1994 MAZDA MX-5 Workshop Manual

L PROPELLER SHAFT 2. Remove the propeller shaft from the extension housing, and immediately install the SST to prevent oil leakage. Inspection Propeller shaft Caution Cleaning sealed bearings with cleaning fluids or a steam cleaner can wash the grease out of the bearing. 1. Clean the propeller shaft (except for the universal joint) with a steam cleaner or solvent. 2. Measure the propeller shaft runout with a dial indicator. Replace the propeller shaft if runout is excessive. Maximum runout: 0.4mm (0.016 in} 3. Move the universal joints in the directions shown, and check for universal joint looseness. If there is looseness, replace the propeller shaft. ii 4. Check operation of the universal joint. If the universal joint has excessive resistance, replace the propeller shaft. Installation Note Propeller shaft 1. Align the marks, and install the propeller shaft. Tightening torque: 50-58 N.m (5.0-6.0 kgf.m, 37-43 ft4bf) 2. Verify that there is no abnormal noise or vibration when driving the vehicle. If noise or vibration comes from the propeller shaft, replace the propeller shaft. 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

FRONT AXLE M FRONT AXLE PREPARATION SST 49 01 18 850C Puller, ball joint 49 VOOl 795 For installation of Installer, oil sensor rotor seal (AW 49 0839 425C Puller set, bearing For disconnection of lower arm ball joint For disconnection of tie-rod end and upper arm ball joint For removal of sensor rotor (AW 49 0727 575 Puller, ball joint For removal of sensor rotor (ABS) 49 F027 007 Attachment @72 Gartner Banana

FRONT AXLE WHEEL HUB, STEERING KNUCKLE Inspection / Removal / lnstallation 1. lnspect wheel bearing play, referring to Inspection. 2. Remove in the order shown in the figure, referring to Removal Note. 3. lnspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal, referring to Installation Note. 25UOMX-OC 1. Front wheel 9. Lower arm 2. Brake caliper assembly Removal Note .............. page M-7 3. Disc plate 4. Hub cap 5. Locknut Installation Note ............ page M-7 6. Front wheel hub assembly lnspect for cracks and damage Disassembly / Inspection / Assembly ................. page M-8 7. Wheel speed sensor (ABS) 8. Tie-rod end Removal Note .............. page M-7 Service ..................... section N .............. Removal Note page M-7 ..................... Service section R 10. Upper arm .............. Removal Note page M-7 ..................... Service section R 11. Dust cover and knuckle spindle lnspect dust cover for damage and distortion lnspect knuckle spindle for cracks and damage Disassembly / Inspection 1 ................. Assembly page M-8 lnspection Wheel bearing play 1. Remove the wheel, brake caliper assembly, and disc plate, referring to Removal note below. 2. Position a dial indicator against the wheel hub. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play. If the bearing play exceeds specification, check and adjust the locknut torque or replace the wheel hub i assembly if necessary. Maximum wheel bearing play: 0.05mm i0.002 in) Gartner Banana

FRONT AXLE M Removal note Brake caliper assembly Note For easier installation, do not depress the brake pedal after removing the brake caliper assembly. Suspend the brake caliper assembly with a rope. Tie-rod end Loosen the nut and disconnect the tie rod end the SST. 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. Lower arm Caution The sharp edges of the SST can slice the lower arm dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. Loosen the nut and disconnect the lower arm by using the SST. Upper arm Caution The sharp edges of the SST can slice the upper arm dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle. Loosen the nut and disconnect the upper arm by using the SST. Installation note Locknut Install a new locknut and stake it. Tightening torque: 167-21 6 N.m (1 7-22 kgf.m, 123-1 59 ft-lbf) Gartner Banana