1991 MAZDA MIATA brake

DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
Rotor-To-Hub Bolt
B2200 & B2600i40-51 (54-69)
MX-6 & 62636-43 (49-58)
32333-40 (45-54)
Wheel Bearing Lock Nut
B2200 & B2600i (Rear)145-217 (197-295)
323 (Front)116-174 (158-237)
Wheel Lug Nut
B2200 & B2600i
Standard Wheel65-87 (88-118)
Styled Wheel87-108 (118-147)
Navajo85-115 (115-155)
All Others65-87 (88-118)
INCH Lbs. (N.m)
Parking Brake Cable Lock Nut
B2200 & B2600i60-84 (7-10)
All Others168-252 (19-29)
Wheel Cylinder Mounting Bolt
B2200 & B2600i 2WD108-144 (12-16)
B2600i 4WD180-216 (20-24)
Except B2200, B2600i & Navajo (2) 84-108 (10-12)
(1)These bolts secure caliper directly to steering knuckle. On Protege, tighten to 29-36 ft. lbs. (39-49
N.m). On RX7, tighten to 58-72 ft. lbs. (78-98 N.m).
(2)Information is not available from manufacturer for Navajo.
ApplicationIn. (mm)
B2200 & B2600i 2WD Front (1)
Original Thickness.79 (20)
Discard Thickness.71 (18)
B2600i 4WD Front (1)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Miata
Front (2)
Original Thickness.71 (18)
Discard Thickness.63 (16)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:09 PMPage 39 © 2005 Mitchell Repair Information Company, LLC.

Rear (2)
Original Thickness.35 (9)
Discard Thickness.28 (7)
MPV Front (2)
Original Thickness.94 (24)
Discard Thickness.87 (22)
MX-6 & 626
Front (2)
Original Thickness.94 (24)
Discard Thickness.87 (22)
Rear (2)
Original Thickness.39 (10)
Discard Thickness.31 (8)
Navajo Front (3)
Original Thickness.94 (24)
Discard Thickness.81 (21)
Protege & 323
Front (2)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Rear (2)
Original Thickness.35 (9)
Discard Thickness.28 (7)
RX7
Front (2)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Rear (2)
Solid Rotor
Original Thickness.39 (10)
Discard Thickness.31 (8)
Ventilated Rotor
Original Thickness.79 (20)
Discard Thickness.71 (18)
929
Front (2)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Rear (2)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:09 PMPage 40 © 2005 Mitchell Repair Information Company, LLC.

DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS
.71 (18)
Discard Thickness.63 (16)
(1)Maximum lateral runout is .006" (.15 mm).
(2)Maximum lateral runout is .004" (.10 mm).
(3)Maximum lateral runout is .003" (.08 mm).
ApplicationIn. (mm)
B2200 & B2600i
Drum Diameter
Original10.24 (260.0)
Minimum10.30 (261.5)
Wheel Cylinder Bore Diameter
B2200 & B2600i 2WD0.750 (19.05)
B2600i 4WD0.688 (17.46)
MPV
Drum Diameter
Original10.24 (260)
Minimum10.30 (261.5)
Wheel Cylinder Bore Diameter0.690 (17.50)
MX-6 & 626
Drum Diameter
Original9.00 (228.6)
Minimum9.06 (230.1)
Wheel Cylinder Bore Diameter0.875 (22.22)
Navajo
Drum Diameter
Original
9"9.00 (228.6)
10"10.00 (254.0)
Minimum
9"9.09 (230.8)
10"10.09 (256.3)
Protege & 323
Drum Diameter
Original9.00 (228.6)
Minimum9.04 (229.6)
Wheel Cylinder Bore Diameter0.875 (22.22)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:09 PMPage 41 © 2005 Mitchell Repair Information Company, LLC.

Battery voltage is always applied to terminal "B".
DO NOT ground terminal "L" while engine is running.
DO NOT start engine with connector disconnected from terminals "L" and "S".
DO NOT apply battery voltage to terminal "L".
ON-VEHICLE TESTING
ALTERNATOR OUTPUT
1. Connect an ammeter (80-amp minimum) in-line between terminal "B" connector and wire. See Fig. 2
,
Fig. 3
and Fig. 4 . Turn all headlights and accessories on and depress brake pedal. With engine operating
at 2500-3000 RPM, measure output amperage. NOTE: Check alternator wiring harness connections and drive belt tension. Battery
must be fully charged before testing. Wait at least 30 seconds after starting
engine before measuring system voltage.
CAUTION: Ensure alternator terminal "B" does not contact ground.

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
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Sunday, July 05, 2009 2:14:54 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Identifying Alternator Terminals (1992 All Other Models)
Courtesy of MAZDA MOTORS CORP.
2. If output amperage is not equal to or more than amount specified in ALTERNATOR OUTPUT table,
repair or replace alternator as necessary.
3. Turn off all accessories and release brake pedal. With engine operating at 2500-3000 RPM, measure
output amperage. If output amperage is not at least 5 amps, repair or replace alternator as necessary.
4. With engine operating at 2500-3000 RPM, measure voltage between terminal "S" and ground. If reading
is not 14.1-14.7 volts, repair or replace alternator as necessar
y.

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
Microsoft
Sunday, July 05, 2009 2:14:54 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

DIFFERENTIAL CAPACITY SPECIFICATIONS (1)
FLUID TYPE
DIFFERENTIAL LUBRICATION SPECIFICATIONS
(1)
TROUBLE SHOOTING
See TROUBLE SHOOTING - BASIC PROCEDURES article in the TROUBLE SHOOTING Section.
REMOVAL & INSTALLATION
REAR AXLE SHAFTS & BEARINGS
Removal (B2200 & B2600i)
1. Raise and support vehicle. Remove rear wheels. Remove brake drum and shoes. Using a dial indicator,
measure axle flange lateral movement. If bearing play is not within specification, bearing shim must be
adjusted during installation. See END PLAY SPECIFICATIONS
.
2. Disconnect brake line from wheel cylinder. Plug line openings. Disconnect parking brake cable. Remove
backing plate retaining nuts. Remove axle shaft and backing plate as an assembly.
ApplicationQts. (L)
B2200 (Front & Rear)1.3 (1.2)
B2600i
Front1.6 (1.5)
Rear1.8 (1.7)
Miata.69 (.65)
MPV 2WD1.6 (1.5)
MPV 4WD
Front1.8 (1.7)
Rear1.6 (1.5)
Protege 4WD.69 (.65)
RX7
Non-Turbo1.4 (1.3)
Turbo1.5 (1.4)
9291.4 (1.3)
(1)Fill to lower edge of filler plug hole.
ApplicationSpecification
Above 0°F (-18°C)GL-5/SAE 90W
Below 0°F (-18°C)GL-5/SAE 80W
(1)Fill to lower edge of filler plug hole.

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
Microsoft
Sunday, July 05, 2009 2:17:01 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, July 05, 2009 2:17:01 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

1. Raise and support vehicle. Remove rear wheels. Remove brake drum and shoes. Using a dial indicator,
measure axle flange lateral movement. Replace bearing if play exceeds If bearing play exceeds .023" (.57
mm). Disconnect brake line from wheel cylinder. Plug line openings. Disconnect parking brake cable.
2. Remove backing plate retaining nuts. Remove axle shaft and backing plate as an assembly. Use puller or
slide hammer to pull axle and bearing from axle housing. With axle removed, remove retaining ring and
bearing collar. See Fig. 1
.
Fig. 1: Exploded View of Rear Drive Axle (MPV; Others Similar)

Courtesy of MAZDA MOTORS CORP.
3. To remove bearing collar, grind collar until a section of it is .020" (.5 mm) and cut through it with a
chisel. Use a puller or press to remove bearing and brake backing plate. Check axle shaft for straightness.
Maximum runout is .059" (1.5 mm).
4. Use a press to replace wheel studs (if necessary), never use a previously used wheel stud as a
replacement. Lubricate seal lips before replacement. DO NOT lubricate bearing retainer collar before
replacement. Use a press to install bearing collar. If press-fit of collar requires less than 2.7 tons (2699
kg.) replace collar or axle shaft. Reverse removal procedures to complete installation.
DIFFERENTIAL ASSEMBLY

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
Microsoft
Sunday, July 05, 2009 2:17:01 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.