1994 MAZDA MX-5 torque

DIFFERENTIAL M DIFFERENTIAL OIL Inspection 1. Remove the filler plug. 2. Verify that the oil is at the bottom of the filler plug hole. If it is low, add the specified oil. 3. Install the filler plug. Tightening torque: 39-54 N.m (4.0-5.5 kgf.m, 29-40 ft4bf) Replacement 1. Remove the filler and drain plugs. 2. Drain the differential oil into a suitable container. 3. Wipe the plugs clean. 4. Install the drain plug and a new washer. Tightening torque: 39-54 N.m (4.0-5.5 kgf-m, 29-40 ft4bf) 5. Add the specified oil from the filler plug until the level reaches the bottom of the plug hole. Specified oil TY pe Above -18°C (0°F): API GL-5, SAE 90 Below -18°C (0°F): API GL-5, SAE 80 Capacity: 1 .OO L {I .06 US qt, 0.88 Imp qt) 6. lnstall the filler plug. Tightening torque: 39-54 N.m (4.0-5.5 kgf.m, 29--40 ft.lbf) OIL SEAL (OUTPUT SHAFT) Replacement 1. On level ground, Jack up the vehicle and support it on safety stands. 2. Drain the differential gear oil. 3. Mark the drive shaft and output shaft flanges for proper reassembly. 4. Remove the upper arm installation bolt and nut. Gartner Banana

M DIFFERENTIAL 5. Separate the driveshaft from the differential and sus- pend it. 6. Remove the output shaft by using two pry bars as shown in the figure. J 7. Remove the oil seal. 8. Apply lithium-based grease to the new oil seal lip and install it by using'the SST. 9. Install the new clips. 10. Install the output shaft into the side gears by lightly tap- ping with a plastic hammer. 11. Verify that the output shaft is hooked into the side gears by pulling it by hand. ./ 12. Align the marks and install the drive shaft. Tightening torque: 54-64 N.m (5.5--6.5 kgf.m, 40-47 ft-lbf) 13. Install the upper arm installation bolt and nut. Tightening torque: 46-67 N.m (4.7-6.8 kgf.m, 34--49 ftlbf) 14. Add the specified oil. 15. Adjust the rear wheel alignment. (Refer to section R.) I Gartner Banana

DIFFERENTIAL M DIFFERENTIAL, STANDARD; DIFFERENTIAL, TORQUE SENSING LIMITED SLIP ("TORSEN" LSD) Removal 1 lnstallation 1. Drain the differential oil. ,, 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Add the specified oil to the specified level. 1. Rear wheels 7. Drive shafts 2. Differential mounting pipe Removal Note ............. page M-29 3. Exhaust pipe 8. Differential 4. Propeller shaft Removal Note ............. page M-29 Service ..................... section L Installation Note ........... page M-30 ' 5. Speedometer cable Overhaul .................. page M-32 ,, 6. Power plant frame (PPF), Differential mounting spacer Removal Note ............. page M-28 Installation Note ........... page M-30 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 8. Tighten the differential-side bolts. Tightening torque: lO4--123 N.m (1 0.6-1 2.6 kgf.m, 77-91 ft~lbf) 9. Install the power plant frame bracket. (Manual transmis- sion) Tightening torque 0: 104-123 N-m (10.6-12.6 kgf.m, 77-91 ftlbf) 0: 36-54 N.m I3.7--5.5 kgf-m, 2740 ft-lbf) 10. Remove the jack, and connect the wire harness. Gartner Banana

DIFFERENTIAL M 4. Without installing the oil seal, Install the drive pinion, spacer, new collapsible spacer, front bearing, washer, and companion flange to the carrier, and temporarily tighten the locknut by using the SST. Tightening torque: 128 N-m (13.0 kgf-m, 94.1 ft-lbf) 5. Turn the companion flange several turns by hand to seat the bearing. 6. Measure the drive pinion preload. Adjust the preload by tightening the locknut, and record the tightening torque. STANDARD "TORSEN" 45UOMX-07; Preload: 0.9-1.3 N.m (9-1 4 kgf.cm, 7.9-1 2.1 in4bf) Tightening torque: 128-284 N.m (13.0-29.0 kgf.m, 94.1-209.7 ft-lbf) 7. Remove the locknut, washer, and companion flange. 8. T~D a new oil seal into the differential carrier with the 9. Apply a light coat of grease to the end face of the com- panion flange. 10. Install the companion flange and washer; while holding the flange with the SST, and tighten a new locknut to the tightening torque recorded in step 6. Gartner Banana

M DIFFERENTIAL Thrust washers (Standard) 1. Adjust the backlash of the side gears and pinion gear as follows. (Standard) (1) Set a dial gauge against the pinion gear as shown. ,+, (2) Secure one of the side gears. (3) Move the pinion gear, and measure the backlash at the end of it. If not within specification, replace the dif- ferential gear as an assembly. ("TORSEN" LSD) Standard backlash: 04.1 mm (0-0.004 in) (4) If the backlash exceeds the standard, use the select- able thrust washers for adjustment. 2. Install the new knock pin to secure the pinion shaft. Stake the pin with a punch to prevent it from coming out of the case. Thrust washer thickness: 3. Apply thread-locking compound to bolt threads @ and points @I of the gear back face. Apply approximately 0.04 cm3 I0.04 cc, 0.0024 cu in} of thread-locking com- pound at each point and bolt thread. 4. lnstall the ring gear onto the gear case. Identification mark 0 0.5 1 1.5 2 Tightening torque: 69-83 N.m (7.0--8.5 kgf-m, 51-61 ft-lbf) Thickness 2.00mm i0.0787 in} 2.05mm (0.0807 in) 2.10mm {0.0827 in) 2.15mm (0.0846 in} 2.20mm i0.0866 in} 5. Press the bearing inner races (side bearing) on by using the SST. 6. Install the differential gear assembly in the carrier. 7. Note the identification marks on the adjusting nuts, and install them on their respective sides. 8. lnstall the differential bearing caps, making sure that the identification mark on the cap corresponds with the one on the carrier by using the SST. Then temporarily tighten the bolts. Gartner Banana

M DIFFERENTIAL I HEEL CONTACT FACE CONTACT I (2) Heel and face contact Replace the spacer with a thicker one to bring the drive pinion in. d Bearing caps 1. Tighten the bearing cap bolts. Tightening torque: 37-52 N-m {3.8-5.3 kgf-m, 27-38 ft4bf) 2. Install the lock plates on the bearing caps. Tightening torque: 18-25 N.m (1.8-2.6 kgf-m, 13-19 ft.lbf) Differential case 1. Apply sealant to the housing face. 2. Tighten the bolts. Tightening torque: 23-26 N.m (2.3-2.7 kgf.m, 17-20 ft.lbf) Output shaft 1. Install a new clip. 2. Install the output shafts into the side gears by lightly tap- ping them with a plastic hammer. 3. Verify that the output shafts are hooked into the side gears by pulling them by hand. Gartner Banana