1994 MAZDA MX-5 Oil

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

M DIFFERENTIAL Differential mount 1. Drill holes around the differential mount. 2. Hit the edge of the differential mount to remove it. Assembly note Differential mounting rubber 1. Install the new differential mount with the voids facing front and rear. 2. Press in the differential mount by using the SST. Press force: 19600 N (2000 kgf, 4400 Ibf) Oil seal (Output shaft) Apply lithium based grease to the new oil seal lip and install it by using the SST. Bearing outer race (front bearing) Instdl the bearing outer race (front bearing) by using the SST. 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

Before beginning any service procedure. refer to section T of this manual for I air bag system service warnings and audio antitheft system alarm conditions . STEERING SYSTEM INDEX ....................................... N- 2 OUTLINE ..................................... N- 4 SPECIFICATIONS ........................... N- 4 MANUAL STEERING .......................... N- 4 PREPARATION ............................. N- 4 ................ TROUBLESHOOTING GUIDE N- 5 BOOT ...................................... N- 6 STEERING WHEEL AND COLUMN ........... N- 8 ............. STEERING GEAR AND LINKAGE N-12 ENGINE SPEED SENSING POWER STEERING .......................... N-18 PREPARATION ............................. N-18 TROUBLESHOOTING GUIDE ................ N-20 AIR BLEEDING ............................. N-21 POWER STEERING FLUID ................... N-22 STEERING WHEEL AND COLUMN ........... N-24 STEERING GEAR AND LINKAGE ............. N-25 POWER STEERING OIL PUMP ............... N-33 DRIVE BELT ................................ N-37 25UONX-001 Gartner Banana

INDEX POWER STEERING STEERING WHEEL PLAY: [ 0-30mm (0-1.18 in) ] / DRIVE BELT DEFLECTION I=' I LIMIT: 11.5mm (0.45 in) at 98 N (1 0 kgf, 22 Ibf) 'I =!IS 1. Boot Replacement ................ page N- 6 2. Steering wheel. and column .... On-vehicle inspection pages N- 8,24 Removal / ................... page N- 9 Disassembly / Inspection 1 Assembly .................. page N-10 3. Steering gear and linkage Removal I Installation ......... page N-25 Air bleeding ................. page N-21 Disassembly I Inspection / Assembly .................. page N-26 4. Power steering oil pump ......... Removal / Installation page N-33 ................. Air bleeding page N-21 .......... Power steering fluid page N-22 5. Drive belt ................... Inspection page N-37 .................. Adjustment page N-38 ................ Replacement page N-38 Gartner Banana

N OUTLINEIMANUAL STEERING OUTLINE SPECIFICATIONS Steering wheel Steering shaft and joint d Type Steering gear Outer diameter mm {in) I 370 {I 4.6) I Manual steering Power steering Lock-to-lock turns Shaft ~oinr Power assist 3.36 2-cross joint - I Engine speed sensing Gear Gear ratio 2.8 Rack-and-pinion m (infinite) Rack stroke mm {in} Power steering fluid MANUAL STEERING Collapsible, non-tilt 121 .O i4.76) - I ATF DexronBII or M-111 ~luidca~acit~ L~S qt, Imp qt) I - PREPARATION SST 0.8 (0.85, 0.70) Preload attachment 25UONX-003 Hexagon wrench 49 GO30 797 Handle For removal of tie-rod end 49 1243 785 Installer, boot For measurement of pinion torque For installation of bushing 49 0208 701 A Boot air out tool - For removal and installation of adjusting cover For installation of tie-rod end boot 49 DO32 31 6 Protractor For removal of oil seal For tightening of adjusting cover 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

MANUAL STEERING N Disassembly 1 Inspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. i, 3. Assemble in the reverse order of disassembly, referring to Assembly Note. 1. Tie-rod end 15. Upper bearing Inspect ball joint for damage and malfunction Inspect for wear, damage, and malfunction 2. LocknLt (Tie-rod end) 16. Pinion shaft .............. 3. Boot band Assembly Note page N-16 4. Boot wire Inspect teeth for wear, damage and cracks 5. Boot 17. Rack ............ Inspect for cracks and other damage Disassembly Note page N-14 6. Tie-rod Inspection ................... page N-15 Disassembly Note ............ page N-14 Assembly Note .............. page N-16 Assembly Note .............. page N-32 18. Mounting bracket and mount 7. Washer 19. Lower bearing 8. Locknut (Adjusting cover) 9. Adjusting cover Disassembly Note ............ page N-14 Assembly Note .............. page N-17 10. Roller assembly lnspect parts for wear, damage, weakness and malfunction 11. Dust cover lnspect for cracks and other damage 12. Locknut (Rear cover) u 13. Rear cover Assembly Note .............. page N-17 14. Oil seal Disassembly note ............ page N-14 ~isassembl~ Note ............ page N-14 Assembly Note .............. page N-16 lnspect for wear, damage, and malfunction 20. Rack bushing Disassembly Note ............ page N-15 Assembly Note .............. page N-15 lnspect for wear and damage 21. Bushing Disassembly Note ............ page N-15 Assembly Note .............. page N-15 lnspect for wear and damage 22. Gear housing lnspect for cracks and other damage Gartner Banana