1994 MAZDA MX-5 transmission oil

TRANSMISSION K TRANSMISSION UNIT (INSTALLATION) Preparation SST Wrench d b For installation of torque converter bolts 1. On level ground, raise the vehicle and support it evenly on safety stands. 2. Install in the order shown in figure, referring to Installation Note. 3. Fill the transmission with the specified amount and type of the ATF after installation. 4. Warm up the engine, inspect for oil leakage, and verify correct transmission operation. 49 0259 440 Holder, rnainshaft For prevention of oil leakage Gartner Banana

K TRANSMISSION 1. Transmission 10. ATF thermosensor connector Installation Note . . . . . . . . . . page K-149 11. Solenoid connector 2. Transmission mount bolt 12. Vehicle speed pulse generator connector 3. Starter 13. Parklneutral switch connector 4. Torque converter bolt 14. Vacuum hose lnstallation Note . . . . . . . . . . page K-149 15. Speedometer cable 5. Under cover 16. Propeller shaft 6. Power plant frame (PPF) Installation . . . . . . . . . . . . . . . . . . section L lnstallation Note . . . . . . . . . . page K-149 17. Exhaust pipe 7. Harness 18. Performance rod -1 8. Oil pipe 19. Undercover 9. Lockup solenoid connector 20. Shift rod Gartner Banana

TRANSMISSION K Installation Note Transmission Set the transmission onto the transmission jack, paying special attention not to damage the oil pipes. Make sure that the torque converter side of the transmission is tilted slightly upward. Torque converter bolts 1. Align the holes by turning the torque converter. 2. Lock the drive plate by using a screwdriver. 3. Hand-tighten the torque converter mounting bolts in a crisscross pattern. 4. Modify the torque converter mounting bolts tightening torque to allow for a torque wrench-SST combination (Refer to Section GI "Torque Formulas") 5. Tighten the torque converter mounting bolts by using the SST. Tightening torque: 35-49 N-m (3.5-5.0 kgf-m, 26--36 ft-lbf) Power plant frame (PPF) 1. Support the transmission with a jack so that it is level. 2. Position the power plant frame and tighten the transmis- sion-side bolts by hand. 3. Verify that the sleeve is installed into the block. 4. Install the spacer and reamer bolts in the forward hole, and hand-tighten them. Gartner Banana

OIL COOLER K OIL COOLER REMOVAL / INSPECTION / INSTALLATION 1. Remove in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to lnstallation Note. 45UOKX-57 1. Connector bolts 4. Oil pipe Inspect for clogging ins~ect for damaae or cracks -- - - 2. Packing installation Note ................ below 3. Transmission 5. Oil hose Removal ................. page K- 45 Inspect for damage or cracks Installation ............... page K-148 6. Radiator I UP SIDE DOWN SlDE lnstallation Note Oil pipe 1. Align the marks, and slide the oil cooler hose onto the oil cooler pipe until it contacts the ridge. 2. Install the hose clamp onto the hose at the center of the mark and at the angle shown. If reusing the hose, posi- tion the new hose clamp in the mark left by the previous hose clamp. 3. Verify that the hose clamp does not interfere with any other parts. Gartner Banana

MANUAL STEERING TROUBLESHOOTING GUIDE Problem Steering heavy Posslble Cause Poor lubrication, foreign material, or abnormal wear of steering ball joint Stuck or damaged lower arm ball joints lmproper steering pinion preload Damaged steering gear Malfunction of steering shaft joint lmproperly adjusted wheel alignment Malfunctioning steering gear Replace Replace gear Replace Replace Adjust Replace ~ction- Lubricate or replace section R N-12 N-12 N- 9 section R N-12 ~i&d~ection N-13 General instability while driving Steering wheel pulls to one side Shake (Steering wheel vibrates upidown) Worn or damaged stabilizer and/or suspension arm bushings Dragging brake Loose lower arm lmproperly adjusted wheel alignment lncorrect tire pressure Damaged or unbalanced wheel Worn or damaged steering joints lmproper steering pinion preload Weak front coil spring Worn or damaged stabilizer andlor suspension arm bushings Malfunctioning shock absorber lmproperly adjusted wheel alignment Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Incorrect tire pressure Incorrect tire pressure Unevenly worn tires Weak front spring Replace Repair Tighten Adjust Adjust Adjust or replace Replace Replace gear Replace Replace Replace Adjust Replace Tighten Adjust or replace section R section P section R section R section Q section Q N- 9 N-12 section R section R section R section R section Q section Q section Q Adjust Adjust Replace Replace section Q section Q section Q section R I Cracked or worn transmission mount I Cracked or worn engine mount 1 ~e~lace I section B lncorrect tire pressure Unevenly worn tires Malfunction of shock absorber Shimmy (Steering wheel vibrates circumferentially) Excessive steering wheel play Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Adjust Replace Replace Replace Replace Tighten Replace Replace Tighten Adjust or replace section Q section Q section R section J N-12 N-12 N-13 section Q section Q section Q I Loose shock absorber mounting bolts 1 Tighten I section R Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Worn steering gear Worn or damaged steering joints Worn or damaged suspension arm bushings Loose steering gear mounting bolts I lmproperly adjusted front wheel alignment Poor steering wheel return Replace Replace Replace Adjust Replace Replace Replace Tighten Replace Adjust Replace Adjust Worn linkage &-tie-rod ball joint lncorrect tire pressure Stuck or damaged steering joints section R section R section M section R N-12 N- 9 section R N-12 N-12 section Q N- 9 section R Abnormal noise from steering system 25UONX-00! Improper steering pinion preload Ball joint not operating smoothly Steering shaft contacting something Loose steering gear Malfunctioning steering gear Obstruction near steering column Loose steering linkage Worn steering joints Replace gear Replace Repair Tighten Replace Repair or replace Tighten or replace Replace N-12 N-13 N- 9 N-12 N-12 N- 9 N-12 N- 9 Gartner Banana

N ENGINE SPEED SENSING POWER STEERING TROUBLESHOOTING GUIDE Steering feels heavy - - Poor lubrication, foreign material, or abnormal wear of steering ball joint Stuck or damaged lower arm ball joints lmproper steering pinion preload Damaged steering gear Malfunctioning steering shaft joint Problem I lmproperly adjusted wheel alignment Possible Cause 1 Malfunctioning steering gear lncorrect tire pressure Loose or damaged oil pump drive belt Low fluid level or air in fluid I Leakage of fluid I Insufficient oil pump pressure Steering wheel pulls lncorrect tire pressure to one side Unevenly worn tires ( Weak front spring General instability while driving Worn or damaged stabilizer and/or upper or lower arm bushing Dragging brake Loose lower arm lmproperly adjusted wheel alignment lncorrect tire pressure Damaged or unbalanced wheel Worn or damaged steering joint(s) lmproper steering pinion preload Weak front coil spring Worn or damaged stabilizer and/or upper or lower arm bushing Malfunctioning shock absorber Cracked or worn engine mount Cracked or worn transmission mount Shake (Steering wheel vibrates up/ down) Shimmy (Steering wheel vibrates left1 right) lmproperly adjusted wheel alignment Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Excessive steering wheel play Poor steering wheel return Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel@) lncorrect tire pressure Unevenly worn tires Malfunctioning shock absorber Loose shock absorber mounting bolts Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Worn steering gear Worn or damaged steering joints Worn or damaged lower arm bushing Loose steering gear mounting bolts Worn linkage or tie-rod ball joint lncorrect tire pressure Stuck or damaged steering joints lmproperly adjusted front wheel alignment lmproper steering pinion preload Ball joint not operating smoothly Steering shaft contacting something Action Lubricate or replace Replace Adjust Replace Replace Adjust Replace Adjust Adjust or replace Add fluid or bleed air Repair or replace Replace Adjust Replace Replace Replace Repair Tighten or replace Adjust Adjust Adjust or replace Replace Adjust Replace Replace Replace Adjust Replace Tighten Adjust or replace Replace Replace Replace Tighten Replace Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Replace Adjust Replace Replace Replace Tighten Replace Adjust Replace Adjust Adjust Replace Repair Pagelsection N-25 section R N-32 N-25 N- 9 section R N-25 section Q N-37 N-21,22 - N-34 section Q section Q section R section R section P section R section R section Q section Q N- 9 N-32 section R section R section R section R section Q section Q section Q section B section J N-26 N-25 N-25 section Q section Q section Q section Q section Q section R section R section R section R section M section R N-25 N- 9 section R N-25 N-25 section Q N- 9 section R N-32 N-25 N- 9 Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Front Suspension - Transmission item (Stabilizer Specifications MT I AT - I Susoension tvoe I . , . , I . , Shock absorber Cylindrical double acting, low-pressure-gas charged I Double-wishbone TY pe Torsion bar Coil spring I - Diameter mm linl I 20.0 10.79) Identification mark color 19.0 (0.75) White Wire diameter mm (in) Coil inner diameter mm {in) I Blue Free length mm {in) Coil number 11 .O (0.43) 83 i3.27) 11 .O (0.43) 83 (3.27) 292.5 (1 1 32) 6.32 3 +. 3 (0.12 + 0.12) 0°18' + 18' Total toe-in I - I 35UORX-001 Rear Suspension 302.0 (1 1.89) 6.32 mm {in) degree Total toe-in (per side) 1 degree Front wheel alignment (Unladedt1) 0°09' +. 09' Caster anglee3 4"26' +. 45' Kingpin angle 11 "20' Maximum steering angle Transmission Specifications MT I AT Item Differential - Suspension type Inner Outer "TORSEN" LSD 1 Standard Double-wishbone Coil springs 370 23' a 2" 32" 32' -t 2" Camber anglee2 Torsion bar 12.0 (0.47) 1 11.0 (0.43) 1 11 .O (0.43) Cylindrical double acting, low-pressure-gas charged - Stabilizer Identification mark color Wire diameter mm {in) 0°24' + 45' Type Diameter mm {in) I Coil number I 7.68 I 7.96 I Shock absorber Yellow 10.1 {0.40} Coil inner diameter mm {in) Free length mm {in) Green 10.2 {0.40) 35UORX-002 *I Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. '2 Difference between left and right must not exceed I O. '3 Difference between left and right must not exceed 1'30'. "TORSEN" is a registered trademark of ZEXEL-GLEASON USA.INC 83 I3.27) 348.5 j13.72) Rear wheel alignment (Unladed*') 83 (3.27) 356.5 (1 4.04) Total toe-in Total toe-in (per side) mm (in) degree degree 3 -c 3 (0.12 + 0.121 0°18' + 18' 0°09' + 09' Camber angle*2 -0°43' 2 30' Gartner Banana

INSTRUMENT CLUSTER T I OIL PRESSURE SENSOR 3. If not as specified, replace the oil pressure sensor. OIL PRESSURE SENSOR lnspection 1. Disconnect the oil pressure sensor connector. 2. Measure resistance between the oil pressure sensor and a body ground as shown. SPEEDOMETER CABLE lnspection 1. Disconnect the speedometer cable from the instrument cluster and transmission case. 2. Verify that the cable and gear spin easily when turned by hand. 3. If the cable or gear is stiff, replace as necessary. Condition Engine stopped Engine running Resistance 110-13052 13- 55R Gartner Banana