1991 MAZDA MIATA length

Fig. 14: Installing Balls In To Inner Ring
Courtesy of MAZDA MOTORS CORP.
3. Install a NEW snap ring in axle shaft snap ring groove. Apply specified amount of grease to joints and
boots. See LUBRICATION SPECIFICATION
table. Aling marks and install NEW clip.
LUBRICATION SPECIFICATION
4. Ensure that boots are not dented or twisted. Set axle shaft to standard length. See AXLE SHAFT
LENGTH table. Release any trapped air from boots by carefully lifting up small end of each boot with a
cloth-wrapped screwdriver. See Fig. 15
. Ensure that axle shaft length is within standard. If drive shaft
length is not within standard, repeat this step.
ApplicationQuantity
Wheel Side CV Joint Boot1.9-2.7 oz. (55-75 g)
Differential Side CV Joint Boot2.7-3.4 oz. (75-95 g)

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
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Fig. 16: Installing Boot Band
Courtesy of MAZDA MOTORS CORP.
AXLE SHAFT LENGTH
REAR AXLE SHAFT BOOT IDENTIFICATION
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationIn. (mm)
1990
On Vehicle25.96 (659.3)
Off Vehicle25.97-26.37 (695.7-669.7)
1991-93
On Vehicle25.87 (657)
Off Vehicle25.30-26.68 (642.6-677.7)
ApplicationIn. (mm)
Wheel Side Diameter3.58 (90.8)
Differential Side Diameter3.44 (87.4)

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 2:16:33 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

4. On all models, measure applied pedal height. If distance is not as specified, check brake adjustment or
system for air. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.
BRAKE PEDAL HEIGHT SPECIFICATIONS
TESTING
POWER BRAKE UNIT
1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake
pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal
does not move as specified, go to next step.
2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is
operating. If length of strokes is equal, test check valve and vacuum hose between vacuum source and
power brake unit. Repair as necessary, and go to next step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
height remains at same height, power brake unit is operating. If pedal height recedes, test check valve and
vacuum hose between vacuum source and power brake unit. Repair as necessary.
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (Protege & 323)
Raise and support front of vehicle. Remove wheels. Remove spring "A". See Fig. 5 . Remove spring "B".
Remove pad pins. Remove pads, shims and anti-squeak shim. Replace pad if lining thickness is less than
specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE. To install, reverse removal
ApplicationIn. (mm)
Pedal Released
B2200 & B2600i7.1-7.3 (180-185)
Miata, MX-6, 626 & 9296.7-7.1 (171-181)
MPV7.5-7.9 (191-201)
Protege & 3237.6-7.7 (193-196)
RX77.2-7.4 (184-189)
Pedal Applied (1)
B2200 & B2600i4.1 (105)
Miata, MX-6, 626 & 9293.7 (95)
MPV5.2 (133)
Protege & 3232.8 (70)
RX73.9 (100)
(1)Minimum height.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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Fig. 11: Checking Pinion Installation & Position
Courtesy of MAZDA MOTORS CORP.
Pinion Assembly (RX7)
1. Using a press, install rear pinion bearing outer race in differential housing. Install center bearing outer
race. Using original rear bearing spacer, install rear bearing on Setting Pinion (49 F027 001 ).
2. Position drive pinion in carrier and install center bearing, long collar and companion flange. Tighten
pinion nut just enough so pinion can be turned by hand.
3. Place a dial indicator on Pinion Height Gauge (49 0727 570 ). Place pinion height gauge on a flat surface
and zero dial indicator. Position Gauge Block (49 0305 555 ) on top of Setting Pinion (49 F027 001 ).
4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to lowest point
where side bearing sits. 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 setting pinion, select spacer and press
rear pinion bearing on drive pinion shaft.
6. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential
housing. DO NOT install pinion seal yet. Press center bearing onto drive pinion using Adapter (49 1243
465A ). DO NOT exceed one-ton force or collapsible spacer will be damaged. Two different collapsible
spacers are available, ensure correct one is used.
RX7 DRIVE PINION COLLAPSIBLE SPACERS
7. Lubricate ends of long collar with grease and install. Using a press, install front bearing using Adapter
(49 F027 009 ). Press fit with a 2-3 ton force. DO NOT install oil seal yet. Install companion flange and
nut. Tighten drive pinion nut to 94 ft. lbs. (128 N.m). Turn companion flange by hand to seat bearing.
8. Pinion bearing preload at drive pinion nut should be 11.3-15.6 INCH lbs. (1.3-1.8 N.m). Adjust preload
by tightening drive pinion nut. If correct preload cannot be obtained within drive pinion nut tightening
range of 94-210 ft. lbs. (128-284 N.m), replace collapsible spacer and recheck preload.
9. 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 specification established for correct
preload.
Carrier Assembly (All Models)
1. Position differential assembly into differential housing. Install side bearing adjusters. Position side
bearing caps. Align marks made during disassembly. Install side bearing cap bolts. DO NOT tighten yet.
2. Tighten side bearing adjusters equally until adjuster contact bearing races. Mark ring gear in 4 locations,
90 degrees apart. Position a dial indicator against ring gear to check ring gear backlash.
3. Check backlash at all 4 locations. Ti
ghten side bearing adjusters equally until backlash is .0035-
ApplicationLength In. (mm)
Non-Turbo1.923-1.935 (48.85-49.15)
Turbo2.238-2.250 (56.85-57.15)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
Microsoft
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ARMATURE TESTING
1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly
rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.
2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If
continuity exists, the armature is shorted and must be replaced. Check continuity between commutator
and shaft. If continuity exists, replace armature.
3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace
armature.
COMMUTATOR TESTING
1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted,
turn commutator in a lathe.
2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after
turning. See COMMUTATOR SPECIFICATIONS table.
3. Commutator mica undercut depth should be .02 -.03" (.5 -.8 mm). Minimum mica undercut depth
is .008" (.20 mm). If not within specification, undercut to standard depth.
COMMUTATOR SPECIFICATIONS
BRUSH TESTING
1. Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity
exists, brush holder assembly is shorted and must be replaced.
2. Check brush length. If less than specification, replace brushes. See BRUSH LENGTH
SPECIFICATIONS table. Use brush spring scale to check spring tension. Spring tension is measured at
point where spring separates from brush.Tension should be greater than 2 lbs. (0.9 kg). Tension
specification for a new spring is 3.1-5.7 lbs. (1.4-2.6 kg). Brushes must move freely in holders.
BRUSH LENGTH SPECIFICATIONS
FIELD COIL TESTING
1. Connect one ohmmeter lead to field coil lead ("M" terminal lead). Connect other lead to soldered portion
of brush lead. If continuity does not exist, repair or replace field coil.
2. Check field coil for shorts to
ground by connecting ohmmeter lead to field coil lead. Connect other lead
Application
Maximum Runout In.
(mm)Minimum Diameter
In. (mm)
B2200 (M/T)
Protege (M/T) & 323.004 (.10)1.22 (31)
Miata.001 (.03)1.22 (31)
ApplicationStandard In. (mm)Minimum In. (mm)
All Models.67 (17.0).45 (11.5)

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
Microsoft
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Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MPV, MX-6 & 626)
1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and
COMBINATION SWITCH
under REMOVAL & INSTALLATION. Remove steering lock assembly.
See IGNITION SWITCH & STEERING LOCK
under REMOVAL & INSTALLATION.
2. Remove lower dash panel and A/C duct. Remove lower column cover and steering shaft-to-intermediate
shaft "U" joint bolt. On MPV with A/T, remove shift lever mechanism.
3. On all models, separate steering shaft from intermediate shaft. Remove steering column upper bracket
bolts. Remove steering column. To install, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS TABLE
at end of article.
OVERHAUL
STEERING COLUMN
Disassembly
Remove wiring and switches. Clamp column in vise. Turn steering shaft to remove. With a hammer and chisel,
make a groove in steering lock assembly shear screws. Remove shear screws. Remove steering lock.
Inspection
Check all components for damage or wear. Check steering shaft for bends, damage or sheared plastic pins.
Check bearings for excessive play. Replace parts as necessary. Measure length of steering shaft. See Fig. 9
.
Reassembly
To reassemble, reverse disassembly procedure. Grease steering shaft, bushings and bearings. Always use NEW
shear screws.
STEERING SHAFT DIMENSIONS
(1) NOTE: Steering shaft dimension for 929 is not available from manufacturer.
ApplicationLength - In. (mm)
B2200 & B2600i32.69-32.99 (830.0-835.6)
Miata22.09-23.02 (561.1-584.7)
MPV24.05-24.17 (611.0-614.0)
MX-6 & 62624.00-24.05 (609.6-611.1)
Protege & 32323.86-23.94 (606.0-608.0)
RX732.05-32.17 (814.0-817.0)
929(2)
See Fig. 9 for measuring points.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
Microsoft
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