1994 MAZDA MX-5 differential

ROAD TEST L-range (Hold) shift diagram LOCKUP AVAILABLE WHEN COASTING 0 20 (1 2) 40 (25) 60 {37) 80 {50) 100 {63) 120 {75) 1 40 (87) 1 60 (99) VEHICLE SPEED kmh {mph) Noise and Vibration Drive the vehicle in 1 st (Hold) and listen closely for any out of the ordinary noise or vibration. The torque converter, propeller shift, and differential can be sources of abnormal noise and vibration if they are not functioning properly. Check these when searching for sources of noise and vibration. P-RANGE TEST 1. Shift into P range on a gentle slope, release the brake, and verify that the vehicle does not roll. 2. Shift into P range while driving the vehicle at 4 kmlh (2.5 mph) maximum on a level surface, and verify that the vehicle stops. Gartner Banana

K TRANSMISSION 5. Tighten the transmission-side bolts. Tightening torque: 104--123 N.m (10.6-12.6 kgf-m, 76.7-91.1 ft-lbf} 6. Tighten the differential-side bolts. Tightening torque: lO4--123 N.m {10.6-1 2.6 kgf-m, 76.7-91.1 ft-lbf} 7. Remove the jack. 8. Measure distance A with a straightedge and vernier cali- pers. Distance A: 51.5-61 Smm (2.023--2.417 in} 9. If the distance is not within specification, reposition the power plant frame at the transmission. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . FRONT AND REAR AXLES ....................................... INDEX M- 2 ..................................... OUTLINE M- 3 SPECIFICATIONS ........................... M- 3 TROUBLESHOOTING GUIDE .................. M- 4 ............................... FRONT AXLE M- 4 ................................ REAR AXLE M- 4 ............................. DIFFERENTIAL M- 4 ................................. FRONT AXLE M- 5 PREPARATION ............................. M- 5 WHEEL HUB. STEERING KNUCKLE .......... M- 6 .................................. REAR AXLE M-10 PREPARATION ............................. M-10 ......................... DISC BRAKE TYPE M-11 ................................ DRIVE SHAFT M-17 .................... DOUBLE OFFSET JOINT M-17 ............................... DIFFERENTIAL M-23 PREPARATION ............................. M-23 DIFFERENTIAL OIL ......................... M-25 ................. OIL SEAL (OUTPUT SHAFT) M-25 DIFFERENTIAL. STANDARD; DIFFERENTIAL. TORQUE SENSING LIMITED SLIP ("TORSEN" LSD) ........................... M-27 45UOMX-001 "TORSEN" is a registered trademark of ZEXEL-GLEASON USA . INC Gartner Banana

INDEX INDEX OIL SPECIFICATION ABOVE -1 8°C (O°F1: GL-5. SAE 90 / I 1 ,BELOW -1 8°C Ioo~: GL-5, SAE 80 ..-.. - - - - .. - ...... SERVICE, SECTION L REAR'BRAKE PROPELLER SHACT SERVICE, SECTION P FRONT-BRAKE SERVICE SECTION P 1. Front axle Inspection / Removal / Installation ............... page M- 6 Disassembly 1 Inspection / Assembly. ............... page M- 8 2. Rear axle Inspection / Removal / Installation ............... page M-1 1 Disassembly 1 Inspection / Assembly ................ page M-13 M-2 3. Drive shaft Ins~ection / Removal 1 ............... Installation page M-17 Overhaul .................. page M-19 4. Differential (Standard, Torque sensing limited slip differential) Differential oil .............. page M-25 . Oil seal (Output shaft) ...... page M-25 Removal 1 Installation ....... page M-27 Overhaul .................. page M-32 Gartner Banana

OUTLINE OUTLINE Front axle Rear axle Differentlal Drive shaft Item I Specifications TY pe Bearing Double-wishbone Angular ball bearing Maximum wheel bearing play mm {in} TY pe Bearing 0.05 {0.002} Double-wishbone Angular ball bearing Maximum wheel bearing play mm {in} Type Reduction gear Reduction ratio Oil I Viscosity 0.05 {0.002} -- ---- Differential gear Ring gear size mm {in} Grade Above -1 8°C {O°F}: SAE 90 Below -1 8°C {O°F}: SAE 80 Standard Hypoid gear Straight-bevel gear 182.88 {7.20) API service GL-5 I Capacity L {US qt. imp qt} I 1 .OO {I .06,0.88) "TORSEN" LSD Worm gear 4.100 TY ~e Length mm {in} Constant velocity (double offset) joint 640.6 I25.220) 45UOMX-00 Gartner Banana

TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE FRONT AXLE I Problem Posslbk Cause Worn or damaged wheel bearing Worn or damaged wheel bearing Steering wheel vibration braking Action Replace Replace REAR AXLE Page M- 6 M-6 I Problem Possible Cause Bent drive shaft Page Action Replace I Abnormal nolse Worn or damaged wheel bearing Worn drive shaft spline Worn or deteriorated upper arm bushing M-13 Replace I M-17 Body "rolls" I Replace section R Body leans Weak upper arm bushing Abnormal nolse from suspension system Worn or deteriorated upper arm bushing DIFFERENTIAL Problem Posrlble Cause lnsufficient differential oil Incorrect differential oil lmproperly adjusted ring gear backlash Poor contact of ring gear teeth Worn or damaged side bearing Worn or damaged ring gear Worn or damaged drive pinion bearing Worn or damaged pinion and side gear (STANDARD) Worn or damaged gear in LSD assembly ("TORSEN" LSD) Seized side gear and case Worn side gear spline Worn pinion shaft Worn thrust washer Worn or damaged needle bearing ("TORSEN" LSD) lmproperly adjusted side gear backlash lmproperly adjusted drive pinion gear preload Action Add oil Replace Adjust Adjust Replace Replace Replace Replace Replace Page M-25 M-25 M40 M4l M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-32 M-40 M-39 Abnormal nolse Replace Replace Replace Replace Replace Adjust Adjust Heat buildup lnsufficient differential oil lnsufficient drive pinion gear backlash Excessive bearing preload Add oil Adjust Adjust Oil leakage Excessive differential oil Loose differential carrier Worn or damaged oil seal Remove oil Tighten or repair Replace I - No dlfferentlal operation I Misassembled or damaged Repair Gartner Banana

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

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