MAZDA MX-5 1997 Factory Repair Manual

MX-3 (4-Cylinder)
1. Install and temporarily tighten adjusting cover to 95 INCH lbs. (10.7 N.m). Move steering rack back and
forth about 3 times, then loosen adjusting cover. Tighten adjusting cover 40-47 INCH lbs (4.5-5.3 N.m)
then loosen adjusting cover 0-40 degrees. Apply thread sealant to adjusting cover lock nut. Install lock
nut. Holding adjusting cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m).
2. Center steering rack. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure
pinion preload using spring scale. With steering rack in center position, pinion preload should be 2.2-3.0
lbs. (1.0-1.4 kg). With steering rack in any other position, pinion preload should be a maximum of 3.7 lbs.
(1.7 kg). If preload is not as specified, repeat steps 1) and 2).
MX-3 (V6)
1. Center steering rack. Install and temporarily tighten adjusting cover to 100 INCH lbs. (11.3 N.m), then
loosen cover. Tighten adjusting cover 40-47 INCH lbs. (4.5-5.3 N.m), then loosen cover 45 degrees.
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. With steering rack in center position (plus or minus 90 degrees), preload should be 2.2-2.6
lbs. (1.0-1.2 kg). With steering rack in any other position, preload should be a maximum of 3.7 lbs. (1.7
kg).
3. If preload is as specified, apply thread sealant to adjusting cover lock nut. Install lock nut. Holding
adjusting cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m). If preload is not as specified, repeat
steps 1) and 2).
MX-6 & 626
1. Center steering rack. Install and temporarily tighten adjusting cover to 87 INCH lbs. (9.8 N.m), then
loosen adjusting cover. Tighten adjusting cover 39-48 INCH lbs (4.4-5.4 N.m) then loosen adjusting
cover 20 degrees. Apply thread sealant to adjusting cover lock nut. Install lock nut. Holding adjusting
cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m).
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. With steering rack in center position (plus or minus 90 degrees), pinion preload should be
2.8-3.3 lbs. (1.3-1.5 kg). If preload is not as specified, repeat steps 1) and 2).
RX7
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover 87 INCH lbs. (9.8 N.m), then loosen adjusting cover 20-25 degrees. See Fig. 2
.
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. Pinion preload should be 3.3 lbs. (1.5 kg) maximum.
3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to
adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-50 ft. lbs.
(50-68 N.m).
929
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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adjusting cover 15-21 ft. lbs. (20-28 N.m), then loosen adjusting cover 25 degrees. See Fig. 2.
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. Pinion preload should be 3.3 lbs. (1.5 kg) maximum.
3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to
adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-50 ft. lbs.
(50-68 N.m).
PINION SHAFT & VALVE HOUSING ASSEMBLY
Miata
1. With steering rack assembly secured in a vise, pull steering rack out until distance between end of rack
and end of rack housing is 2.38" (60.5 mm). See Fig. 4
.
2. If reusing original gear housing, pinion shaft and valve housing, install same number of shims that were
removed during disassembly procedure. If installing a NEW gear housing, pinion shaft and/or valve
housing, install same number of shims that were removed during disassembly procedure, and go to next
step.
3. Install and tighten valve housing bolts 15-21 ft. lbs. (20-28 N.m). Using a feeler gauge, measure clearance
between gear housing and valve housing. See Fig. 5
. Add or remove necessary shims until clearance is
zero.
Fig. 4: Centering Steering Rack (Miata Shown; Others Are Similar)

Courtesy of FORD MOTOR CO.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Sunday, July 05, 2009 1:39:26 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Measuring Gear Housing To Valve Housing Clearance (1996-97 Miata)
Courtesy of FORD MOTOR CO.
POWER STEERING PUMP BELT
BELT ADJUSTMENT SPECIFICATIONS
Application(1) Deflection In. (mm)
Miata & Protege
New Belt.31-.35 (8.0-9.0)
Used Belt.35-.39 (9.0-10.0)
Millenia
2.3L(2)
2.5L
New Belt.23-.27 (6.0-7.0)
Used Belt.27-.31 (7.0-8.0)
MPV
New Belt.27-.35 (7.0-7.5)

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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REMOVAL & INSTALLATION
STEERING GEAR
Removal & Installation (Miata & MPV)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove cotter pins and castle nuts from tie rod ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. Mark steering column
intermediate shaft-to-steering column gear pinion for installation reference. Remove steering column
intermediate shaft-to-steering gear pinion shaft bolt. Place reference marks on steering gear and pressure
line fitting for reassembly.
3. Disconnect pressure and return line connections from steering gear. On Miata, remove steering gea
r-to-
Used Belt.35-.33 (7.5-8.2)
MX-3
4-Cylinder
New Belt.31-.35 (8.0-9.0)
Used Belt.35-.39 (9.0-10.0)
V6
New Belt.23-.27 (6.0-7.0)
Used Belt.27-.31 (7.0-8.0)
MX-6 & 626
4-Cylinder
New Belt.30-.35 (7.5-9.0)
Used Belt.32-.37 (8.1-9.4)
V6
New Belt.24-.27 (6.0-7.0)
Used Belt.27-.31 (7.0-8.0)
RX7
New Belt.14-.16 (3.5-4.0)
Used Belt.18-.20 (4.5-5.0)
929
New Belt.23-.25 (5.8-6.3)
Used Belt.27-.30 (6.9-7.7)
(1)Belt deflection is measured at midpoint between idler pulley and pump, with 22 lbs. (10 kg.) of
pressure applied.
(2)Serpentine belt with an automatic tensioner is used. No adjustment is necessary. If pointer on
tensioner is not within wear gauge limit, replace belt.
NOTE: Use a suitable container or rags to collect fluid when disconnecting pressure
and return lines.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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frame mounting bolts. Remove steering gear and linkage from vehicle. On MPV, remove steering gear
bracket-to-frame mounting bolts. Remove steering gear and linkage with steering bracket from vehicle.
Remove 4 steering gear-to-bracket bolts and separate gear from bracket.
4. On all models, to install, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table. On MPV, tighten steering gear-to-bracket bolts in sequence: left front, right
front, left rear, right rear. On all models, fill and bleed power steering system. Check and adjust front
wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (Millenia)
1. Disconnect negative battery cable. Support engine using Engine Support (49-G017-5A0 ). Raise and
support front of vehicle. Remove front wheel assemblies. Remove cotter pins and castle nuts from tie rod
ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. Remove transverse
member bolts and remove transverse member. See Fig. 6
Disconnect pressure and return line connections
from steering gear. Remove intermediate shaft pinch bolt.
3. Reference mark lower steering column-to-intermediate shaft. Remove engine mount member. Remove
No. 1 engine mount bolts. Remove upper lateral link bolt and separate upper lateral link from
crossmember. Remove lower control arm-to-crossmember mounting bolt and gusset. Separate lower
control arm from crossmember.
4. Remove stabilizer link-to-lower control arm nut. Separate stabilizer link from lower control arm. Using a
jack, support front suspension crossmember. Remove crossmember retaining nuts. Carefully lower
crossmember. Disconnect stabilizer link from stabilizer bar. Remove stabilizer bar brackets, bushings and
stabilizer bar. Remove steering gear mounting nuts. Remove steering gear assembly.
5. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table. Tighten steering gear mounting nuts in sequence: right front, left rear, right rear, left front. Fill and
bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Fig. 6: Removing Steering Gear Assembly (Millenia)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-3 & Protege)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. On MX-3 DOHC, remove
support bracket bolt, nut and rubber insulator. Remove steering gear insulator bolts and remove insulator.
On all models, remove intermediate shaft dust cover.
3. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference.
Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Disconnect pressure and
return line connections from steering gear.
4. On M/T, remove mounting nuts and bolts from extension bar and control rod. Remove extension rod and
control rod. On all models, remove steering gear mounting nuts. Remove steering gear and linkage from

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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vehicle through passenger side wheelwell.
5. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS table. Tighten steering gear mounting nuts in sequence: left rear, right rear, left
front, right front. Fill and bleed power steering system. Check and adjust front wheel alignment. See
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (MX-6 & 626)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove cotter pins and castle nuts from tie rod ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. On 2.5L engines, remove
transverse member bolts and remove transverse crossmember. Remove front exhaust pipe and catalytic
converter assembly nuts and remove assembly.
3. On all models, support engine using Engine Support (49-G017-5A0 ), and remove engine mount. Mark
steering column intermediate shaft-to-steering column gear pinion for installation reference. Remove
steering column intermediate shaft-to-steering gear pinion shaft bolt.
4. Disconnect pressure and return line connections from steering gear. Remove steering gear mounting nuts.
Remove steering gear and linkage from vehicle through passenger's side wheelwell.
5. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table. Tighten steering gear mounting nuts in sequence: left front, right front, right rear, left rear. Fill and
bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (RX7)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends. Using Puller Set (49-
T028-3A0 ), separate tie rod ends from steering knuckles.
2. Remove stabilizer bar-to-frame bolts and brackets. Disconnect pressure and return line connections from
steering gear. Mark steering column intermediate shaft-to-steering column gear pinion for installation
reference.
3. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove steering gear
mounting bolts. Support crossmember with jack and remove crossmember nuts and bolts. Slowly lower
jack and remove steering gear and linkage from vehicle.
4. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS table. Tighten steering gear mounting bolts in sequence: left rear, right rear, left
front, right front. Fill and bleed power steering system. Check and adjust front wheel alignment. See
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (929)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends. Using Puller Set (49-
T028-3A0 ), separate tie rod ends from steering knuckles.
2. Disconnect pressure and return line connections from steerin
g gear. Mark steering column intermediate

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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shaft-to-steering column gear pinion for installation reference. Remove steering column intermediate
shaft-to-steering gear pinion shaft bolt. Remove steering gear mounting nuts. Remove steering gear and
linkage from vehicle.
3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS table. Tighten steering gear mounting nuts in sequence: left rear, left front, right
front, right rear. Fill and bleed power steering system. Check and adjust front wheel alignment. See
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
POWER STEERING PUMP
Removal & Installation
1. Remove drive belt. On Millenia, MPV, MX-6, RX7, 626 and 929, remove pulley lock nut and remove
pulley from pump. On all models, disconnect power steering pressure switch electrical connector (if
equipped).
2. Place reference marks on steering pump and pressure line fitting for reassembly. Disconnect pressure and
return line connections from steering pump. Remove pump-to-
bracket bolts and nuts. Remove pump from
vehicle.
3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS table. Adjust belt tension. See POWER STEERING PUMP BELT under
ADJUSTMENTS. Bleed air from system. Inspect system for leaks.
OVERHAUL
STEERING GEAR
Disassembly & Reassembly
1. Remove steering gear assembly. See STEERING GEARunder REMOVAL & INSTALLATION. As an
aid to disassembly and reassembly, use illustrations. See Fig. 7
-16 . For reassembly reference, keep
components in order of disassembly. Replace worn or damaged components as necessary.
2. On 1996-97 Miata, after installing valve housing, check clearance between gear housing and valve
housing. See PINION SHAFT & VALVE HOUSING ASSEMBLY
under ADJUSTMENT. Adjust
clearance as necessary. On all models, after steering rack reassembly, but before installing tie rods, check
pinion preload. See PINION PRELOAD
under ADJUSTMENTS. NOTE: Use a suitable container or rags to collect fluid when disconnecting pressure
and return lines.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Fig. 7: Exploded View Of Rack & Pinion Steering Gear (1995 Miata)
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Fig. 8: Exploded View Of Rack & Pinion Steering Gear (1996-97 Miata)
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Sunday, July 05, 2009 1:39:26 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.