. (N.m)
Miata7.8-12.1 (0.9-1.3)
MPV 2WD11.3-15.6 (1.3-1.8)
MPV 4WD
Front7.8-12.2 (0.9-1.4)
Rear11.3-15.6 (1.3-1.8)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 20 © 2005 Mitchell Repair Information Company, LLC.

90 degrees apart. Position dial indicator against ring gear to check ring gear backlash.
14. Check backlash at all 4 locations. Tighten side bearing adjusters equally until backlash is .0035-
.0043" (.09-.11 mm). Minimum backlash at any point is .002" (.05 mm). Difference between minimum
and maximum backlash should not exceed .0028" (.07 mm).
15. To set differential bearing preload, tighten adjusters equally until distance between measuring points on
carrier bearing caps is within specification. See Fig. 13
. See DIFFERENTIAL CARRIER
DIMENSIONS table.
16. Ensure backlash did not change when preload was set. Tighten side bearing cap bolts to specification. See
TORQUE SPECIFICATIONS. Check ring gear tooth patterns. See GEAR TOOTH CONTACT
PATTERNS article in GENERAL INFORMATION.
17. To complete reassembly, reverse disassembly procedure. Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS
.
DIFFERENTIAL CARRIER DIMENSIONS
Application(1) In. (mm)
Miata7.300-7.303 (185.43-185.50)
MPV 2WD8.022-8.050 (203.78-204.50)
MPV 4WD
Front7.275-7.303 (184.78-185.50)
Rear8.022-8.050 (203.78-204.50)
(1)See illustration for measuring point. See Fig. 13 .

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Measuring Carrier Case Spread
Courtesy of MAZDA MOTORS CORP.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (MIATA)
ApplicationFt. Lbs. (N.m)
Differential Carrier Bearings Cap Bolts28-38 (38-52)
Differential Carrier Bearings Lock Plate Bolt13-18 (18-25)
Differential Carrier-To-Housing Bolts17-19 (23-26)
Differential-To-Chassis Mount Nuts
Inner Nut61-72 (83-98)
Outer Nuts (2)13-20 (18-27)
Drive Axle Inner CV Joint Flange Nuts40-47 (54-64)
Drive Pinion Lock Nut94-209 (128-284)
Drive Shaft Companion Flange Nuts20-22 (27-30)
Exhaust Pipe Mount Nuts30-41 (40-55)
Filler Plug29-40 (39-54)
Power Plant Frame Bracket
To-Power Plant Frame Bolt (M/T)77-91 (104-123)
To-Transmission Bolts (M/T)27-40 (37-54)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS (MPV)
Power Plant Frame-To-Differential
Side Mounting Bolts (Long)77-91 (104-123)
Spacer Bolt (Short)27-38 (37-52)
Power Plant Frame-To-Transmission Side Mounting Bolts (Long)77-91 (104-123)
Ring Gear Retaining Bolts51-61 (69-83)
Wheel Lug Nuts65-87 (88-118)
ApplicationFt. Lbs. (N.m)
AFW Extension Housing Mount Nut (4WD)49-72 (66-98)
Brake Pipe Union10-16 (14-22)
Differential Carrier Bearings Cap Bolts Front Differential27-38 (37-52)
Differential Carrier Bearings Cap Bolts Rear Differential54-78 (73-106)
Differential Carrier Bearings Lock Plate Bolt13-19 (18-26)
Differential Carrier-To-Housing Nuts/Bolts17-19 (23-26)
Differential-To-Chassis Mount Nuts (4WD)49-72 (66-98)
Drive Pinion Lock Nut94-210 (127-284)
Drive Shaft Companion Flange Nuts37-43 (50-58)
Filler Plug29-40 (39-54)
Lower Ball Joint-To-Control Arm Bolts (4WD)75-101 (102-137)
Lower Ball Joint-To-Control Arm Nut (4WD)94-127 (127-172)
Rear ABS Wheel Speed Sensor Bolt12-16 (16-22)
Rear Axle Shaft Assembly-To-Axle Shaft Housing Retaining Nuts40-49 (54-66)
Rear Brake Caliper Bolts37-43 (50-58)
Ring Gear Retaining Bolts51-61 (69-83)
Skid Plate Bolts (4WD)12-17 (16-23)
Tie Rod End Nut (4WD)43-58 (58-78)
Wheel Lug Nuts65-87 (88-118)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.