1994 MAZDA MX-5 lock

M DRIVE SHAFT Note If the drive shaft will not come out of the wheel hub easily, install a discarded nut onto the drive shaft so that the nut is flush with the end of the drive shaft. Tap _i the nut with a copper hammer to loosen the drive shaft from the wheel hub. Installation note Drive shaft Align the marks and install the drive shaft. Tightening torque: 54-64 N.m (55-6.5 kgf.m, 40--47 ftlbf) Locknut Install a new locknut and stake it. Tightening torque: 21 6-294 N-m (22-30 kgf.m, 159-217 ft4bf) Gartner Banana

M DRIVE SHAFT Disassembly note Boot bands To remove the boot bands, pry up the locking clip with a screwdriver, then raise the end of the band. d Clip 1. Mark the drive shaft and outer ring with paint as shown. 2. Remove the clip. Snap ring 1. Mark the drive shaft end and inner ring with paint as shown. 2. Remove the snap ring with snap ring pliers. Cage, inner ring, and balls Disassemble in the following order: 1. Insert a screwdriver between the inner ring and cage to remove the balls. 2. Mark the inner ring and cage with paint. 3. Turn the cage approximately 30°, then pull it away from the inner ring. Gartner Banana

M DRIVE SHAFT 5. Align the marks, then install a new clip. Boot bands 1. Set the boots onto the rings. 2. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth-wrapped screwdriver. 3. Verify that the boots are not dented or twisted. 4. Measure the drive shaft length. Standard length: 623.7--658.8mm (24.556-25-936 in) 5. If not within specification, return to step 1. J Standard length (On-vehicle): 640.6mm (25,220 in) 6. Fold the new band back by pulling on the end of it with pliers. The band should be folded in the direction oppo- site the forward revolving direction of the drive shaft. 7. Lock the end of the band by bending the locking clips. Gartner Banana

DIFFERENTIAL M DIFFERENTIAL PREPARATION u SST 49 01 07 680A Engine stand For disassembly and assembly of differential 49 MOO5 561 Hanger, differential carrier For disassembly and assembly of differential For removal of bearing inner race (side bearing) 49 NO34 21 3 Installer, rubber bushing For installation of differential mounting rubber - --.. - Puller, fan pulley boss 49 GO30 795 Installer, oil seal For installation of oil seal For installation of bearing outer race Handle (Part of 49 GO30 795) 49 BOO1 795 Installer, oil seal For installation of oil seal (output shaft) 49 F027 004 Attachment $80 For installation of bearing outer race (rear bearing) 49 F027 OAl For installation of bearing 49 F027 005 Attachment $I62 (Part of 49 F027 OAl ) For installation of bearing outer race (front bearing) Installer set, bearing 49 F027 OAO Gauge set, pinion height adjustment 49 0727 570 Gauge body, pinion height (Part of For adjustment of pinion height For adjustment of pinion height 49 F027 OAO) For adjustment of pinion height For adjustment of oinion height Pinion model @==@ Collar A (Part of 49 8531 565) For adjustment of oinion height adjustment of )inion height Gauge block Gartner Banana

M DIFFERENTIAL SLEEVE BLOCK BOLT (MI 4 x 1.5) dl Removal note Power plant frame (PPF) 1. Disconnect the wire harness from the PPF. 2. Support the transmission with a jack. 3. Remove the power plant frame bracket. (Manual trans- mission) 4. Remove the differential-side bolts, and pry out the spacer. 5. Remove the differential mounting spacer. 6. Turn a bolt (MI4 x 1.5) into the sleeve. 7. Twist and pull the bolt downward. 8. Install a bolt (M6 x 1) into the hole in the block to hold the sleeve, and remove the long bolt (MI4 x 1.5). 9. Remove the bolt ,(M6 x 1). Gartner Banana

DIFFERENTIAL M t- 900mm (35.43 in) 10. Remove the transmission-side bolts, and remove the PPF. Do not remove the spacers from the PPF. If they are removed, replace the PPF as an assembly. Drive shaft Mark the drive shaft and output shaft for proper installa- tion. Differential 1. Support the differential with a jack. 2. Lower the differential and move it forward. Note If the drive shaft will not separate easily from the out- put shaft, remove a bolt and nut from one side of the upper arm. 3. Separate the driveshaft from the output shaft. 4. To prevent damaging the fire wall, crank angle sensor, and engine mount, support the transmission as follows. (1) Prepare a steel plate (as shown in the figure), a wooden block, bolts (M8 x 1.25), and washers. (2) Install the parts as shown in the figure. Gartner Banana

M DIFFERENTIAL Installation note Differential 1. Connect the drive shaft to the output shaft with the marks aligned. 2. Install the differential. - JOMX- Tightening torque 0: 83-98 N-m (8.5-10 kgf.m, 61-72 ft4bf) @I: 18-26 N.m (1.8-2.7 kgf.m, 13-20 ft.lbf) 3. Adjust the rear wheel alignment if the upper arm installa- tion bolt and nut were removed. (section R.) Power plant frame (PPF) 1. Install the differential mounting spacer. Tightening torque: 37-52 N-m (3.8-5.3 kgf.m, 27-38 ftdbf} .i 2. Support the transmission with a jack so that it is level. 3. Position the PPF and snugly tighten the transmission- side bolts by hand. 4. Verify that the sleeve is installed into the block. 5. Install the spacer and bolts and snugly tighten them. The reamer bolt should be installed in the forward hole. 6. Snugly install the power plant frame bracket. 7. Tighten the transmission-side bolts. Tightening torque: lO4--123 N.m (1 0.6-1 2.6 kgf.m, 77-91 ft4bf) Gartner Banana

DIFFERENTIAL M 1. Output shafts Disassembly Note .......... page M-34 Assembly Note ............ page M-42 u 2. Differential case Disassembly Note .......... page M-34 Assembly Note ............ page M-42 3. Differential gear assembly Disassembly Note .......... page M-34 4. Lock plates 5. Bearing caps Disassembly Note .......... page M-34 Assembly Note ............ page M-42 6. Adjusting nuts Disassembly Note .......... page M-34 7. Bearing outer races (Side bearing) 8. Gear case assembly ("TORSEN" LSD) 9. Ring gear lnspect individual gear teeth for wear and cracks 10. Knock pin (Standard) Disassembly Note .......... page M-34 11. Pinion shaft (Standard) 12. Pinion gears (Standard) lnspect individual gear teeth for wear and cracks 13. Thrust washers (Standard) 14. Side gears (Standard) lnspect individual gear teeth for wear and cracks b 15. Thrust washers (Standard) Assembly Note ............ page M-40 16. Bearing inner races (Side bearing) Disassembly Note .......... page M-34 lnspect for damage and rough rotation 17. Gear case 18. Locknut (Companion flange) Disassembly Note .......... page M-35 19. Washer 20. Companion flange Disassembly Note .......... page M-35 lnspect splines for wear and damage 21. Oil seal (Companion flange) 22. Washer 23. Drive pinion Disassembly Note .......... page M-35 lnspect splines for wear and damage lnspect individual gear teeth for wear and cracks 24. Spacer Assembly Note ............ page M-37 25. Bearing inner race (Front bearing) lnspect for damage and rough rotation ............ Assembly Note page M-38 26. Collapsible spacer 27. Bearing outer race (Rear bearing) Disassembly Note .......... page M-35 Assembly Note ............ page M-37 28. Bearing outer race (Front bearing) Disassembly Note .......... page M-35 Assembly Note ............ page M-36 29. Bearing inner race (Rear bearing) Disassembly Note .......... page M-35 lnspect for damage and rough rotation Assembly Note ............ page M-37 30. Differential carrier 31. Oil seal (Output shaft) Assembly Note ............ page M-36 32. Baffle 33. Breather 34. Differential mount Disassembly Note .......... page M-36 Assembly Note ............ page M-36 45UOMX-053 Gartner Banana