1994 MAZDA MX-5 ECU

M FRONT AXLE Disassembly 1 Inspection 1 Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. DO NOT DISASSEMBLE @$ REPLACE N.m (kgfm, ftdbf} 1. Dust cover 4. Hub bolt 2. Knuckle spindle Disassembly Note ........... page M-8 3. Sensor rotor (ABS) Assembly Note ............. page M-9 Disassembly Note ........... page M-8 5. Front wheel hub assembly Assembly Note ............. page M-9 Inspection .................. page M-9 Disassembly note ' Sensor rotor (ABS) I Secure the front wheel hub in a vise and remove the sen- sor rotor by using the SST. Note The sensor rotor does not need to be removed unless you are replacing it. ..-.' Gartner Banana

M DIFFERENTIAL Disassembly note Output shafts Remove the output shafts with two pry bars as shown in the figure. -J Differential case Caution The differential case is made of aluminum, and is therefore easily dented and scratched by metal tools. When. separating the differential carrier from the case, use only a plastic hammer at the point shown in the figure. Strike the differential carrier with a copper hammer to separate it from the case. Differential gear assembly Mount the differential gear assembly on the SST. Bearing caps Mark one bearing cap and the carrier. Adjusting nuts Mark one adjusting nuts and the carrier. Knock pin Secure the gear case in a vise and tap out the knock pin toward the ring gear side. Bearing inner races (Side bearing) Note Mark the bearings so that they can later be reinstalled in the same position. Remove the bearing inner races (side bearing) from the gear case by using the SST. -1 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 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

MANUAL STEERING N Removal Note Locknut Before loosening the locknut from the tie-rod end, make a reference mark for proper reinstallation. Tie-rod endlsteering knuckle Caution The sharp edges of the SST can slice the tie-rod end dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. 1. Remove the cotter pin. 2. Loosen the nut until it is flush with the end of the ball stud. 3. Disconnect the tie-rod end from the knuckle by using the SST. Tie-rod end boot 1. Secure the tie-rod end in a vise. 2. Place a chisel against the boot and hold it at the angle shown. 3. Remove the boot by tapping it with a hammer. Installation Note Tie rod end boot 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot onto the tie-rod end by using the SST and a press. 4. Wipe away any excess grease. Steering gear boot Verify that the boot is not twisted or dented. Gartner Banana

N MANUAL STEERING LOWER BEARING 1 IT-71 GEAR HOUSING FACE NSK MARK DOWNWARD 15UONX-018 VENTILATION HOLE 95AONX-02; RACK CENTRAL POSITION 95AONX-025 N-16 Lower bearing 1. Apply grease to a new lower bearing. 2. Set the lower bearing onto the pinion shaft so that the NSK mark on the bearing faces downward. u 3. Insert the pinion shaft together with the lower bearing. 4. Press the pinion shaft to seat the lower bearing. 5. Apply grease to the inside of the gear housing as shown. Rack 1. Secure the mounting bracket in a vise. 2. Apply grease to the rack bushing. 3. Apply grease to the rack teeth and the sliding surface. Caution Do not plug the ventilation holes with the grease. Caution Installing the rack from the tube side can damage the rack bushing by dragging the rack teeth across it. When installing the rack, install it slowly and carefully. 4. Slide the rack in from the tube side. Pinion shaft 1. Apply grease to the inner race of the upper bearing and install it to the pinion shaft. 2. Apply grease to the teeth of the pinion shaft. 3. Turn the flat section of the rack toward the pinion, and insert the pinion. Gartner Banana

MANUAL STEERING N Rear cover 1. Apply grease to the outer race of the upper bearing and install it in the gear housing. 2. Install a new oil seal to the rear cover. 3. Apply sealant to the threads of the rear cover and install it into the gear housing. 4. Rotate the pinion to the left and right a few times to seat the bearing. 5. Tighten the rear cover so that the starting torque of the pinion is 200-350 g (7.1-12.3 oz} as checked by using the SST and a pull gauge. 6. Tighten the locknut. Do not allow the rear cover to turn. Tightening torque: 50--68 N-m (5.0-7.0 kgf.m, 37-50 ft.lbf} Adjusting cover 1. Carefully move the rack so that the pinion is set to the center (neutral position) of the rack gear as shown. 2. Install the roller assembly, needle roller, holder, dish springs, friction block, and the spring as shown. 3. Torque the adjusting cover to 9.8 N.m (1 kgf-m, 85 in.lbf), then loosen it 25O45". Use the SST to secure the adjusting cover and the locknut. Tightening torque: 40-58 N.m (4.CL6.0 kgf-m, 29--43 ft-lbf} 4. Measure the starting torque of the pinion by using the SST. Center position + 90" Pull gauge reading: 1,000-1,400 g (35-50 oz} Any other position Pull gauge reading: less than 1,700 g (60 or) 5. If not within specification, repeat steps 2 and 3. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Tie rod 1. Uncrimp the washer. 2. Carefully remove the tie rod. Pinion shaft assembly 1. Secure the mounting bracket in a vise. 2. Remove the retaining ring. 3. Tap the pinion shaft with a punch to remove it. Plug assembly 1. Remove the plug assembly from the pinion shaft. 2. Press out the upper bearhg and oil'seal by using the SST. 3. Remove the O-ring from the plug. Steering rack assembly 1. Remove the stop ring with a pin punch. 2. Temporarily tighten the tie rod to the tube side and pull it carefully to remove the rack. Backup ring and oil seal Tap the SST from the gear housing side to remove the backup ring and the oil seal. Gartner Banana