1994 MAZDA MX-5 height

CLUTCH PEDAL, CLUTCH MASTER CYLINDER H CLUTCH MASTER CYLINDER PREPARATION SST b 49 0259 7708 For disconnecting Wrench, flare and connecting nut clutch pipe Removal Note Spring 1. Place the clutch pedal assembly in the vise. 2. Pry the spring off the clutch pedal as shown in the figure. Installation Note Spring 1. Place the clutch pedal assembly in the vise. 2. Install the spring onto the clutch pedal as shown in the ~ - figure. 3. Adjust the clutch pedal height and free play after installa- tion. (Refer to page H-5.) Gartner Banana

CLUTCH MASTER CYLINDER H After-installation Procedure 1. Bleed the clutch system. (Below) I 2. Add fluid to the reservoir MAX mark. ' 3. Inspect and adjust the clutch pedal height and free play. (Refer to page H-5.) AIR BLEEDING The clutch hydraulic system must be bled to remove air introduced whenever a hydraulic line is disconnected. Caution Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe it off immediately. 1. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug. 2. Insert the other end of the vinyl hose into a fluid-filled clear container. 3. Working with another person, have the person depress the clutch pedal several times, then hold it down. 4. With the clutch pedal depressed, loosen the bleeder screw by using the SST to let fluid and air escape. Close the bleeder screw. 5. Repeat steps 3 and 4 until no air bubbles are seen in the fluid. Make sure the reservoir is always 314 full or more during this procedure. 6. Modify the bleeder screw tightening torque to allow for use of a torque wrench-SST combination. (Refer to sec- tion GI "Torque Formulas".) 7. Tighten the bleeder screw by using the SST. Tightening torque: 5.9-8.8 N.m (60-90 kgf.cm, 53-78 in4bf) 8. Fill the reservoir to MAX with new fluid of the specified type. 9. Check for correct clutch operation. 10. Verify that there is no fluid leakage. Gartner Banana

TRANSMISSION J Bearing Inspect for damage and rough rotation. Reverse Idler Gear and Shaft 1. Inspect gear teeth for wear and cracks. 2. Measure the clearance between the reverse idler gear b~~shing and shaft. Standard clearance: 0.02-0.05mm {0.000&-0.0020 in) Maximum: 0.15mm (0.006 in) Springs Measure the free length of the springs. Standard free length Shift rod (Sth/Reverse) spring: 75mm (2.953 in) Detent ball spring (lst/2nd, 3rdI4th): 22.5mm (0.886 in) Detent ball spring (Sth/Reverse): 17.0mm (0.669 in) Intermediate housing Measure the intermediate housing pin height. Standard height: 9.0-10.0mm (0.354-0.394 in) Gartner Banana

K TRANSMISSION APPLY SEALANT a 23. Insert the intermediate shaft. The end with the long splines should face front. 24. Apply petroleum jelly to the large bearing race and install it into the fourth gear case. 2 Bearing race outer diameter: 70mm (2.756 in) 25. Apply petroleum jelly to the small bearing and small bearing race, and install them as shown. Bearing outer diameter: 35.0mm (1.378 in) Bearing race outer diameter: 33.0mm (1.299 in) 26. lnstall the fourth gear brake band and band strut. 27. lnstall the fourth gear connecting shell and fourth gear planetary gear unit (fourth gear sun gear, fourth gear planetary pinion carrier, fourth gear clutch hub) onto the direct clutch. 28. lnstall the direct clutch assembly into the fourth gear case. --/ 29. lnstall the oil pump assembly into the transmission case by hand only, using two converter housing bolts as guides. Measure the height difference between the top of the transmission case and the oil pump. 30. Remove the converter housing bolts. Apply sealant to the bolts. 31. Apply sealant to the contact surfaces of the converter housing and oil pump. 32. lnstall the converter housing onto the oil pump, and tight- en the bolts evenly in a crisscross pattern. Tightening torque: 59-68 N-m (6.0-7.0 kgfm, 44--50 ft4bf) 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

DIFFERENTIAL M Bearing outer race (rear bearing) Install the bearing outer race (rear bearing) by using the SST. Bearing inner race (rear bearing), Bearing inner race (front bearing), Spacer 1. Adjust the drive pinion height as follows, by using the SST. (1) Install the previously-removed spacer onto the SST so that the beveled side of the spacer faces the drive pinion. Then install the rear bearing and O-ring onto the SSTIspacer as shown in the figure. (2) Assemble the spacer, bearing inner race (rear bear- ing), and SST. Secure the SST with the O-ring. Install this assembly in the carrier. Install the bearing inner race (front bearing), the SST, companion flange, washer, and nut. (3) Tighten the nut just enough so that the companion flange can still be turned by hand. Gartner Banana

M DIFFERENTIAL (4) Place the SST on the surface plate and set the dial indicator to "Zero". (5) Place the SST atop the drive pinion model. Set the gauge body atop the gauge block. (6) Place the feeler of the dial indicator so that it contacts where the bearing inner race (side bearing) is installed in the carrier. Measure the lowest position on the left and right sides of the carrier. (7) Add the two (left and right) values obtained in step (6) and divide the total by 2. Specification: Omm (0 in) Thickness mm {tP2"13 in} 3.11mm (0.1 224 in} 3.14mm (0.1 224 in} 3.1 7mm (0. I248 in} 3.20mm (0.1260 in} 3.23mm (0.1271 in] 3.26mm 40.1283 in} Thickness rnm {t&5 in} 3.32mm (0.1307 in} 3.35mm (0.1319 in] 3.38m (0.1331 in) 3.41 mm (0.1343 in) 3.44mm {0.1354 in) 3.47rnm (0.1366 in) 45UOMX-47: (8) If not within specification, adjust the pinion height by selecting a spacer. Select the spacer of the thickness closest to that necessary. Spacers are available in increments of 0.03mm (0.001 2 in). (9) Install the spacer, selected in the procedure above, with the beveled side facing the drive pinion. (1 0)Press the spacer onto the drive pinion until the force SPACER required starts to increase sharply. 2. Install the sDacer. 3. Press the bearing inner race (rear bearing) on with the SST. Gartner Banana

DIFFERENTIAL M (1) Mark the ring gear at four points at approx. 90" inter- vals. Mount a dial indicator to the carrier so that the feeler comes in contact at a right angle with one of the ring gear teeth. (2) Turn both bearing adjusters equally by using the SST until the backlash is 0.09-0.11mm {0.0036-€).0043 in). (3) Check the backlash at the three other marked points, and make sure the maximum backlash is less than 0.07mm (0.0028 in). 9. Tighten or loosen the adjusting nuts equally until the dis- tance between the pilot sections on the bearing caps is 185.428-1 85SOmm (7.3004--7.3031 in). 10. Recheck the back lash. Inspection and adjustment of teeth contact 1. Coat both surfaces of 6-8 teeth of the ring gear with a thin coat of red lead. 2. While moving the ring gear back and forth by hand, rotate the drive pinion several times and check the tooth contact. 3. If the tooth contact is good, wipe off the red lead. 4. If it is not good, adjust the pinion height, and then adjust the backlash. (1) Toe and flank contact Replace the spacer with a thinner one to move the drive pinion outward. Gartner Banana