1991 MAZDA MIATA Air Force

A double-lock mechanism is used on clockspring connectors. DO NOT use excessive force when
disconnecting connectors, as damage to connector may occur.
DISABLING & ACTIVATING AIR BAG SYSTEM
AIR BAG SYSTEM
DISABLING SYSTEM
On Miata, obtain radio code number from customer, and deactivate audio anti-theft function. On all models,
turn ignition switch off. Disconnect and shield negative battery cable. Remove knee protector. Disconnect
Orange and Blue clockspring connectors at base of steering column. See Fig. 1
.
ACTIVATING SYSTEM
Reconnect battery and clockspring connectors. Turn ignition switch to RUN position. Check AIR BAG
indicator li
ght to ensure system is operating properly. See SYSTEM OPERATION CHECK. WARNING:Wait about 10 MINUTES after disabling air bag system before servicing.
Air bag system voltage is maintained for about 10 MINUTES after system
is disabled. Failure to wait 10 MINUTES before servicing system may
cause accidental air bag deployment and possible personal injury.

1991 Mazda MX-5 Miata
AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS
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ADJUSTMENTS
CLOCKSPRING CENTERING
Set front wheels in straight-ahead position. Turn clockspring connector clockwise until it stops (do not force).
Return connector 2 3/4 turns counterclockwise. Rotate clockspring connector further, if necessary, to align
marks on connector and outer housing.
DISPOSAL PROCEDURES
DEPLOYED AIR BAG
Dispose deployed air bag module as you would any other part. Wear gloves and safety glasses when handling
air bag module.
SCRAPPED VEHICLE
1. Ensure vehicle is outside, and away from other vehicles and people. Open convertible top and doors.
Disconnect negative battery cable.
2. Ensure air bag module is firmly mounted to steering wheel. Remove knee protector and disconnect
Orange and Blue clockspring connectors at base of steering column. See Fig. 1
. Cut clockspring
connector Blue wires.
3. Connect 2 jumper wires (20 feet long) to cut clockspring wires. Connect other ends of wires to a 12-volt
battery to deploy air bag. Because of heat, wait 10 MINUTES before touching deployed air bag.
REMOVAL & INSTALLATION
CRASH SENSORS NOTE: Perform the following procedures when scrapping a vehicle with undeployed air
bag.
WARNING:Follow air bag service precautions to prevent accidentalair bag
deployment and personal injury. See SERVICE PRECAUTIONS.
NOTE: After component replacement, check system to ensure proper operation. See
SYSTEM OPERATION CHECK.
NOTE: Crash sensor orientation and mounting is important for proper operation. All
sensors must be positioned so that arrow points forward. If there is sheet metal
damage near sensor mounting point, inspect body structure at sensor
mounting point for deformation. If damaged, restore to original shape. Ensure
sensor mounting bolts or nuts are tightened to specification. See TORQUE
SPECIFICATIONS table.

1991 Mazda MX-5 Miata
AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS
Microsoft
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Fig. 3: Locating Crash Sensors (RX7 Convertible)
Courtesy of MAZDA MOTORS CORP.
Installation
To install, reverse removal procedure. Position sensor with arrow toward front of vehicle. Tighten mounting
bolts to specification. See TORQUE SPECIFICATIONS table. Reactivate air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM. Check AIR BAG indicator light to ensure system is functioning properly.
See SYSTEM OPERATION CHECK.
Removal (Rear Safing Sensor)
Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS. Disable air bag system.
See DISABLING & ACTIVATING AIR BAG SYSTEM. Rear safing sensor is located under center of
instrument panel. Remove instrument panel. Locate and disconnect safing sensor connectors. See Fig. 2
or Fig.
3 . Remove sensor and cover.
Installation
To install, reverse removal procedure. Position sensor with arrow toward front of vehicle. Tighten mounting
nuts to specification. See TORQUE SPECIFICATIONS table. Reactivate air ba
g system. See DISABLING &
CAUTION: A double-lock mechanism is used on clockspring connectors. DO NOT
use excessive force when disconnecting connectors, as damage to
connector may occur.

1991 Mazda MX-5 Miata
AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS
Microsoft
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engagement while rotating adjusting screw to prevent burring screw slots. Ensure adjusting screw rotates
freely.
PARKING BRAKE
B2200 & B2600i
1. Depress brake pedal several times while vehicle is moving in Reverse. Ensure brakes are properly
adjusted. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 7-12 notches, parking brake
is properly adjusted.
2. If stroke is not 7-12 notches, raise and support rear of vehicle. Release parking brake lever. Loosen cable
lock nut at lever end of cable. Rotate adjusting nut until correct stroke is obtained. Operate parking brake
several times and ensure rear wheels rotate freely. Ensure parking brake warning light illuminates when
brake lever is pulled one notch.
Navajo
1. Adjust service brakes before adjusting parking brake cable. Ensure brake drums are cold. Apply parking
brake to fully depressed position. Grip threaded rod to prevent it from spinning.
2. Thread equalizer nut 6 full turns past its original position on threaded rod. See Fig. 4
. Check cable
tension at rear of equalizer assembly using Cable Tension Gauge (021-00018). If tension is not 400-600
lbs. (182-272 k
g), repeat step 2).

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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Fig. 4: Adjusting Parking Brake (Navajo)
Courtesy of FORD MOTOR CO.
3. Release pedal, and check rear wheel drag. If drag is noted, remove drums, and check for clearance
between parking brake lever and cam plate. Cables should be tight enough to allow full application of rear
brakes and loose enough to allow full release of rear brakes.
929
1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 6-8
notches, parking brake is properly adjusted. If stroke is not 6-8 notches, adjust parking brake shoes. See
PARKING BRAKE SHOES under ADJUSTMENTS
.
NOTE: Tension limiter will reset parking brake tension any time system is
disconnected if distance between bracket and cinch strap hook is reduced
during adjustment. When adjustment has been performed so cinch strap
contacts bracket, system tension will increase greatly. This may cause an over-
tension condition. When available adjustment travel has been used, replace
tension limiter.
NOTE: If rear brake shoes are removed for any reason, parking brake cable

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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2. Release parking brake lever. Using a screwdriver, reach through parking brake handle hole in console and
rotate adjusting screw until stroke is 6-8 notches. Ensure rear wheels rotate freely. Ensure parking brake
warning light illuminates when brake lever is pulled one notch.
Miata, MX-6, MPV, Protege, RX7, 323, 626
1. On models with rear disc brakes, depress brake pedal several times. On models with rear drum brakes,
start engine and depress brake pedal several times while vehicle is moving in Reverse. Stop engine.
2. On all models, pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 5-7 notches, parking
brake is properly adjusted. If stroke is not 5-7 notches, raise and support rear of vehicle. Release parking
brake lever.
3. Rotate cable adjusting nut at lever end of cable (under console cover) until stroke is within specification.
On models equipped with rear disc brakes, ensure clearance between stopper and lever (at each caliper) is
not less than .08" (2 mm) on RX7, or zero on all other models. On all models, ensure parking brake
warning light illuminates when brake lever is pulled one notch.
PARKING BRAKE SHOES
929
Raise and support vehicle. Remove rear wheels. Remove service plug from rotor. Using a screwdriver, rotate
star wheel adjuster toward axle until rotor locks. Rotate adjuster in opposite direction 3-5 notches. Ensure rotors
turn freely and parking brake functions properly. Install service plug and rear wheels.
PEDAL FREE PLAY
Depress pedal a few times to eliminate vacuum. Pedal free play should be .16-.28" (4-7 mm). Adjust play by
loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut.
PEDAL HEIGHT & STOPLIGHT SWITCH
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Move switch away
from pedal. Loosen push rod lock nut. Turn rod until correct pedal height is obtained. See BRAKE
PEDAL HEIGHT SPECIFICATIONS .
2. Adjust pedal free play. See PEDAL FREE PLAY
under ADJUSTMENTS. Tighten push rod lock nut.
Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight
switch lock nut. Reconnect stoplight switch electrical connector.
3. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. On B2200, B2600i and MPV, depress brake pedal with 33 lbs. (15 kg) pressure. On all other
models, depress brake pedal with 132 lbs. (60 k
g) pressure. tension should be checked and adjusted.
NOTE: Pedal height and stoplight switch information is not available for Navajo.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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3. Using Bearing Nut Wrench (49 0603 635A ) and Shaft Holder (49 S120 645A ), remove bearing lock nut
from axle shaft. Remove bearing and bearing retainer from axle using Puller (49 S120 520A ). Remove
outer race from hub.
END PLAY SPECIFICATIONS
(1)
Installation
1. Press new oil seal and bearing outer race into bearing retainer. Coat bearing race and outer seal with
grease. Tap inner oil seal flush with end of axle housing. Coat inner seal lip with grease.
2. Position brake backing plate onto axle shaft. Install spacer against backing plate with chamfer facing
backing plate. Using Press Attachment (49 S120 748 ) and a press, install wheel bearing onto axle shaft.
Standard press force is 4.6-6.7 tons (4200-6100 kg). If press fit force is too high or too low, replace the
bearing collar or shaft.
3. Using Bearing Nut Wrench (49 0603 635A ), install bearing lock nut to axle shaft and tighten to 145-217
ft. lbs. (196-245 N.m). Bend tab up into groove. Install one axle shaft into axle housing. Tighten backing
plate nuts to specification. Install dial indicator on backing plate and check drive axle end play.
4. To adjust end play, remove axle and insert appropriate size adjustment shim between axle hub and
housing. End play for second drive axle installed should be set to normal end play clearance of .002-
.010" (.05-.25 mm), with both axles installed.
5. Install parking brake cable, attaching pin and brake line. Install brake shoes and actuating hardware.
Bleed brake system. Install wheel and tire.
BEARING RETAINER SHIMS (B2200 & B2600i)
MPV 4WD
NOTE: On B2200 and B2600i, left axle bearing lock nut has left-hand threads.
ApplicationIn. (mm)
B2200 & B2600i
One Axle Installed.026-.037 (.65-.95)
Both Axles Installed.002-.010 (.05-.25)
(1)Check at axle flange with dial indicator.
NOTE: Ensure end play for first drive axle is within specification before inserting
second drive axle. Use shims to adjust end play if necessary.
Part NumberThickness In. (mm)
083 26 165.004 (.10)
083 26 166.006 (.15)
083 26 167.020 (.50)
083 26 168.030 (.75)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to a point where
side bearing sits. Measure lowest point. See Fig. 11
. Measure both sides. Add both measurements
together and divide sum by 2.
5. If measurement is not zero, replace pinion spacer. Spacers are available in a range of .1213-
.1366" (3.081-3.470 mm), in .001" (.03 mm) increments. Remove dummy pinion shaft. Press rear pinion
bearing on pinion shaft.
6. Install pinion shaft, spacer, front bearing, collapsible spacer and companion flange in differential housing.
DO NOT install pinion seal at this time. DO NOT exceed one ton force or collapsible spacer will be
damaged.
7. Temporarily tighten drive pinion nut. Turn companion flange by hand to seat bearing. Tighten drive
pinion nut to 94-130 ft. lbs. (128-177 N.m). Check pinion bearing preload, at drive pinion nut. See
PINION PRELOAD SPECIFICATIONS
. If pinion bearing preload is not as specified, replace
collapsible spacer and recheck preload.
8. Remove drive pinion nut and companion flange. Install pinion seal. Apply oil to seal lip. Install
companion flange. Using a new drive pinion nut, tighten nut to 94-130 ft. lbs. (128-177 N.m). Recheck
pinion bearing preload.
PINION PRELOAD SPECIFICATIONS
4WD &
929
Miata49 N027 001
ApplicationINCH lbs. (N.m)
B2200 & 92911.3-15.6 (1.3-1.8)
B2600i 4WD
Front11.3-15.6 (1.3-1.8)
Rear7.8-12.2 (0.9-1.4)
Miata & Protege 4WD (Rear)2.6-6.1 (0.3-0.7)
MPV 4WD
Front7.8-12.2 (0.9-1.4)
Rear11.3-15.6 (1.3-1.8)
RX7
Non-Turbo7.8-12.1 (0.9-1.4)
Turbo11.3-15.6 (1.3-1.8)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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