1994 MAZDA MX-5 boot

DRIVE SHAFT M TAPE 45UOMX-031 DIFFERENTIAL SlDE WHEEL SlDE 45UOMX-031 SNAP RING GROOVE I 45UOMX-032 Boots 1. Wrap the shaft splines with tape. 2. Remove the boot. Assembly note Boots 1. Before putting the boot onto the shaft, wrap the shaft splines with tape. 2. lnstall the wheel-side and differential-side boots, noting the shape and size of each one in the figure. Outer diameter of large boot end Differential side : 87.4mm (3.441 in) Wheel side : 90.8mm (3.575 in) Cage, inner ring, and balls 1. Align the marks and install the balls to the inner ring. 2. Install the cage, inner ring, and ball assembly to the drive shaft in the direction shown in the figure. The larger diameter of the (age should be) facing the snap ring groove. 3. Install a new snap ring in the drive shaft snap ring groove. 4. Apply the specified grease (molybdenum disulfide) to the joints and boots. Total quantity Differential side : 75-95 g (2.65-3.35 oz) Wheel side : 55-75 g (1.94--2.65 oz) 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

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 INDEX MANUAL STEERING STEERING WHEEL PLAY: [ (MOrnrn (0-1 .I 8 in) ] 1. Boot 3. Steering gear and linkage Replacement ................ page N- 6 Removal 1 Installation ......... page N-12 2. Steering wheel and column Disassembly / Inspection / On-vehicle inspection ......... page N- 8 Assembly .................. page N-13 -, Removal / Installation ......... page N- 9 Disassembly / Inspection / Assembly .................. page N-10 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

N MANUAL STEERING BOOT Replacement 1. Loosen the wheel lug nuts. 2. On level ground, jack up the front of the vehicle and support it on safety stands. 3. Remove the wheel. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to lnstallation Note. 6. After installation, check the steering angle and toe-in, and adjust if necessary. (Refer to section R.) Nm (kgfm, ftdbf) 1. Cotter pin 6. Tie-rod end boot 2. Nut Removal Note ................ page N-7 3. Tie-rod endfsteering knuckle Installation Note .............. page N-7 Removal Note ................ page N-7 7. Boot clamp J 4. Locknut 8. Boot wire Removal Note ................ page N-7 9. Steering gear boot 5. Tie-rod end Installation Note .............. page N-7 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